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Front Axle Differential Lock, Installing

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview and parts information prior to starting procedure.

Mandatory Replacement Parts

NOTE:

Refer to "Front Axle Differential Lock, Removing" to get a list of the special tools needed. Refer to FRONT AXLE DIFFERENTIAL LOCK, REMOVING .

Replace self-locking bolts and nuts after removing them.

Replace bolts that were tightened with an additional turn after removing them.

Install any cable ties that were loosened or cut off during removal at their same location.

Install in the reverse order of removal while noting the following:

-- Coat the splines on the manual transmission differential with Grease for Clutch Disc Shaft Splines.

-- Push the engine/transmission to the front a little bit (a second technician is needed).

-- Slide flange shaft front axle differential lock completely onto manual transmission. While doing this, join splines of input shaft/bevel box centrally with differential. If necessary, turn on the flange shaft.

-- With proper tooth position and central guiding, front axle differential lock slips up to stop against manual transmission.

NOTE:

Do not pull front axle differential lock with mounting bolts against manual transmission, otherwise front axle differential lock is canted and mounting eyelets can break off.

-- Install the lower bolts (-arrows-) that attach the front differential lock to the manual transmission and tighten to tightening specification -Item 12- OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK => List Item:Hex bolt .

GWWN34-12017Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the upper bolts (-arrows-) that attach the front differential lock to the manual transmission and tighten to tightening specification -Item 12- OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK => List Item:Hex bolt .

GWWN34-12018Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the flange shaft -Item 13- OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK => List Item:Bolt .

GWWA34-0615Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

Threaded inserts (for example, "Heli Coil") are found in the pendulum support fastening holes on some transmissions. Refer to Figure.

GWWN34-10973Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install pendulum support with new bolts. Refer to OVERVIEW - SUBFRAME MOUNT .

-- Install the connector -arrow- on the Axle Differential Lock Control Module -J647-.

GWWN34-12013Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

GWWA34-10415Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If removed, install the drive axle heat shield -arrows-. Refer to DRIVE AXLE .

-- Check oil level in front axle differential lock. Refer to FRONT AXLE DIFFERENTIAL LOCK FLUID .

-- Assemble the exhaust system. Refer to EXHAUST PIPES/MUFFLERS .

-- Install the noise insulation. Refer to NOISE INSULATION .

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