Fig. 3.107. Transfer case components:
1 - nut, 130 Nm; 2 - O-ring round section; 3 - PTO shaft flange; 4 - metal dust cover; 5 - sealing ring; 6 - ventilation tube; 7 - primary shaft sealing ring; 8 - O-ring round section; 9 - nut, 130 Nm; 10 - O-ring round section; 11 - PTO shaft flange; 12 - metal dust cover; 13 - sealing ring; 14 - O-ring round section; 15 - mounting sleeve; 16 - transfer case electric motor; 17 - bolt, 27 Nm; 18 - bolt, 14 Nm; 19 - clamp; 20 - oil drain plug, 20 Nm; 21 - bolt, 20 Nm; 22 - bolt, 20 Nm; 23 - console; 24 - oil temperature sensor, 17 Nm; 25 - sealing ring; 26 - oil filler hole bolt, 20 Nm; 27 - bolt, 32 Nm; 28 - damper; 29 - transfer case.
Secure the transfer case to the mounting stand with bolts (fig. 3.108).
Press out the metal boot (fig. 3.109).
A - Puller 22-115 mm, for example Kukko 17/2.
Press metal boot A until it stops (fig. 3.110).
Remove the PTO/rear propeller shaft flange seal ring.
Figure 3.111 shows the removal of the PTO/rear propeller shaft flange seal ring.
The procedure for removing the PTO/front propeller shaft flange sealing ring is similar.
Press in the PTO/Rear Propeller Shaft Flange O-ring (fig. 3.112).
Fill the space between the working and dust lips of the seal halfway with plastic grease G 052 128 A1.
Install the O-ring into the groove of the input shaft.
Press metal boot A until it stops (fig. 3.110).
Press in the PTO/front propeller shaft flange seal ring.
Fill the space between the working and dust lips of the seal halfway with plastic grease G 052 128 A (fig. 3.112).
Remove ventilation tube A.
Install the B mandrel with ∅ 5 mm into the ventilation tube hole.
Move the ventilation tube A in the direction of the arrow, at the same time lift it up with the screwdriver C and remove the ventilation tube from the transfer case (fig. 3.113).
The original can be seen on the portal [VWmanual.ru]
Press the ventilation tube (fig. 3.114).
Before pressing in, lubricate the ventilation tube with Loctite 648 fixing varnish.
Repair method when replacing the V253 transfer case electric motor and when the G8 oil temperature sensor is faulty.
When replacing the V253 transfer case electric motor and if the oil temperature sensor 4 is faulty, it is necessary to replace the oil temperature sensor (with sealing ring 3) through the screw plug 1 with the sealing ring 2 (fig. 3.115).
Disassembling the wiring harness of the oil temperature sensor G8 occurs in the following order.
Remove the holder 1 of the transfer case electric motor plug by unscrewing the bolts.
Remove the 10-pin connector 2 from the holder (fig. 3.116).
Remove wires 1 and 2 of the 10-pin plug using a suitable tool from the VAS 1978 cable repair kit.
Disconnect the oil temperature sensor harness 3 (fig. 3.117).
Cover the 10-pin plug wire holes 1 and 2 with a suitable plug.
Visitor comments