Touareg Transfer Case

Service
Workshop Manual
Touareg 2003 ➤
Transfer box and final drive
Edition 08.2007
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
34 - Controls, housing
39 - Final drive - rear differential
39 - Final drive - front differential
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0058960720

Touareg 2003 ➤
Transfer box and final drive - Edition 08.2007
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Overview - drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transfer box identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Location on transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Identification code, assembly allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Identifying front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Location on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Identification code, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Identifying rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Location on rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Identification code, assembly allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . 15
5 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1 Electrical and electronic components and their locations for transfer box . . . . . . . . . . . . . . 25
1.1 Removing and installing transfer box control unit J646 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Removing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Transporting transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Routing breather line on transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Removing and installing gearbox carrier and bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Removing gearbox carrier and bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2 Installing gearbox n AG. Volkswagen AG do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Renewing by Vbonded metal bush in gearboxt carrier ua ................................ 36
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5 Checking
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ho gear oil in transfer box . . . . . . . . . . . .or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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6 sRemoving and installing oil seals for output flange to propshaft and for transfer box motor
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6.1 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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6.2 Renewing output flange oil seal for front propshaft (transfer box installed) . . . . . . . . . . . . 48
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6.3 Renewing output flange oil seal for rear propshaft (transfer box installed) . . . . . . . . . . . . 50
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7 Removing and installing transfer box motor V253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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7.1 Removing transfer box motor V253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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7.2 Installing transfer box motor V253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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1 Electrical and electronic components and their locations for differential lock on rear final
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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1.1 Removing and installing differential lock control unit J647 . . . . . . . . . . . . . . . . . . . . . . . . 59

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2 Check gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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3 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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3.1 Removing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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3.2 Installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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3.3 Routing breather line for rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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4 Removing and installing axle differential lock motor V304 . . . . . . . . . . . . . . . . . . . . . . . . 66

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4.1 Removing axle differential lock motor V304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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4.2 Installing axle differential lock motor V304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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5 Renewing oil seals on rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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5.1 Renewing left flange shaft seal, vehicles without differential lock . . . . . . . . . . . . . . . . . . . . 68
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Contents i
Touareg 2003 ➤
5.2 Renewing left flange shaft seal, vehicles with differential lock . . . . . . . . . . . . . . . . . . . . . . 70
5.3 Renewing right flange shaft seal, vehicles without differential lock . . . . . . . . . . . . . . . . . . 73
5.4 Renewing right flange shaft seal, vehicles with differential lock . . . . . . . . . . . . . . . . . . . . . . 75
5.5 Renewing propshaft flange oil seal on rear final drive (final drive removed) . . . . . . . . . . . . 76
6 Renewing bonded rubber bush on rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.1 Installation position of bonded rubber bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.2 Pulling bonded rubber bush on propshaft flange out and in . . . . . . . . . . . . . . . . . . . . . . . . 82
6.3 Pulling rear bonded rubber bush out and in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1 Checking oil in front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Removing and installing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1 Removing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.2 Installing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.3 Routing breather line for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3 Renewing oil seals on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3 Renewing seal for propshaft flange on front final drive (final drive removed) . . . . . . . . . . 96
4 Renewing needle bearing for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.1 Removing needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2 Installing needle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5 Renewing bonded rubber bush on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1 Installation position of bonded rubber bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.2 Pulling bonded rubber bush on propshaft flange out and in . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3 Pulling bonded rubber bush out of and into front of housing . . . . . . . . . . . . . . . . . . . . . . . . 105
5.4 Pulling bonded rubber bush out of and into left flange shaft extension tube . . . . . . . . . . . . 105
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1 Removing and installing propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Assembly overview . . . . . . . . . . . . e.n.A.G.. V. o. lk. s.w.a.ge. n. A. G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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1.2 Removing and installing frontVopropshaft
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propshaft . . . . . . . . . . . . . . . . . a. r.an.t . . . . . . . . . . . . . . . . . . . . 110
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1.4 Installing centre bearingho for rear propshaft free of stress . . . . . . . e.o. . . . . . . . . . . . . . . . . . 114
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1.5 Removing and installing
ss flexible coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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Contents Prote AG.
Touareg 2003 ➤
00 – Technical data
1 Overview - drivetrain
Note
For some engine types, the “08D” manual gearbox is installed as an alternative to the “09D” automatic gearbox.
1 - Transfer box
❑ Removing and installing
transfer box
⇒ page 28
2 - Propshafts
propshafts ⇒ page 106
3 - Rear final drive
rear final drive
⇒ page 62
4 - Front final drive
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1. Overview - drivetrain 1
Touareg 2003 ➤
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2 Transfer box identification
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The transfer box
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A reduction gearing is integrated into the transfer box.
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Code -arrow 1- and date of manufacture -arrow 2- of transfer box. t. C rig
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Identifica‐ Day Month Year (2002)
tion code of manufac‐
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Additional data depend on manufacture.
2.2 Identification code, assembly allocation, capacities

Transfer box 0AD
Identification code FJZ FKA FKB
Allocation Model Touareg 2003 ▸ Touareg 2003 ▸ Touareg 2003 ▸
Engine 6.0 l - 316 kW 4.2 l - 228 kW 3.2 l - 162 kW
4.9 l - 230 kW 2.5 l - 128 kW
turbo diesel turbo diesel
Gearbox housing extension length 66.2 mm 127.4 mm 139.9 mm
Capacity 0.85 l
The following data can be found in the ⇒ Electronic parts cata‐
logue “ETKA” .
♦ The allocation to the respective vehicle according to manual
or automatic gearbox code
♦ Gear oil
2 Rep. Gr.00 - Technical data

Touareg 2003 ➤
Transfer box 0AD

Identification code FKC GFG GFH
4.9 l - 230 kW
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Capacity 0.85 l
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Identification code GJL GTL GTM
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6.0 l - 331 kW turbo diesel
Capacity 0.85 l
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♦ Gear oil
Transfer box 0AD

Identification code GTN GTP HCH
2. Transfer box identification 3

Touareg 2003 ➤
Transfer box 0AD

Identification code GTN GTP HCH
3.2 l - 177 kW 3.2 l - 177 kW turbo diesel
2.5 l - 120 kW 3.6 l - 206 kW 4.9 l - 230 kW
2.5 l - 128 kW 3.2 l - 228 kW
turbo diesel
Capacity 0.85 l
logue “ETKA” .
♦ Gear oil
Transfer box 0AD

Identification code lkswage es n HCJ HPW HPX
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Engine 2.5 l - 120 kW ac 4.9 l - 230 kW 4.9 l - 230 kW
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Identification code HMW HMX HTD

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logue “ETKA” .
♦ Gear oil
Transfer box 0AD

Identification code HWZ HXE HXA

Touareg 2003 ➤
Transfer box 0AD

Identification code HWZ HXE HXA
3.6 l - 206 kW 4.2 l - 257 kW
Capacity 0.85 l
logue “ETKA” .
♦ Gear oil
Transfer box 0AD

Identification code HXB HXC HXD
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Identification code JWC JWD JWE
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♦ Gear oil

Touareg 2003 ➤
Transfer box 0AD

Identification code JWF JWG JWH
Allocation Touareg 2003 ▸ Model Touareg 2003 ▸ Touareg 2003 ▸
2.5 l - 120 kW Engine 3.0 l - 165 kW 3.0 l - 165 kW
2.5 l - 128 kW 3.2 l - 177 kW
turbo diesel 3.2 l - 206 kW
3.0 l - 165 kW
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Gearbox housing extension length 139.9gmm ua 139.9 mm 158.2 mm
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Transfer box 0AD
Identification code JXD JXE JXF
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Allocation Model Touareg Touareg
Touareg
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2003 ▸ 2003 ▸2003 ▸

Engine 6.0 l - 4.2 l - 257
3.0 l -
nform
ercia
331 kW kW 155 kW
turbo die‐
m
sel
com
tio
3.0 l - 165
n in
r
te o
kW
thi
s
iva
turbo die‐
do
r
rp
sel
um
fo
4.9 l - 230
en
ng
t.
yi
kW
Co
Cop py
turbo die‐
t. rig
gh ht
yri
sel
p by
o Vo
by c lksw
Prote
cted 5.0 l - 230 agen
kW
AG.
turbo die‐
sel
Gearbox housing exten‐ 66.2 mm 127.4 mm 127.4 mm
sion length
Capacity 0.85 l
logue “ETKA” .
♦ Gear oil
Transfer box 0AD
Identification code JXG JXH JXJ
2.5 l - 128 kW
turbo diesel

Touareg 2003 ➤
Transfer box 0AD

Identification code JXG JXH JXJ
Capacity 0.85 l
logue “ETKA” .
♦ Gear oil
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
3 Identifying front final drive

The front final drive 0AA is allocated to the automatic gearbox
09D and the manual gearbox 08D.
Codes ⇒ page 8 .
3.1 Location on front final drive

Location on front final drive -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Codes and manufacturing data for front final drive.
t to the co
Example FKK 20 08 02
rrectness of i
I I I I
I I I I
l purpos

nform
ercia
ture
m
a
com
t
Additional data depend on manufacture.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
3.2 Identification code, assembly allocation, ratios, capacities en

ng
t.
yi Co
Cop py
t. rig
Front final drive 0AA
gh ht
pyri by
Vo
co
Identification code FKK FKM FKN
by lksw
cted agen
Prote AG.
6.0 l - 316 kW 3.2 l - 177 kW
6.0 l - 331 kW 3.6 l - 206 kW
Ratio: Z1 : Z2 Final drive 37 : 10 = 3.700 39 : 10 = 3.900 41 :10 = 4.100
Capacity 1.0 l
Drive shaft flange ∅ 122 mm 114 mm 114 mm
Electromechanical differential lock without without without
logue “ETKA” .
♦ Allocation to respective vehicle according to engine code
♦ Gear oil

Identification code FKQ FLH FLJ

Touareg 2003 ➤

Identification code FKQ FLH FLJ
3.2 l - 177 kW 3.6 l - 206 kW 3.2 l - 177 kW
Ratio: Z1 : Z2 Final drive 41 : 9 = 4.556 39 : 10 = 3.900 41 : 9 = 4.556
Capacity 1.0 l
Electromechanical differential lock without with with
logue “ETKA” .
♦ Gear oil

Identification code FVX FVY FVZ
AG. Volkswagen AG d
4.2 l - 257 kW
olksw
agen oes
not 3.6 l - 206 kW
yV g
Ratio: Z1 : Z2 Final isdrive
ed b 36 : 11 = 3.273 39 : 11 = u3.545
ara
nte 43 : 10 = 4.300
or eo
h
Capacity s aut 1.0 l ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
logue “ETKA” .
wit
, is n
h re
hole
spec
es, in part or in w
♦ Gear oil t to the co

rrectness of i

l purpos
Identification code FWD FWE GFA

nform
ercia

m
a
com
2.5 l - 128 kW
ion in
turbo diesel
r
te o
thi
s

iva
do
r
rp
cum
Capacity 1.0 l
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
The following data can be found in the ⇒ Electronic parts cata‐ p by
o Vo
by c
logue “ETKA” .
lksw
cted agen
Prote AG.
♦ Gear oil
3. Identifying front final drive 9

Touareg 2003 ➤

Identification code GFB GFF GLZ
3.2 l - 177 kW turbo diesel turbo diesel
4.0 l - 250 kW
Capacity 1.0 l
logue “ETKA” .
♦ Gear oil agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
Front final drive s au 0AA ra
c
s
Identification code GMC GMN GNJ
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Capacity 1.0 l
t to the co
rrectne
logue “ETKA” .
♦ Allocation to respective vehicle according to engine code ss o
cial p
f inform
♦ Gear oil
mer
atio
om
n
c
i
or
n thi
te

sd
iva
o
pr
Identification code GNL GNM GPP

um
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
Engine
gh
2.5 l - 120 kW 3.2 l - 162 kW 2.5 l - 120 kW
ht
yri by
turbo diesel 3.2 l - 177 kW turbo diesel
cop Vo
by lksw
cted
2.5 l - 128 kW 3.6 l - 206 kW 2.5 l - 128 kW
agen
Prote AG.
turbo diesel 4.2 l - 228 kW turbo diesel
3.2 l - 177 kW
4.5 l - 250 kW
Capacity 1.0 l
logue “ETKA” .
♦ Gear oil

Touareg 2003 ➤

Identification code GTG HDL HDM
2.5 l - 128 kW 2.5 l - 128 kW
3.0 l - 165 kW 3.0 l - 165 kW
Capacity 1.0 l
logue “ETKA” . agen
AG. Volkswagen AG d
oes
olksw not
yV gu
♦ Allocation to respective vehicle according to engine code ed b ara
nte
ris
o eo
♦ Gear oil aut
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Identification code HMK FKL FKP
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.0 l - 165 kW
turbo diesel
3.0 l - 171 kW
rrectness of i
turbo diesel
l purpos

Capacity 1.0 l
nform
ercia

m
at
om
ion
c
in t
or

his
ate
logue “ETKA” .
do
priv
cum
or

f
en
ng
t.
yi Co
op
♦ Gear oil C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Identification code FKQ GMA GMB
Allocation Model Touareg Touareg Touareg
2003 ▸ 2003 ▸ 2003 ▸
Engine 3.2 l - 162 4.5 l - 250 4.5 l -
kW kW 250 kW
3.2 l - 177 4.5 l - 330
kW kW
Ratio: Z1 : Z2 Final drive 41 : 9 = 37 : 10 = 41 : 10 =
4.556 3.700 4.100
Capacity 1.0 l

Touareg 2003 ➤

Identification code FKQ GMA GMB
Electromechanical differ‐ without without without
ential lock
The following data can be found in the ⇒ Electronic parts cata‐ n AG. Volkswagen AG do
kswage es n
logue “ETKA” . byV
ol ot g
ua
d ran
ir se
♦ Allocation to respective vehicle according to engine code th o tee
or
au ac
♦ Gear oil ss
ce
le
un
pt
an
d
itte
y li
rm
ab
Identification code GNK JTB JTC
pe
ility
ot
wit
, is n
h re
2003 ▸ 2003 ▸ 2003 ▸
hole
spec
Engine 4.5 l - 250 4.9 l - 2.5 l - 120
es, in part or in w
kW 230 kW kW
t to the co
4.5 l - 330 turbo die‐ turbo die‐
kW sel sel
5.0 l - 2.5 l - 128
rrectness of i
230 kW kW
turbo die‐ turbo die‐
l purpos
sel sel
3.0 l - 165
nform
ercia
kW
turbo die‐
m
a
sel
com
tion in
3.0 l - 176
r
te o
thi
kW
s
iva
turbo die‐
do
r
rp
c
sel
um
fo
en
ng
t.
yi Co
op
3.700 3.273 3.273
C py
t. rig
gh ht
yri by
Capacity 1.0 l cop Vo
by lksw
cted agen
Drive shaft flange ∅ 122 mm 122 mm 114 mm Prote AG.

ential lock
logue “ETKA” .
♦ Gear oil
Identification code JTD JTG JTH
2003 ▸ 2003 ▸ 2003 ▸
Engine 6.0 l - 3.0 l - 2.5 l -
331 kW 155 kW 120 kW
sel sel
3.0 l - 165 2.5 l - 128
kW kW
sel sel
3.0 l - 176 3.0 l - 165
kW kW
sel sel
4.300 3.900 4.100

Touareg 2003 ➤

Identification code JTD JTG JTH
Capacity 1.0 l
ential lock
logue “ETKA” .
♦ Gear oil
Identification code JTJ JTK JTM
Allocation ModelTouareg Touareg Touareg
2003 ▸ 2003 ▸ 2003 ▸
AG. Volkswagen AG d
agen oes
Engine 3.6 l - 206 3.6 l - 206 3.2 l -Volksw not
gu
kW kW 177kW
e d by ara
nte
is
4.2 l - 257 4.2 l - 257 3.6
thor l - 206 eo
kW kW s au kW ra
c
s
4.2 l - 228
ce
e
nl
kW
pt
du
an
itte
y li
erm
ab
3.700 4.300 4.556
ility
ot p
Capacity 1.0 l
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
ential lock
rrectness of i
logue “ETKA” .
l purpos

♦ Gear oil
nf
ercia
or
m
m
atio
m
Identification code JVL KDJ

o
n in
or c
Allocation Model Touareg Touareg thi

te
sd
a
2003 ▸ 2003 ▸
iv
o
r
rp
cu
Engine 4.9 l - 3.2 l - 177

o
m
f
en
ng
230 kW kW
t.
yi Co
op
turbo die‐
C py
ht. rig
sel rig ht
py by
Vo
5.0 l - 230
co lksw
by
cted agen
kW Prote AG.
turbo die‐
sel
5.0 l - 258
kW
turbo die‐
sel
Ratio: Z1 : Z2 Final drive 36 : 11 = 39 : 10 =
3.273 3.900
Capacity 1.0 l
Drive shaft flange ∅ 114 mm 114 mm
Electromechanical differ‐ without
ential lock

Touareg 2003 ➤

logue “ETKA” .
♦ Gear oil
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
4 Identifying rear final drive

Rear final drives 0AB/OAC are allocated to the automatic gearbox
09D and the manual gearbox 08D.
Codes ⇒ page 15 .
4.1 Location on rear final drive

Location on rear final drive -arrow-.
Codes and manufacturing data for rear final drive

Example FKY 20 08 02
I I I I
I I I I
ture
AG. Volkswagen AG d
agen oes
Additional data depend on manufacture. olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.2 Identification code, assembly allocation, ratios, capacities

Rear final drive 0AB/0AC
rrectness of i
Identification code FKS FKU FKV

l purpos

nform
ercia
3.2 l - 177 kW
m
3.2 l - 206 kW
at
om
ion

c
in t
or
his
te
Capacity 1.25 l 1.25 l 1.25 l

a
do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
logue “ETKA” . by c lksw
cted agen
Prote AG.
♦ Gear oil
4. Identifying rear final drive 15

Touareg 2003 ➤

Identification code FKW FKY FLM
Capacity 1.25 l 1.40 l 1.60 l
Electromechanical differential lock without without with
logue “ETKA” .
♦ Gear oil

Identification code FLN FLP FLR
2.5 l - 120 kW
turbo diesel
2.5 l - 128 kW
turbo diesel
Capacity 1.6 l 1.6 l 1.6 l
Electromechanical differential lock with with with
AG. Volkswagen AG d
agen oes
The following data can be found in the ⇒ ElectronicVol parts cata‐
ksw not
gu
logue “ETKA” . se
d by ara
nte
i
th to engine code or eo
♦ Allocation to respective vehicle according
au ra
c
ss
♦ Gear oil
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p

wit
is n
Identification code FLT FWA FWB

h re
ole,
spec

t to the co

rrectne
Capacity 1.6 l 1.25 l 1.25 l

ss

o
cial p
f i
Electromechanical differential lock with without without

nform
mer

atio
m
logue “ETKA” .
o
n
c
i
or
n thi
e

t
sd
iva
o
pr
♦ Gear oil
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
16
cted agen
Prote AG.
Rep. Gr.00 - Technical data
Touareg 2003 ➤

Identification code FWC FWF FWG
turbo diesel turbo diesel 2.5 l - 128 kW
turbo diesel
Electromechanical differential lock without with with
Rear final drive “FWG”: in conjunction with automatic gearbox

09D = drive shaft flange 112 mm ∅. In conjunction with manual
gearbox 08D = drive shaft flange 118 mm ∅
logue “ETKA” .
♦ Gear oil
Identification code FWH GFC GFD
Allocation AG. VolksModel
wagen AG Touareg 2003 ▸ Touareg 2003 ▸ Touareg 2003 ▸
agen does
ksw
y Vol
Engine 4.9nol t-g230
ua kW 3.2 l - 162 kW 4.9 l - 230 kW
edb turbo diesel
ran turbo diesel
ris tee
tho
Ratio: Z2 : Z1s au Final drive 36 : 11 = 3.273 or
ac 41 : 9 = 4.556 36 : 11 = 3.273
s
Capacity 1.6 l 1.25 l 1.25 l
ce
le
un
pt
an
d

itte
y li
rm
ab

pe
ility
ot
wit
, is n

h re
logue “ETKA” .
hole
spec
es, in part or in w

t to the co
♦ Gear oil
rrectness of i
l purpos

Identification code GLM GLN GLP
nform
ercia

m

com
tion in
turbo diesel turbo diesel 3.2 l - 177 kW

r
te o
thi

s
iva
do
r
rp
cum
Capacity 1.25 l 1.25 l 1.25 l

fo
en
ng
t.
yi
Co
Cop py
t. rig
Electromechanical differential lock opyri
gh by
Vo without ht
without without
by c lksw
The following data can be found in the ⇒ Electronic parts cata‐cted agen
Prote AG.
logue “ETKA” .
♦ Gear oil

Touareg 2003 ➤

Identification code GLQ GLR GLS
3.2 l - 206 kW
Capacity 1.25 l 1.25 l 1.4 l
logue “ETKA” .
♦ Gear oil
Rear final drive 0AB/0AC AG. Volkswagen AG d

agen oes
Identification code GLT y Volksw GMP nGMQ
ot g
d b ua
ran
Allocation Model Touareg 2003 orise
▸ Touareg 2003 ▸ Touareg 2003tee ▸
h
ut or
Engine 6.0 l s-s 331 kW
a 4.2 l - 228 kW 4.2 l - 228 kW ac
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
logue “ETKA” .
t to the co
♦ Gear oil
rrectness of i
l purpos
nf
ercia
o
Identification code GNF GNG GNH
rm
m
atio
m

o
n in
or c

thi
te
sd
a

iv
o
r
rp
turbo diesel 2.5 l - 128 kW 2.5 l - 128 kW

cu
o
m
f

en
ng
t.
yi
Co
Cop py
turbo diesel
t. rig
gh ht
yri
3.2 l - 177 kW
p by
co Vo
by lksw
cted
agen
Prote AG.
Capacity 1.25 l 1.25 l 1.6 l

logue “ETKA” .
♦ Gear oil

Touareg 2003 ➤

Identification code GNN GTH GTJ
turbo diesel 6.0 l - 331 kW 6.0 l - 331 kW
Electromechanical differential lock with without with
logue “ETKA” .
♦ Gear oil

Identification code HLQ HLR HLS
2.5 l - 128 kW 2.5 l - 128 kW
AG. Volkswagen AG d
3.0 l - 165 kW 3.0 l - 165 kW
lksw
agen oes
not turbo diesel turbo diesel
Vo g
y
Ratio: Z2 : Z1sed b Final drive 36ua: r11
an = 3.273 36 : 11 = 3.273 41 : 10 = 4.100
ri tee
ho
Capacity aut 1.6 l or
ac 1.6 l 1.6 l
ss
ce
e
nl
pt
du

an
itte
y li
erm
ab

ility
ot p
logue “ETKA” .
wit
, is n
h re

hole
spec
es, in part or in w
♦ Gear oil
t to the co
rrectness of i

Identification code HLT HLU HLV
l purpos

nf
ercia

orm
6.0 l - 331 kW 4.2 l - 228 kW 3.2 l - 177 kW

m
atio
m
3.6 l - 206 kW
o
n in
or c

thi
te
sd
iva

o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
cop Vo
by lksw
cted
logue “ETKA” .
agen
Prote AG.

Touareg 2003 ➤
♦ Gear oil
AG. Volkswagen AG d
agen oes
ksw
Rear final drive 0AB/0AC byV
ol not
gu
ara
ed
Identification code HLW ho ris FLA GLV nte
eo
aut ra
Allocation Model Touareg 2003
ss ▸ Touareg 2003 ▸ Touareg 2003 ▸ c
ce
e
nl
pt
du
an
turbo diesel
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
logue “ETKA” .
rrectness of i
l purpos
♦ Gear oil
nf
ercia
orm
m
atio
om
n in
c
Identification code HMA HMB JAJ

or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
.
Ratio: Z2 : Z1 Final drive 37 : 10 = 3.700 43 : 10= 4.300 41 : 09 = 4.556
ht rig
rig ht
py by
co Vo
Capacity 1.25 l 1.25 l 1.6 l
by lksw
cted agen
Prote AG.
logue “ETKA” .
♦ Gear oil

Identification code JLP JLQ JSF
5.0 l - 230 kW 5.0 l - 230 kW 2.5 l - 120 kW
3.0 l - 165 kW
turbo diesel
Electromechanical differential lock without with without

logue “ETKA” .

Touareg 2003 ➤

♦ Gear oil
Identification code HEX JSG JMB
Allocation Model Touareg 2003 ▸
Touareg 2003 ▸ Touareg 2003 ▸
Engine 3.2 l - 177 kW
2.5 l - 120 kW 4.2 l - 257 kW
AG. Volkswa gturbo
en
diesel
ksw
agen 2.5 Al G- d128
oes kW
not
y Vol turbo diesel gu
d b ara
orise 3.0 l - 165 kW nte
eo
aut
h turbo diesel ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
logue “ETKA” .
t to the co
♦ Gear oil
rrectness
o
cial p
f in
Identification code JSM KBR KLH
form
mer
atio
om
2003 ▸ 2003 ▸ 2003 ▸
n
c
i
or
n thi
Engine 3.6 l - 206 3.6 l - 206 3.0 l -
te
sd
va
kW kW 165 kW
i
o
pr
cum
4.2 l - 257 4.2 l - 257 turbo die‐
r
fo
en
ng
kW kW sel
t.
yi Co
op py
Ratio: Z2 : Z1 Final drive 43 : 10= 43 : 10 = . 41 : 10 = t. C rig
gh ht
4.300 4.300 4.100 pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Electromechanical differ‐ without with without
ential lock
logue “ETKA” .
♦ Gear oil
Identification code KLJ JVQ JVT
2003 ▸ 2003 ▸ 2003 ▸
Engine 3.0 l - 4.9 6.0 l -
165 kW l - 230 kW 331 kW
turbo die‐ turbo die‐ turbo die‐
sel sel sel
5.0
l - 230 kW
turbo die‐
sel

Touareg 2003 ➤

Identification code KLJ JVQ JVT
4.100 3.272 3.700
Electromechanical differ‐ with without without
ential lock
logue “ETKA” .
♦ Gear oil
Identification code FKZ FLS GFE
2003 ▸ 2003 ▸ 2003 ▸
Engine 4.5 l - 4.5 l - 4.5 l -
250 kW 250 kW 250 kW
4.100 4.100 4.100
Drive shaft flange ∅ 118 mm 118 mm 118 mmAG. Volkswagen A
agen G do
Electromechanical differ‐ without with y Vowithout
lksw es n
ot g
ential lock db e
ua
ran
ris tee
tho or
The following data can be found in the ⇒ Electronic
au parts cata‐ ac
ss
logue “ETKA” .
ce
e
nl
pt
du
♦ Allocation to respective vehicle according to engine code an

itte
y li
erm
♦ Gear oil ab
ility
ot p
wit
, is n

h re
hole
Identification code GLU HEW HLX

spec
es, in part or in w

t to the co
2003 ▸ 2003 ▸ 2003 ▸

Engine 4.5 l - 250 4.5 l - 250 4.5 l - 250
rrectness of i
kW kW kW
4.5 l - 330
l purpos
kW
nform
ercia
4.100 3.700 4.100

m

at
om
ion

c
in t
or
his
e
Electromechanical differ‐ without with with

at
do
riv
ential lock
p
cum
for
en
ng

t.
yi Co
op
logue “ETKA” .
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote
♦ Gear oil
AG.

Touareg 2003 ➤
5 General repair notes

To ensure perfect and successful gearbox repairs, agen
Athe
G. Vogreatest
lkswagen AG
does
care and cleanliness as well as the use of ogood
lksw and proper tools not
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is essential. Of course, the basic rules edfor safety also apply during
b ara
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is
repair work. thor eo
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c
A number of instructions generally
ss applicable to the various repair
ce
le
procedures - which were previously repeated a number of times
un
pt
an
at various places in the workshop manual are summarised under itte
d
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the topic “components” ⇒ page 23 . They apply to this workshop
rm
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manual.
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5.1 Components
h re
hole
spec
es, in part or in w
t to the co
5.1.1 Gearbox
♦ When installing the transfer box, ensure that the dowel sleeves
rrectness of i
between the gearbox and transfer box are correctly installed.
l purpos
♦ When installing mounting brackets or waxed components,

clean the contact surfaces. Contact surfaces must be free of
wax and grease.
nform
mercia
♦ Allocate bolts and other components using ⇒ Electronic parts
a
com
ti
catalogue (ETKA) .
on in
r
te o
thi
♦ When changing the transfer box, fill with gear oil up to lower
s
iva
do
edge of filler hole.
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fo
♦ Capacity of transfer box ⇒ page 2 .
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ng
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♦ When changing a front final drive, fill with gear oil up to lower
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♦ Capacity of front final drive ⇒ page 8 .
agen
Prote AG.
♦ When changing a rear final drive fill with gear oil up to lower
♦ Capacity of rear final drive ⇒ page 15 .
5.1.2 Seals and sealing rings

♦ Renew O-rings.
♦ Radial oil seals.
Before installing:
Lightly oil outer diameter and half-fill space between sealing lips
-arrow- with grease -G 052 128 A1- .
After installation:
♦ Check oil level in transfer box ⇒ page 38 .
♦ Checking oil level in front final drive ⇒ page 83 .
♦ Checking oil level in rear final drive ⇒ page 61 .
5.1.3 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
5. General repair notes 23

Touareg 2003 ➤
♦ Retaining rings must locate properly in grooves.
5.1.4 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary. agen
AG. Volkswagen AG d
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olks ot g
♦ Use a thread chaser to clear residual d blocking fluid from all
yV ua
ran
rise bolts are to be screwed.
threaded holes into which self-locking tee
ho
Otherwise there is a danger ofabolts
ut shearing when subse‐ or
ac
quently being removed. ss
ce
le
un
pt
5.1.5 Bearings
an
d
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♦ Install needle bearings with lettered side (thicker metal) to‐
pe
ility
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wards fitting tool.
wit
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5.1.6 Guided fault finding, vehicle self-diag‐
hole
spec
nosis and testing
es, in part or in w
t to the co
♦ Before replacing the transfer box motor -V253- , transfer box,
and the axle differential lock motor -V304- on vehicles with a
rrectness of i
rear axle differential lock, check for source of damage using
vehicle diagnosis, testing and information system -VAS 5051-
l purpos
in operating modes “Guided fault finding”, “vehicle self-diag‐

nosis” and “Test instruments”.
nform
mercia
a
com
tion in
r
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Prote AG.

Touareg 2003 ➤
34 – Controls, housing
1 Electrical and electronic components and their locations for transfer
box
1 - Transfer box control unit -

J646-
❑ Location ⇒ page 26
⇒ page 27
2 - Transfer box operating unit
-E473-
⇒ page 26
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
3 - Transfer box motor -V253-
❑ Location
⇒ Item 16 (page 43)
⇒ page 54 AG. Volkswagen AG d
agen oes
❑ The following compo‐ olksw not
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nents are integrated in rise
d b ara
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the Transfer box motor - utho eo
ra
V253- : ss a c
ce
le
Transfer box potentiom‐

un
pt
an
d
eter -G398-
itte
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ility
Transfer box potentiom‐
ot
wit
eter 2 -G482-
, is n
h re
hole
Engine temperature
spec
es, in part or in w
sender -G407-
t to the co
Differential lock motor
brake
rrectness of i
4 - Diagnostic connection
l purpos
5 - Idling switch -F60-
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❑ Only fitted to vehicles with a manual gearbox

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❑ Removing and installing ⇒ page 26

thi
s
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6 - Multi-function display in dash panel insert

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❑ Display of status and of information on the central differential lock and off-road reduction gearing in the
n
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transfer box t. Cop py
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Prote AG.
1. Electrical and electronic components and their locations for transfer box 25
Touareg 2003 ➤
Location of Transfer box control unit -J646-

The Transfer box control unit -J646- is located under the front
right-hand seat -arrow B-.
Removing and installing transfer box control unit -J646-
⇒ page 27 .
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Location of transfer box operating unit -E473-

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The transfer box operating unit -E473- -1- is located in the gear‐
ility
ot
box cover -2- in the centre console.
wit
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Removing and installing transfer box operating unit -E473- ⇒
hole
spec
General body repairs, interior; Rep. Gr. 68 ; Compartments, cov‐
es, in part or in w
ers and trims; Removing and installing centre console .
t to the co
rrectness of i
l purpos
nform
ercia
Diagnostic connection
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a
com
tio
The diagnosis connector is located under the cover of the driver's

n in
r
side footwell.
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Prote AG.
Location of idling switch -F60-

The idling switch -F60- -1- is located near the shift mechanism
cover with selector forks on the manual gearbox -2-.
Removing and installing the idling switch -F60- ⇒ 6-speed manual
gearbox 08D; Rep. Gr. 34 ; Assembly overview - removing and
installing seals, switch, selector mechanism cover and angled
rod .
26 Rep. Gr.34 - Controls, housing

Touareg 2003 ➤
1.1 Removing and installing transfer box

control unit -J646-
1.1.1 Removing
– Remove the front right-hand seat ⇒ General body repairs;
Rep. Gr. 72 ; Front seats; Removing and installing the 12-way
seat .
– Remove seat frame cover, if fitted.
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Switch of the ignition and all electrical consumers and remove
the ignition key.
– Disconnect battery earth strap ⇒ Electrical system; Rep. Gr.
27 ; Disconnecting and connecting battery .
– Remove connector -1- on transfer box control unit -J646- and,
if fitted, the connector -2- on automatic gearbox control unit -
J217- .
– Unscrew bolt -3-.
– Pull the retainer with the transfer box control unit -J646- in
-the direction of the arrow- out of the bracket on the seat frame.
– Press the retaining lugs -1- in -the direction of the arrow- and
pull the transfer box control unit -J646-
gen AGout of the nretainer.
. Volkswage AG
does
Please ensure that you do not ol swa the transfer box control
kdrop not
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unit -J646- when doingsthis.
ed
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es, in part or in w
t to the co
1.1.2 Installing
Install in the reverse order of removal, observing the following:
rrectness of i
– Push the retainer for the transfer box control unit -J646- with
l purpos
the tabs -2- into the mounts -1- on the seat frame.
– Tighten bolt -3- to 8 Nm.
nform
ercia
– Connect the battery earth strap and follow procedure after

m
at
connecting battery ⇒ Electrical system; Rep. Gr. 27 ; Battery;

om
ion
Disconnecting and connecting battery .

c
in t
or
his
ate
do
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cum
for
en
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t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
1. Electrical and electronic components and their locations for transfer box 27
Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
V
2 Removing and installing transfer box by gu
d ara
ise nte
or eo
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aut ra
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Special tools and workshop
ce
le
un
pt
equipment required
an
d
itte
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♦ Retaining tool -VW 785/1B- erm
ab
ility
ot p
♦ Adapter -10 - 222 A /7-
wit
is n
h re
ole,
♦ Lifting tackle -2024 A-
spec
♦ Thrust pad -3062-
t to the co
♦ Gearbox support -3282-
♦ Adjustment plate -3282/37-
rrectness o
cial p
f inform
mer
atio
om
n
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te
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Prote AG.

Touareg 2003 ➤
♦ Torque wrench -V.A.G

1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383/A-
♦ Grease for clutch plate
splines -G 000 100-
lkswage es n
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byV ua
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tho
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ss
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2.1 Removing transfer box

y li
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ab
ility
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– Raise vehicle.
wit
, is n
– Remove noise insulation below gearbox. h re

hole
spec
– If there is a skid plate beneath transfer box, remove it ⇒ Rep.
es, in part or in w
t to the co
Gr. 50 ; Skid plate .

– Remove rear section of exhaust system and, if necessary,
catalytic converters (V10 TDI) ⇒ Rep. Gr. 26 ; Removing and
rrectness of i
installing parts of the exhaust system .

l purpos
– Remove rear propshaft ⇒ page 110 .

– Remove securing bolts for front propshaft at front final drive
nf
ercia
and at transfer box.

rm
m
atio
om
n in
or c
thi
te
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Cop py
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Prote AG.
2. Removing and installing transfer box 29

Touareg 2003 ➤
– If balance weight -A- is installed, remove balance weight (bolts

-B-) from transfer box.
Before removing, mark the installation position of balance weight
relative to transfer box. “Top” -arrow- must face upwards.
– Assemble engine and gearbox support -V.A.G 1383/A- , gear‐
box support -3282- , adjustment plate -3282/37- for “OAD”
gearbox and mounting elements as follows:
– Fit adjustment plate -3282/37- on gearbox support -3282- ( ad‐
justment plate only fits in one position).
– Align arms of gearbox support according to holeswin
agadjust‐
en AG. V
olkswagen AG
does
ment plate . olks not
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The symbols on the adjustment plate indicate
tho
ris the mounting ele‐ e or
ments required; the arrow points forward.
sa
u ac
s
ce
le
un
pt
– Position engine and gearbox jack -V.A.G 1383/A- with gear‐
an
d
itte
box support -3282- under vehicle, align adjusting plate parallel
y li
erm
ab
to gearbox and support gearbox.
ility
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wit
– Secure gearbox to gearbox support -3282- using bolt -A-.
is n
h re
ole,
– Remove gearbox carrier -B- from body.
spec
– Then remove gearbox carrier from transfer box bracket
t to the co
-arrows-.
– Remove front propshaft.
rrectne
– Remove side and lower connecting bolts for gearbox/transfer
box.
ss o
cial p
f in
– Pull connectors -A- and -B- off transfer box motor .
form
mer
– Lower engine and gearbox assembly approx. 60 mm using
atio
om
engine and gearbox jack -V.A.G 1383/A- .
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c
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or
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Prote AG.
– Secure engine and gearbox assembly to body -arrows- with

retaining tool -VW 785/1B- as follows:
– Grease contact surfaces of pressure plate of -VW 785/1B- with
multi-purpose grease .
– Seat thrust pad -3062- on pressure plate . The smaller diam‐
eter of -3062- faces towards the pressure plate .
– Place a wooden block -A- between gearbox and pressure
plate -3062- .

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
autho eo
ra Touareg 2003 ➤
ss Transfer box and final drive - Edition 08.2007
c
ce
e
nl
pt
du
an
– Remove upper connecting bolts -A- for transfer box/gearbox.
itte
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erm
ab
– Remove breather line -B- from transfer box -arrow 1- and un‐
ility
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clip -arrow 2-.
wit
, is n
h re
– Press transfer box off gearbox.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Lower transfer box.
orm
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atio
om
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or c
thi
te
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t.
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pyri by
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cted agen
Prote AG.
2.2 Transporting transfer box

– Attach lifting tackle -2024A- as follows to lifting eyes of transfer
box and transport using workshop hoist .
Input shaft side:
4. Hole of hook rail in position 1 of lifting tackle -arrow A-.
Output shaft side (propshaft flange):
2. Hole of hook rail in position 8 of lifting tackle -arrow B-.
Caution
Use locking pins to secure hooks and locating pins.
2.3 Installing transfer box

– Check whether dowel sleeves for aligning gearbox and trans‐
fer box are fitted in gearbox; install if necessary.
2. Removing and installing transfer box 31

Touareg 2003 ➤
Always renew O-ring to seal transfer box and gearbox -arrow-.

Lubricate lightly.
Grease transfer box input shaft splines and gearbox output shaft
splines with clutch plate spline grease -G 000 100- .
Push transfer box completely onto gearbox, ensuring that transfer
box input shaft splines are centred as they are guided onto the
gearbox output shaft.
If splines are correctly positioned and shafts are centred, then
transfer box will slide to stop against gearbox.
Do not use securing bolts to pull transfer box onto the gearbox.
Otherwise transfer box will cant. n AG. Volkswagen A ge G do
swa es n
– Install front propshaft ⇒ page 107 . by Volk ot g
ua
d e ran
ris tee
ho
– If balance weight -A- is part ofa original
ut equipment, install on or
ac
transfer box using bolts -B- ss
ce
le
.
un
pt
an
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itte
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“Top” -arrow- must face upwards.
erm
ab
ility
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– Install rear propshaft ⇒ page 110 .
wit
is n
h re
– If there was a skid plate beneath transfer box, install it ⇒ Rep.
ole,
spec
– Check oil in transfer box ⇒ page 38 .
t to the co
– Install exhaust system ⇒ Rep. Gr. 26 ; Removing and instal‐
ling parts of the exhaust system.
rrectne
2.4 Torque settings
ss o
cial p
f i
Transfer box to gearbox 45 Nm
nform
mer
Balance weight to transfer box 32 Nm atio

om
Bracket to transfer box, bracket to gearbox carrier and gearbox

c
i
or
n thi
carrier to body ⇒ page 34 .

te
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2.5 Routing breather line on transfer box

p
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The breather line -1- for the transfer box runs over the transfer Cop py
box and the gearbox to the coolant hose -4-.
t. rig
gh ht
pyri by
Vo
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It is clipped into the retainers -2- on the transfer box and the re‐
c by lksw
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tainers -3- on the manual gearbox.
Prote AG.
The figure shows the routing on a manual gearbox. The routing

on an automatic gearbox is analogue.

Touareg 2003 ➤
AG. Volkswagen AG d
agen
3 RemovingVol and installing gearboxot g carrier and bracket
es n o
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Special tools andau
ss workshop
ac
equipment required
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nl
pt
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itte
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1331-
erm
ab
ility
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1332-
h re
hole
spec
es, in part or in w
V.A.G 1383 A- with univer‐
t to the co
sal gearbox mounting -
V.A.G 1359/2-
rrectness of i
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nf
ercia
orm
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t. rig
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Prote AG.
3.1 Removing gearbox carrier and bracket

– Raise vehicle.
– Remove noise insulation below gearbox.
– If there is a skid plate beneath gearbox carrier and bracket,
remove it ⇒ Rep. Gr. 50 ; Skid plate
– Position engine and gearbox jack -V.A.G 1383 A- with univer‐
sal mounting -V.A.G 1359/2- and a wooden block -A- under
transfer box.
Do not loosen bolts -arrows-.
3. Removing and installing gearbox carrier and bracket 33

Touareg 2003 ➤
– Remove gearbox carrier -A- from body -arrows-.

– Lower transfer box slightly until gearbox carrier hangs free.
AG. Volkswagen AG d
agen oes
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– Then remove gearbox carrier from transfer box bracket ole,
spec
-arrows-.
t to the co
rrectness o
cial p
f inform
mer
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om
n
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a
– Unbolt bracket -A- from transfer box -arrows-.

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Prote AG.
3.2 Installing gearbox carrier and bracket

Install in reverse order of removal.
3.2.1 Torque settings

Bracket to gearbox carrier 50 Nm +90°
♦ Always renew bolts
Due to the various engine options and differing lengths of the

transfer box extension, there are various brackets and gearbox
carriers. Allocation depends on the engine installed ⇒ Electronic
parts catalogue (ETKA) .
The various options result in the following bolting points for brack‐
et to transfer box and gearbox carrier to body:

Touareg 2003 ➤
lkswage es n
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Vehicles with 12-cylinder engine d byV ua
ran
ir se tee
Bracket to gearbox carrier
autho
⇒ page 34 or
ac
ss
Bracket to transfer box
ce
e
nl
pt
du
an
Bolts -1- M8 x 35 itte 20 Nm
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Bolts -2- M8 x 70 20 Nm
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Gearbox carrier to body
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es, in part or in w
Bolts -3- M10 x 80 50 Nm + 90°
t to the co
rrectness of i
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Vehicles with 6 or 8-cylinder engine
or c
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Bracket to gearbox carrier ⇒ page 34
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Bolts -1- M8 x 35 t. Cop
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Bolts -2- M8 x 70
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Gearbox carrier to body Prote AG.
Bolts -3- M10 x 80 50 Nm + 90°
Vehicles with 5 or 10-cylinder engine

Bracket to gearbox carrier ⇒ page 34
Bolts -1- M8 x 35 20 Nm
Bolts -2- M8 x 70 20 Nm
Gearbox carrier to body

Bolts -3- M10 x 80 50 Nm + 90°

– If there was a skid plate beneath gearbox carrier and bracket,
install it ⇒ Rep. Gr. 50 ; Skid plate
3. Removing and installing gearbox carrier and bracket 35

Touareg 2003 ➤
4 Renewing bonded metal bush in gearbox carrier

equipment required
♦ Thrust plate -VW 402-
AG. Volkswagen AG d
♦ Press tool -VW 412- lksw
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♦ Thrust piece -VW 432- rised ara
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♦ Base plate -VW 441- aut ra
ss c
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♦ Tube -3296-
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♦ Assembly tool -T10214- itte
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
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ate
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for
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Cop py
t. rig
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cted agen
Prote AG.
– Remove gearbox carrier ⇒ page 33 .

– Press out bonded rubber bush.

Touareg 2003 ➤
– Bolt new bonded rubber bush to thrust piece -T10214/3- .

– Press new bonded rubber bush -A- into guide sleeve -
T10214/2- with thrust piece -T10214/3- until the thrust piece -
T10214/3- is flush with guide sleeve -T10214/2- .
– Align new bonded rubber bush to gearbox carrier using lever

-T10214- .
– To align, ensure that the threaded holes -A- or the groove
-arrow - on the thrust piece -T10214/3- align centrally with the
holes in the gearbox carrier.
Distances “x” must be identical.
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– Now press new bonded rubber bush into the gearbox carrier
erm
ab
ility
until the guide sleeve -T10214/2- can be turned by hand

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-arrows-.
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hole
Do not press the bonded rubber bush deeper into the gearbox
spec
carrier than the height of the tube -3296- , if necessary press in

es, in part or in w
t to the co
to stop using base plate -VW 441- .

– Install gearbox carrier ⇒ page 33 .
rrectness of i
l purpos
nf
ercia
orm
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Prote AG.
4. Renewing bonded metal bush in gearbox carrier 37

Touareg 2003 ➤
5 Checking gear oil in transfer box

Gear oil specification ⇒ page 2
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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es, in part or in w
– To check gearbox oil, remove oil plug -arrow-.
t to the co
Oil level is correct when transfer box is filled to lower edge of filler
hole.
rrectness of i
– Screw in plug -arrow- and tighten.
l purpos
When filling with fresh oil, note following:

– Remove oil plug -arrow-.
nform
ercia
– Fill with gear oil to lower edge of filler hole.

m
a
com
tion in
– Screw in plug -arrow- and tighten.

r
te o
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Torque settings:
do
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Oil filler plug 20 Nm

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Touareg 2003 ➤
6 Removing and installing oil seals for output flange to propshaft and for
transfer box motor

equipment required
♦ Support clamp -VW 313-
♦ Press tool -VW 408 A-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Multipurpose tool -VW 771-
♦ Puller hooks -VW 771/37-
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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t.
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Cop py
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Prote AG.
6. Removing and installing oil seals for output flange to propshaft and for transfer box motor 39
lkswage es n
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Touareg 2003 ➤auth or
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nl
pt
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♦ Press tool -30 - 504-
erm
ab
ility
♦ Tube -32 - 119- ot p
wit
, is n
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♦ Thrust pad -3062-
hole
spec
es, in part or in w
t to the co
1331-
1332-
rrectness of i
♦ -3- - Kukko 17/2 Separating
l purpos
device
nform
mercia
at
om
ion
c
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ate
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for
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Cop py
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Prote AG.

Touareg 2003 ➤
♦ Thrust piece -T10185-

♦ Socket 36 mm, long -
T10204-
♦ Wiring harness repair set -
VAS 1978- gen AG
. Volkswagen AG
d
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olks not
♦ Loctite -648-
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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t.
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Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.
Mount gearbox on repair stand ⇒ page 44 .
Touareg 2003 ➤
1 - Nut, 130 Nm agen

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❑ Always renew d byV gu
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❑ Unscrewing hor eo
ut
⇒ page 51 ss a ra
c
❑ Fitting ⇒ page 52
ce
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nl
pt
du
an
❑ Locking ⇒ page 53 . itte
y li
erm
ab
❑ Insert with locking com‐
ility
ot p
pound Loctite -648- .
wit
, is n
h re
2 - O-ring
hole
spec
❑ Always renew
es, in part or in w
t to the co
❑ Insert with gearbox oil
⇒ page 52
3 - Output flange
rrectness of i
❑ For rear propshaft.
l purpos

⇒ page 50
nform
ercia
4 - Dust plate
m
at
❑ For output flange
om
ion
c
in t
❑ Pressing off
or
his
e
⇒ page 44
at
do
priv
c
❑ Pressing on
um
for
⇒ page 44
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5 - Seal
C py
ht. rig
rig ht
❑ For output flange for
py by
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by lksw
rear propshaft Prote
cted AG.
agen
❑ Pulling out ⇒ page 44

❑ Driving in ⇒ page 45
❑ Renewing with gearbox
installed ⇒ page 50
6 - Breather pipe
❑ Removing ⇒ page 46
7 - Input shaft seal
8 - O-ring
❑ Always renew
❑ Insert in groove in input shaft ⇒ page 45
9 - Nut, 130 Nm
❑ Always renew
❑ Unscrewing ⇒ page 49
❑ Fitting ⇒ page 50
❑ Locking ⇒ page 50
❑ Insert with locking compound Loctite -648-
10 - O-ring
❑ Always renew
❑ Insert with gearbox oil ⇒ page 50
11 - Output flange
❑ For front propshaft

Touareg 2003 ➤
AG. VTransfer
olkswagenbox
AG doand final drive - Edition 08.2007
agen es n
olksw ot g
V
12 - Dust plate ed by ua
ran
ris tee
❑ For output flange utho
or
a ac
❑ Pressing off ⇒ page 44 ss
ce
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un
❑ Pressing on ⇒ page 45
pt
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13 - Seal
erm
ab
ility
ot p
❑ For output flange for front propshaft
wit
is n
❑ Pulling out ⇒ page 44
h re
ole,
spec
❑ Renewing with gearbox installed ⇒ page 48
t to the co
14 - O-ring
❑ Must lie in peripheral groove of transfer box actuator motor -V253-
rrectne
Allocation ⇒ Electronic parts catalogue (ETKA)
ss o
15 - Dowel sleeve
cial p
f inform
❑ Qty. 2
mer
atio
❑ For centring transfer box motor -V253- on transfer box
om
n
c
i
16 - Transfer box motor -V253-
or
n thi
te
sd
a

iv
o
pr
cum
❑ Components integrated in transfer box motor -G482- : transfer box potentiometer -G398- , transfer box
r
fo
en
ng
potentiometer 2 , engine temperature sensor -G407- , differential lock motor brake and oil temperature
t.
yi Co
op
sender -G8- C py
t. rig
gh ht
❑ The transfer box motor and integrated components can be checked using “guided fault finding” yri
p by
o Vo
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❑ If transfer box motor is renewed, also renew oil temperature sender -G8- ⇒ Item 24 (page 43) cted agen
Prote AG.
⇒ page 46
❑ From 02.05, transfer box motor is available only together with clamp ⇒ Item 19 (page 43)
17 - Bolt, 27 Nm
18 - Bolt, 14 Nm
19 - Clamp
❑ For securing transfer box motor -V253- on transfer box
❑ From 02.05 no longer offered as individual part
20 - Oil drain plug, 20 Nm

❑ Always renew
21 - Bolt, 20 Nm
22 - Bolt, 20 Nm
23 - Bracket
24 - Oil temperature sender -G8- , 17 Nm
❑ A plug might be fitted in some transfer boxes ⇒ page 46
❑ The oil temperature sender was discontinued shortly after start of series production. At the same time,
transfer boxes were introduced which had no mounting hole in the housing for the oil temperature sender .
❑ Repair solution when oil temperature sender ⇒ page 46 is defective
25 - Seal
❑ Always renew
26 - Oil filler plug, 20 Nm
❑ Always renew
Touareg 2003 ➤
27 - Bolt, 32 Nm
28 - Balance weight
❑ Installed on some gearboxes
❑ Observe installation position ⇒ page 32
29 - Transfer box
Securing gearbox to assembly support with bolts -arrows-
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Pressing off dust plate
h re
hole
A - Separating device 22 … 115 mm, e.g. Kukko 17/2
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
Pressing on dust plate -A- to stop

o
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ate
do
priv
cum
for
en
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t.
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rig ht
py by
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Pulling out oil seal for output flange for rear propshaft
♦ Figure shows seal being pulled out of output flange for rear
propshaft.
♦ The procedure for pulling out oil seal for output flange for front
propshaft is the same.

Touareg 2003 ➤
Driving in oil seal for output flange for rear propshaft

– Half-fill space between sealing lip and dust lip with grease -G
052 128 A1- .
AG. Volkswagen AG d
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Inserting O-ring in the groove in the input shaft d -arrow-.
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pt
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ility
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spec
es, in part or in w
t to the co
rrectness of i
Pressing on dust plate -A- to stop
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nf
ercia
orm
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or c
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te
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Driving in oil seal for output flange for front propshaft
co Vo
by lksw
cted agen
Prote AG.
052 128 A1- .
Touareg 2003 ➤
Removing breather pipe -A-.

– Guide drift -B- with 5 mm ∅ into the hole of the breather pipe.
– Move breather pipe -A- in direction of arrow while simultane‐
ously levering breather pipe out of transfer box using a screw‐
driver -C-.
Driving in breather pipe

– Coat breather pipe with locking compound Loctite -648- before
driving in.
Repair solution for renewing transfer box motor -V253- and for
defective oil temperature sender -G8-
If transfer box -V253- is to be renewed or if oil temperature sender
-4- is defective, the oil temperature sender (with seal -3-) is re‐
placed with a plug -1- with seal -2-.
Allocation of sealing plug and oil seal: ⇒ Electronic Parts Cata‐ n AG. Volkswagen AG
logue (ETKA) . wage does
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Remove wiring harness to oil temperature sender -G8- as follows:

ility
ot p
wit
– Remove bracket -1- for connector from transfer box motor ,

, is n
h re
remove bolts -arrows- for this.

hole
spec
– Swing 10-pin connector -2- out of bracket.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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by
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Prote AG.

Touareg 2003 ➤
– Remove wires to pins -1- and -2- from 10-pin connector using
a suitable removal tool from wiring harness repair set -VAS
1978- .
– Remove wiring harness -3- for oil temperature sender .
– Seal holes for pins -1- and -2- in 10-pin connector using suit‐
able plugs ⇒ Electronic Parts Catalogue (ETKA) .
AG. Volkswagen AG d
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6.1 Renewing input shaft seal
ce
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nl
pt
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erm
ab
ility
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equipment required
wit
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♦ Puller -T10055-
hole
spec
♦ Adapter -T10055/2-
es, in part or in w
t to the co
♦ Sealing grease -G 052 128
rrectness of i
A1-
l purpos
♦ Sheet metal screw, about

4 mm in diameter
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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by
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Prote AG.
6.1.1 Removing
– Remove transfer box ⇒ page 29 .
Touareg 2003 ➤
– To pull out seal, screw sheet metal screw of about 4 mm di‐

ameter into seal -arrow-.
Screw sheet metal screw in so that it jams between seal and metal
ring of seal.
Do not screw in sheet metal screw too far to avoid damaging
bearing behind it.
– Pull out seal using puller -T10055- .
6.1.2 Installing
052 128 A1- .
– Drive in new seal to stop, being careful not to cant seal.
– Install transfer box ⇒ page 31 .
AG. Volkswagen AG d
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un
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ab
pe
ility
ot
wit
6.2 Renewing output flange oil seal for front propshaft (transfer box installed)
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
t. rig
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o
by c lksw
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Prote AG.

Touareg 2003 ➤

equipment required
♦ Counterhold -3145-
♦ Torque wrench -V.A.G n AG. Volkswagen AG do
swage es n
1332- byV
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ua
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♦ Thrust piece -T10185- tho tee
or
au ac
♦ Socket 36 mm, long - ss
ce
le
T10204-
un
pt
an
d
itte
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erm
ab
A1-
ility
ot p
wit
♦ Loctite -648-
is n
h re
ole,
♦ Bolts M10 x 25 (Qty. 2)
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.2.1 Removing
– Remove front propshaft ⇒ page 107 .
– Secure counterhold -3145- to output flange using 2 x M10 x
25 bolts -arrows-.
– Remove output flange nut.
– Remove output flange.
– Pull out oil seal using multi-purpose tool -VW 771- and puller
hooks -VW 771/37- .
– Clean thread on nut.
6.2.2 Installing
052 128 A1- .
Touareg 2003 ➤

– Insert output flange.
– Moisten new O-ring -arrow- with gear oil and insert.

wage es n
– Coat threads of new nut with locking compound Loctite yV
o -648- .
lks ot g
ua
d b ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Fit new nut for output flange and tighten to specified torque.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
– Lock nut at intended points -arrows- using, for example, a
Co
op py
punch
t. C rig
gh ht
yri
. p by
co Vo
by lksw
cted agen
Figure shows nut being secured on output flange for rear prop‐ Prote AG.
shaft.
– Install front propshaft ⇒ page 107 .
Torque settings
Nut for output flange to output shaft 130 Nm
♦ Always renew nut
6.3 Renewing output flange oil seal for rear propshaft (transfer box installed)

AG. Volkswagen AG d Touareg 2003 ➤
agen oes
Volksw Transfer box
not and final
gu
drive - Edition 08.2007
by ara
d
rise nte
Special tools and workshoputho eo
ra
equipment required ss a c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1332-
es, in part or in w
t to the co
♦ Socket 36 mm, long -
T10204-
rrectness of i
l purpos
A1-
♦ Loctite -648-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.3.1 Removing
– Remove output flange nut.
A - Hexagon bolts M10 x 30 with nuts
– Remove output flange.
Touareg 2003 ➤
hooks -VW 771/37- .
– Clean thread on nut.
6.3.2 lksw
agen Installing
AG. Volkswagen AG d
oes
not
Vo gu
y
– Half-fill space between isesealing lip and dust lip with grease -G ante
d b ar
052 128 A1- . thor eo
s au ra
c
– Drive in new seals to stop, being careful not to cant seal.
ce
le
un
pt
– Insert output flange.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Moisten new O-ring -arrow- with gear oil and insert.

nform
ercia
Figure shows O-ring on output flange for front propshaft.

m
– Coat threads of new nut with locking compound Loctite -648- .

com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Fit new nut for output flange and tighten to specified torque.

Touareg 2003 ➤
– Lock nut at intended points -arrows- using, for example, a

punch
.
Torque settings
Nut for output flange to output shaft 130 Nm
♦ Always renew nut
AG. Volkswagen AG d
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.
Touareg 2003 ➤
7 Removing and installing transfer box

motor -V253-
AG. Volkswagen AG d
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un
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ility
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7.1 Removing transfer box motor -V253-
h re
ole,
spec
If the transfer box motor -V253- is to be renewed, observe the
t to the co
following:
The new transfer box motor is set to a specified position.
rrectne
– To simplify installation, also set transfer box to this position, if
possible:
ss
– Switch on ignition.
o
cial p
f inform
– Turn transfer box operating unit -E473- to position “LOW”
mer
-arrow-.
atio
om
n
– Then switch off ignition.
c
i
or
n thi
te
If the previously used transfer box motor is to be reinstalled, it is
sd
iva
o
r
not necessary to turn the transfer box operating unit -E473- to the
p
cum
r
fo
position “LOW”.
en
ng
t.
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op
Continuation for all C py
t. rig
gh ht
yri by
– If shield is fitted over transfer box motor , remove it. cop Vo
by lksw
cted agen
Prote AG.
– Disconnect connections -A-, -B- and -C-.

– Remove bracket -D- -arrows-.

Touareg 2003 ➤
– Remove bolts -arrows- and remove transfer box motor from

transfer box.
7.2 Installing transfer box motor -V253-

If a new transfer box motor is to be fitted, observe the following:
Transfer box op‐ • Position of transfer box motor ⇒ (fig. 1)
erating unit - ⇒ page 55
E473- has been
turned to posi‐
tion “LOW” with
ignition on.
⇒ page 54
Transfer box op‐ • Position of transfer box motor ⇒ (fig. 2)
erating unit - ⇒ page 55
E473- has “not”
been turned to
position “LOW”.
(Fig. 1)
• Transfer box operating unit -E473- is in position “LOW”.
• The shaft with the master spline -1- must be in position -a-.
“a = about 10°”
wage es n
– If necessary, y V position transfer box motor shaft
o lks ot g special spline
ua
-1- as shown
ir se
d b
(with a screwdriver). ran
tee
tho
or
(Fig. 2) au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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by
cted agen
Prote AG.
7. Removing and installing transfer box motor V253 55

Touareg 2003 ➤
• Transfer box operating unit -E473- is “not” in position “LOW”

• The shaft with the master spline -1- must be in position -a-.
“a = about 60°”
– If necessary, position transfer box motor shaft special spline
-1- as shown (with a screwdriver).
Continuation for all
– Ensure that O-ring -1- for sealing transfer box motor against
transfer box is completely seated in groove.
– Seat transfer box motor on dowel sleeves -2- of transfer box.

– Ensure that special spline on transfer box motor -arrow A- and
on transfer box selector shaft -arrow B- align with one another.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
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d
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit bolts -arrows- for transfer box motor and tighten.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
Transfer boxoland
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final drive - Edition 08.2007
AG. V agen AG
agen does
lksw not
– Install bracket -D- -arrows-. db
yV
o gu
ara
rise nte
– Reconnect connections -A-, -B- and -C-. tho eo
s au ra
c
– If a shield was fitted over transfer box motor
s
, reinstall it.
ce
e
nl
pt
du
an
itte
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erm
ab
Torque settings
ility
ot p
wit
Transfer box motor to transfer box 27 Nm
, is n
h re
hole
Bracket to transfer box 14 Nm
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Removing and installing transfer box motor V253 57

Touareg 2003 ➤
39 – Final drive - rear differential

1 Electrical and electronic components and their locations for differential
lock on rear final drive
1 - Transverse lock-up control

unit -J647-
⇒ page 59 agen
AG. Volkswagen AG d
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olksw not
2 - Transfer box operating unit d by V gu
ara
-E473- rise nte
tho eo
u
❑ Location ⇒ page 59 ss a ra
c
ce
le
un
pt
⇒ General body repairs,
an
d
itte
y li
interior; Rep. Gr. 68 ;
rm
ab
Compartments, covers
pe
ility
and trims; Removing
ot
wit
, is n
and installing centre
h re
hole
console .
spec
es, in part or in w
❑ Allocation ⇒ Electronic
t to the co
parts catalogue (ETKA)
3 - Axle differential lock motor
-V304-
rrectness of i
l purpos

⇒ page 66
nform
ercia
❑ The following compo‐

m
nents are integrated in
a
com
tio
the axle differential lock
n in
r
motor -V304- :
te o
thi
s
iva
do
Engine temperature
r
rp
cum
sender -G407-
fo
en
ng
t.
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op
Hall sender 1 for axle dif‐ C py
t. rig
ferential lock -G460-
gh ht
pyri by
Vo
co lksw
by
cted
Hall sender 2 for axle dif‐
agen
Prote AG.
ferential lock -G461-
Differential lock motor

brake
4 - Diagnostic connection
5 - Multi-function display in dash panel insert
❑ Display for the status of and information on the axle differential lock on the rear final drive
58 Rep. Gr.39 - Final drive - rear differential

Touareg 2003 ➤
Location of Differential lock control unit -J647-

The differential lock control unit -J647- is located behind the side
trim on the rear left wheel housing -arrow-. agen
AG. Volkswagen AG d
o w es n
olks ot g
Removing and installing differential lock controledunit
by -J647-
V ua
ran
⇒ page 59 . ho
ris tee
t or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
Location of transfer box operating unit -E473-
es, in part or in w
t to the co
The transfer box operating unit -E473- -1- is located in the gear‐
box cover -2- in the centre console.
Removing and installing transfer box operating unit -E473- ⇒
rrectness of i
General body repairs, interior; Rep. Gr. 68 ; Compartments, cov‐
l purpos
ers and trims; Removing and installing centre console .
nf
ercia
orm
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atio
om
n in
or c
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te
sd
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Location of Differential lock motor -V304-
o
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f
en
ng
t.
The differential lock motor -V304- -A- is located in front of the left-
yi Co
op py
hand flange shaft on the rear final drive. t. C rig
gh ht
pyri by
Removing and installing Differential lock motor -V304-
co Vo
by lksw
cted
⇒ page 66
agen
Prote AG.
Diagnostic connection
The diagnosis connector is located under the cover of the driver's
side footwell.
1.1 Removing and installing differential lock

control unit -J647-
1.1.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
1. Electrical and electronic components and their locations for differential lock on rear final drive 59
Touareg 2003 ➤
– Switch of the ignition and all electrical consumers and remove

the ignition key.
– Disconnect battery earth strap ⇒ Electrical system; Rep. Gr.
27 ; Disconnecting and connecting battery .
– Remove trim at rear left ⇒ General body repairs, interior; Rep.
Gr. 70 ; Removing and installing side trim .
Vehicles with Climatronic 4-C
– Adjust the 2nd heating and air conditioning unit in rear to the
repair position ⇒ Heating, Air Conditioning; Rep. Gr. 87 ;
Components for control and regulation of Climatronic 4-C, rear
(2nd heating and air conditioning unit); Moving 2nd heating
and air conditioning unit to repair position .
Continuation for all vehicles
– Remove connector -1- on differential lock control unit -J647- .
– Unscrew bolt -2-.
– Unclip the retainer with the differential lock control unit -J647-
-3- from the assembly -arrows- and remove the retainer with
the differential lock control unit -J647- .
1.1.2 Installing
– First clip the retainer with the differential lock control unit -
J647- -3- to the assembly -arrows-. en AG. V
olkswagen AG
wag does
– Then tighten bolt -2- to 2 Nm. olks not
byV gu
ara
ed
is nte
– Connect the battery earth strap
ut
h and follow procedure after
or eo
ra
connecting battery ⇒ Electrical
ss a system; Rep. Gr. 27 ; Battery; c
Disconnecting and connecting battery .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
2 Check gear oil in rear final drive

AG. Volkswagen AG d
agen oes
olksw not
– To check gearbox oil, removeedoil b plug -arrow-.
y V gu
ara
ris nte
o
The oil level is correct when athe
ut rear final drive is filled to the lower
h eo
ra
edge of the filler hole. ss c
ce
le
un
pt
– Screw in plug -arrow- with new seal.
an
d
itte
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When filling with fresh oil, note following:
erm
ab
ility
ot p
wit
is n
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ole,
– Fill with gear oil to lower edge of filler hole.
spec
– Screw in plug -arrow- with new seal.
t to the co
Torque settings
Oil filler plug to rear final drive 35 Nm
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Check gear oil in rear final drive 61

Touareg 2003 ➤
3 Removing and installing rear final drive

equipment required
1331-
1332-
sal gearbox mounting
-1359/2-
AG. Volkswagen AG d
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un
pt
an
d
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectne
3.1 Removing rear final drive

ss o
cial p
f in
– Raise vehicle.
form
mer
– If there is a skid plate beneath rear final drive, remove it ⇒

atio
m
Rep. Gr. 50 ; Skid plate .

o
n
c
i
or
n thi
– Remove rear section of exhaust system ⇒ Rep. Gr. 26 ; Re‐

te
sd
va
moving and installing parts of exhaust system.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
lkswage es n
o ot g
– Check if there ed
bis
y Va coloured mark on the rear propshaft ua
ran and
the propshaftoris flange of the rear final drive. tee
th or
au ac
– If no marking
ss can be found, mark position of propshaft flange
-arrow A- relative to rear final drive -arrow B- using coloured
ce
e
nl
pt
du
marks.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Separate propshaft from rear final drive and tie up -arrow-
rrectness of i
⇒ page 110 .
l purpos
– If an axle differential lock motor -V304- is fitted, remove it

⇒ page 66 .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Unbolt right -1- and left -2- drive shafts and tie them up.
p by
co Vo
by lksw
cted agen
Prote AG.
sal gearbox support -V.A.G 1359/2- under rear final drive.

– Remove rear final drive securing bolts with nuts at assembly
subframe -arrows-.
– Tip up rear final drive at propshaft flange -A-.

– Lower rear final drive slightly and pull breather line off breather
connection ⇒ page 64 .
– Lower rear final drive.
3.2 Installing rear final drive

Always renew securing bolts for rear propshaft.
3. Removing and installing rear final drive 63

AG. Volkswagen AG d
agen oes
olksw not
V gu
Touareg 2003 ➤ d by ara
ise nte
r
ut
ho eo
ra
s a c
s
– To prevent imbalance, flanges of rear propshaft -arrow A- and
ce
e
nl
pt
du
of rear final drive -arrow B- must be installed so that factory
an
itte
y li
markings, or the markings made on removal, are aligned.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Tighten rear final drive to subframe -arrows- ⇒ Running gear,
nf
ercia
axles, steering; Rep. Gr. 42 ; Repairing rear axle .
orm
m
atio
– Reconnect left -2- and right -1- drive shafts to flange shafts ⇒
om
Running gear, axles, steering; Rep. Gr. 42 ; Repairing drive
n in
or c
shafts .
thi
te
sd
iva
– If an axle differential lock motor -V304- is part of original equip‐
o
r
rp
cu
ment, reinstall it ⇒ page 66 .
o
m
f
en
ng
t.
yi Co
– Reconnect rear propshaft ⇒ page 110 . Cop py
t. rig
gh ht
yri
– When doing this, install centre bearing of propshaft free of p by
o Vo
by c
stress ⇒ page 114 .
lksw
cted agen
Prote AG.
– Check gear oil in rear final drive ⇒ page 61 .
– If there was a skid plate beneath rear final drive, install it ⇒
– Install rear section of exhaust system ⇒ Rep. Gr. 26 ; Re‐
moving and installing parts of the exhaust system.
3.3 Routing breather line for rear final drive

The breather line consists of two sections.
“Section 1” of the breather line -A- runs from the breather con‐
nection -B- of the rear final drive over the subframe to connection
-C-.
“Section 1” of the breather line -A- is locked to the “Section 2” with

connection -C-.
“Section 2” of the breather line -A- is clipped on below the fuel
filler neck (-D-).
Removing
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .

Touareg 2003 ➤
– Unbolt cover plate -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
– Unclip breather line from longitudinal member and below fuel
itte
y li
filler neck.
erm
ab
ility
ot p
– Pull breather line off breather connection of rear final drive.
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
– The push-on connections of both breather lines must engage
with each other.
rrectness of i
– Route breather line free of kinks.
l purpos
– Clip in breather line beneath fuel filler neck.

– Ensure that breather line fits tightly.
nf
ercia
– If the breather connection -B- on rear final drive (⇒ figure orm

m
atio
m
above) was removed or loosened, check torque specification.

o
n in
or c
thi
e
– Bolt on cover plate -arrows-, observing torque specification.

t
sd
iva
o
r
rp
cu
Torque settings
o
m
f
en
ng
t.
yi Co
Breather connection to rear final drive t. Cop
15 Nm py
rig
gh
Cover plate to body 9 Nm
ht
pyri by
Vo
o
by c lksw
cted agen
– Remove rear right wheel housing liner ⇒ General body re‐ Prote AG.
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .
3. Removing and installing rear final drive 65

Touareg 2003 ➤
4 Removing and installing axle differ‐

ential lock motor -V304-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
4.1 Removing axle differential lock motor -
ce
e
nl
pt
du
V304-
an
itte
y li
erm
ab
– Disconnect the two connections on axle differential lock mo‐
ility
ot p
tor .
wit
, is n
h re
hole
– Remove axle differential lock motor -A- with bracket for con‐
spec
nector -B-, remove the four securing bolts to do this.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
4.2 Installing axle differential lock motor -

p
cum
for
V304-
en
ng
t.
yi Co
Cop py
– Renew O-ring -arrow- on differential lock motor . ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ The differential lock motor is supplied as part with O-ring in‐

stalled.
♦ The O-ring is secured with a protective sleeve.
♦ The protective sleeve must be removed before the differential
lock motor is installed.

Touareg 2003 ➤
– Fit the axle differential lock motor -A- with bracket for connec‐
tor -B- onto rear final drive, install the four securing bolts and
tighten to prescribed torque.
– Reconnect the two connections on axle differential lock motor .
Torque settings
Differential lock motor to rear final drive 8 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Removing and installing axle differential lock motor V304 67

Touareg 2003 ➤
5 Renewing oil seals on rear final drive
5.1 Renewing left flange shaft seal, vehicles without differential lock

equipment required
♦ Press tool -VW 412-
♦ Tube -3146-
device
A1-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva

pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
5.1.1 Removing
– Remove rear final drive ⇒ page 62 .
– Secure multi-purpose tool -VW 771- to left flange shaft.
– Pull out left flange shaft.
– Pull out flange shaft oil seal using -VW 771/1- and -
VW 771/37- .
5.1.2 Installing
– Drive in new seal to stop.
052 128 A1- .
AG. Volkswagen A
Before installing flangeolshaft,
ksw
agencheck dust cap for
G do
damage.
es n
ot g
Renew
dust cap if necessary
db
y V⇒ page 70 . ua
r e an
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
– Remove old retaining ring -A- from groove in flange shaft using
ole,
spec
pliers .
t to the co
B - Protective jaw covers

– Insert new retaining ring in groove in flange shaft, being careful
not to overstretch ring.
rrectne
– Drive in flange shaft using a plastic head hammer .

ss
– Install rear final drive ⇒ page 63 .

o
cial p
f inform

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
69
cop Vo
by lksw
Prote
cted AG.
agen 5. Renewing oil seals on rear final drive
Touareg 2003 ➤
5.1.3 Renewing flange shaft dust cap

– Press dust cap -B- off flange shaft.
– Press dust cap -A- onto flange shaft.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
5.2 Renewing left flange shaft seal, vehicles with differential lock
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤

equipment required
♦ Sleeve -3144-
A1-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
♦ -3- - Kukko 17/2 Separating device s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
71
cted agen
Prote AG.
5. Renewing oil seals on rear final drive
Touareg 2003 ➤
5.2.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
– Pull out flange shaft oil seal using multi-purpose tool -VW 771-
y li
erm
ab
and puller hooks -VW 771/37- .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
5.2.2 Installing
m
at
om
ion

c
in t
or
his
te
a
do
riv
052 128 A1- .

p
cum
for
en
ng
Before installing flange shaft, check dust cap for damage. Renew
t.
yi Co
op
dust cap if necessary ⇒ page 73 . C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
pliers .
wage
5.2.3 Renewing flange shaft dust cap lks es n
o ot g
byV ua
d ran
ir se tee
– Press dust cap -B- off flange shaft. utho
or
s a ac
A - Separating device 22 … 115 mm, e.g. Kukko s17/2
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.3 Renewing right flange shaft seal, vehi‐
cles without differential lock
5. Renewing oil seals on rear final drive 73

Touareg 2003 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
♦ Sealing grease -G 052 128 A1- ss a ra
c
ce
e
5.3.1 Removing
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Secure multi-purpose tool -VW 771- to right flange shaft.
wit
, is n
h re
– Pull out right flange shaft.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5.3.2 Installing
052 128 A1- .
dust cap if necessary ⇒ page 70 .

Touareg 2003 ➤
pliers .
5.4 Renewing right flange shaft seal, vehi‐

cles with differential lock
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
♦ Sealing grease -G 052 128 A1-

at
do
priv
5.4.1 Removing
um
for
en
ng
t.
yi Co
op
– Remove rear final drive ⇒ page 62 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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5.4.2 Installing
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
052 128 A1- .

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
thi
te
sd
pliers .
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
– Insert new retaining ring in groove in flange shaft, being careful Cop py
t. rig
not to overstretch ring. opyri
gh by
Vo
ht
by c
lksw
cted agen
Prote AG.
5.5 Renewing propshaft flange oil seal on rear final drive (final drive removed)

Touareg 2003 ➤

equipment required
♦ Press tool -VW 407- lkswage es n
o ot g
yV ua
♦ Press tool -VW 412- ir se
d b ran
tee
tho
or
♦ Multipurpose tool -VW 771- au ac
ss
ce
le
un
pt
an
d
itte
♦ Drift sleeve -40 - 20-
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
♦ Counterhold -3145- (modi‐

fication: enlarge holes to
10 mm diameter)
♦
1576-
♦ Bearing preload gauge a-gen AG. Volkswagen AG do
VAS 6222- Vol
ksw es n
ot g
by ua
ed ran
♦ Thrust piece
ho
r-T10182-
is tee
t or
au ac
♦ -3- - Kukko
ss 17/2 Separating
device
ce
e
nl
pt
du
an
itte
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erm
ab
A1-
ility
ot p
♦ Loctite -648-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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r
rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.5.1 Removing
– If necessary, enlarge holes in counterhold -3145- to 10 mm
diameter.
– Place rear final drive on a workbench.
– Measure friction torque before loosening drive pinion nut.
– Note this value. Friction torque must be restored to this value
after the seal is renewed.
Use bearing preload gauge -VAS 6222- .

Touareg 2003 ➤
– Remove propshaft flange hexagon nut as follows:

– Secure counterhold -3145- to propshaft output flange
-arrows- using 2 x M10 x 25 bolts.
When loosening propshaft flange hexagon nut counterhold using
counterhold tool -3145- (2nd mechanic).
– Mark installation position of propshaft flange -arrow A- relative

to drive pinion -arrow B-.
– Pull off propshaft flange. If it is difficult to move, use multipur‐
pose tool -VW 771- .
hooks -VW 771/37- .
– Clean securing nut thread on pinion shaft.
5.5.2 Installing
AG. Volkswagen AG d
052 128 A1- . ksw
agen oes
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Before installing propshaft flange, check dust cap for damage.ed
b ua
ran
ris
Renew dust cap if necessary ⇒ page 80 . tho tee
or
u ac
sa
– Install propshaft flange, observing the marks made
s before re‐
ce
le
moval ⇒ page 79 .
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Tighten new drive pinion nut until torque friction measured be‐
es, in part or in w
fore removal is attained ⇒ page 78 . t to the co

When tightening propshaft flange hexagon nut counterhold using
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
Increase torque setting slowly and check friction torque at regular

intervals. The friction torque measured prior to removal must not
be exceeded. Otherwise the rear final drive must be renewed.
5.5.3 Renewing dust cap for propshaft flangewagen AG. Volkswagen AG doe
ks s no
Vol t gu
– Press off dust cap for propshaft flange. ed by ara
ris nte
A - Separating device 22 … 115 mm, e.g. Kukko 17/2utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press dust cap -A- onto propshaft flange.
l purpos
Installation position: Recess in dust cap faces upwards towards

drive sleeve -40 - 20- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
6 Renewing bonded rubber bush on rear final drive

equipment required
♦ Thrust piece -VW 442-
♦ Tube -30 - 14-
♦ Assembly tool -3301-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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ce
le
un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
6.1 Installation position of bonded rubber

fo
en
ng
t.
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bush
Co
Cop py
ht. rig
rig ht
by
Bonded rubber bush with 2 notches
copy Vo
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Prote
– The notches -arrows- in bush must be vertical relative to final
AG.
drive.
6. Renewing bonded rubber bush on rear final drive 81

Touareg 2003 ➤

The smaller notches -arrows- and the smaller holes -A- of bush
must be vertical relative to final drive.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
6.2 Pulling bonded rubber bush on prop‐ ris nte
ho eo
ut ra
shaft flange out and in s a c
s
ce
e
nl
pt
du
Before inserting, be sure to grease spindle -3346/2- with molyb‐
an
itte
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denum grease .
erm
ab
ility
ot p
– Pulling out bonded rubber bush.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
– Pull in bonded rubber bush -A- to stop.

c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6.3 Pulling rear bonded rubber bush out and

in
Removing and installing bonded rubber bush on rear final drive
is identical to the procedure for removing and installing bonded
rubber bush on propshaft flange ⇒ page 82 .
Remove respective flange shaft before pulling out bonded rubber
bush ⇒ page 68 .

Touareg 2003 ➤
39 – Final drive - front differential

1 Checking oil in front final drive
– To check gearbox oil, remove oil plug -arrow-.

The oil level is correct when the front final drive isn Afilled
G. Voto
lksthe
wagelower
n AG d
edge of the filler hole. olkswage oes
no
V t gu
by ara
– Screw in plug -arrow- with new
ris seal.
ed nte
tho eo
When filling with fresh oil, note
ss
au following: ra
c
ce
le

un
pt
an
d
itte
– Fill with gear oil to lower edge of filler hole. y li

erm
ab
ility
ot p
– Screw in plug -arrow- with new seal. wit

is n
h re
Torque settings
ole,
spec
Oil filler plug to front final drive 35 Nm

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Checking oil in front final drive 83

Touareg 2003 ➤ AG. Volkswagen AG d
agen
Transfer box and final odrive
lksw - Edition 08.2007
oes
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2 Removing and installing front final drive ss
aut ra
c
ce
e
nl
pt
du
an
itte
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ab
equipment required
ility
ot p
♦ Spring tensioner -VW 552-
wit
, is n
h re
hole
♦ Spindle -10 - 222 A /11-
spec
es, in part or in w
t to the co
1331-
rrectness of i
1332-
l purpos

nform
ercia
-1359/2-
m
at
♦ Bit 14 mm (nominal diame‐
om
ion
ter) -T10099/1-
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.1 Removing front final drive

– Loosen wheel bolts.
– Raise vehicle.
– Remove front wheels.
– Remove wheel housing liners on left and right sides ⇒ General
body repairs, exterior; Rep. Gr. 68 ; Removing and installing
wheel housing liner .
84 Rep. Gr.39 - Final drive - front differential

Touareg 2003 ➤
– If air spring struts are fitted, loosen air line union -1- and let air
escape. Then retighten union to prescribed torque ⇒ Running
gear, axles, steering; Rep. Gr. 40 ; Repairing front suspen‐
sion; Removing and installing air spring strut .
n AG. Volkswagen A ge G do
swa es
– Hook spring compressor by
-VW
Vol 552- into upper opening of
k not
gu
ara
wheel housing -arrow ris A- and onto upper suspension link
ed
nte
-arrow B- on eachuthside of vehicle.
o eo
r a ac
ss
– Pretension suspension link slightly so that ball head pin of
ce
e
nl
swivel joint will not be damaged.
pt
du
an
itte
y li
– Remove noise insulation below engine and gearbox.
erm
ab
ility
ot p
– If there is a skid plate beneath front final drive, remove it ⇒
wit
, is n
h re
hole
spec
– Remove noise insulation retainer.
es, in part or in w
t to the co
– Remove shield from front final drive -arrows-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
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cu
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f
en
ng
t.
yi Co
– Disconnect front propshaft from front final drive flange Cop py
-arrows A- and tie-up ⇒ page 107 . ht. rig
rig ht
py by
co Vo
– Separate left and right drive shafts. Use bit -T10099/1- to loos‐
by lksw
cted agen
Prote
en bolts.
AG.
– If a shield -A- is fitted to steering box, remove it (2 bolts).

– Remove bolts -B- for universal joint on steering box and pull
universal joint off steering box.
2. Removing and installing front final drive 85

Touareg 2003 ➤
– If coolant pipe -1- is fitted to left longitudinal member, remove

it by removing nuts -arrow A- and bracket -B-.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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– Hook spindles -10 - 222 A /11- in eyes -arrows- of engine sub‐
ce
le
un
pt
frame on left and right sides of vehicle.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Seat a wooden block -A-, approximately 300 mm long, in the

stirrup of each spindle -10 - 222 A /11- .
nform
ercia
– The stirrups must face to the rear.

m
a
com
tion in
– Tighten winged nuts of spindles , ensuring that the wooden
r
te o
thi
blocks lie against the assembly subframe -B-.
s
iva
do
r
rp
– Place insert from a trolley jack in engine and gearbox jack -

cum
fo
V.A.G 1383 A- . en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Position engine and gearbox jack -V.A.G 1383 A- under en‐

gine subframe and exert slight counter pressure.
A - Wooden block
– Remove securing bolts -arrows- for subframe.

Touareg 2003 ➤
– Check inner shape of sleeve -arrow- in bonded rubber bush.

Inner shape of
sleeve
squared Subframe cannot be fixed in position.
– Mark position of assembly subframe on
body with a felt tip pen.
round Fix subframe in position prior to removal ⇒
Running gear, axles, steering; Rep. Gr. 40 ;
Assembly overview - subframe, anti-roll bar,
suspension links; Fixing subframe and brack‐
ets in position .
– Remove bolts securing assembly subframe to body -arrows-
in fig. N39-1222.
– Separate left and right coupling rods -1- from anti-roll bar.
– Remove bolted connection from air spring strut or suspension
strut to lower wishbone. To remove bolt -2-, lower assembly
subframe about 50 mm -direction of arrow- using spindles -10
- 222 A /11- .
– Use these bolts -2- with additional washers or bolts M14 x 1.5
about 90 mm long to secure engine carrier to body on left and
right sides -3-.
– Remove engine and gearbox jack -V.A.G 1383 A- fromwunder
agen
AG. Volkswagen AG d
oes
engine subframe. yV
olks not
g b ua
ed ran
oris tee
th or
s au ac
– Position engine and gearbox jack A- with univer‐ -V.A.Gs 1383
ce
e
sal gearbox support -1359/2- under subframe and exert slight

nl
pt
du
an
counter pressure. When doing this, place wooden block -A-
itte
y li
under assembly subframe and -B- under front final drive.
erm
ab
ility
ot p
– Secure subframe with belt from universal gearbox support -
wit
, is n
V.A.G 1359/2- .
h re
hole
spec
– Remove spindle -10 - 222 A /11- from assembly subframe.
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull breather line -A- with connecting nipple -arrow-carefully

off front final drive.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Carefully lower assembly subframe with front final drive to di‐

mension -a-, approx. 200 mm.
– Measure dimension -a- between body and bolt down surface
of assembly subframe.
– Remove connecting bolts with nuts -1- to -3- for front final drive
-A- to assembly subframe -B-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
A second mechanic is required to remove final drive. rrectness of i
– Remove front final drive -1- to rear between assembly sub‐

l purpos
frame and engine/gearbox as follows:

– First lift up left drive shaft.
nf
ercia
or
– Then second mechanic can remove front final drive from sup‐
m
m
atio
ports in assembly subframe.

om
n in
or c
– In the process, guide right drive shaft out of flange shaft.

thi
te
sd
iva
– Raise front final drive over steering box and guide out to rear.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
2.2 Installing front final drive pyri by
Vo
co lksw
by
cted agen
Prote
AG.
Always renew securing bolts for front propshaft.

Touareg 2003 ➤
A second mechanic is required to insert front final drive in as‐

sembly subframe supports.
– Install connecting bolts with nuts -1- through -3- for front final
drive -A- to subframe -B- ⇒ Running gear, axles, steering;
Rep. Gr. 40 ; Repairing front axle .
– Raise assembly subframe using gearbox jack.
lkswage es n
– Push breather d by V line -A- union nipple -arrow-t carefully
o o g
ua on front
final drive.
o
ir se When doing this the connecting nipple
ran
teemust be in‐
serted
au
th between the raised portions of the housing and or
ac be
horizontal.
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Hook spindles -10 - 222 A /11- in eyes -arrows- of engine sub‐

rrectne
frame on left and right sides of vehicle.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Seat a wooden block approximately 300 mm long in the stirrup
p by
co Vo
of each spindle -10 - 222 A /11- .
by lksw
cted agen
Prote AG.
– The stirrups must face to the rear.
– Tighten winged nuts of spindles , ensuring that the wooden
blocks lie against the assembly subframe -B-.
– Remove engine and gearbox jack -V.A.G 1383 A- from under
assembly subframe.
– Place insert from a trolley jack in engine and gearbox jack -
V.A.G 1383 A- .

Touareg 2003 ➤
– Position engine and gearbox jack -V.A.G 1383 A- under en‐

gine subframe and exert slight counter pressure.
A - Wooden block
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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h
aut ra
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– Remove the temporarily installed bolts -3- for engine subframe s
ce
e
on left and right sides.
nl
pt
du
an
itte
y li
– Install bolts -2- for air spring strut or suspension strut on lower
erm
ab
wishbone.
ility
ot p
wit
, is n
– Bolt left and right coupling rods -1- to anti-roll bar ⇒ Running
h re
gear, axles, steering; Rep. Gr. 40 ; Repairing front suspen‐
hole
spec
sion .
es, in part or in w
t to the co
rrectness of i
l purpos
– Before bolting on subframe, check inner shape of sleeve of

bonded rubber bush in subframe -arrow-.
nform
ercia
Inner shape of
m
at
om
sleeve
ion
c
in t
or
squared – After installing subframe, check wheel align‐
his
ate
ment ⇒ Running gear, axles, steering; Rep.
do
priv
c
Gr. 44 ; Wheels, tyres, alignment .
um
for
en
ng
round – If steering wheel is not straight, check wheel

t.
yi Co
op
alignment ⇒ Running gear, axles, steering; C py
t. rig
Rep. Gr. 44 ; Wheel alignment .
gh ht
pyri by
Vo
o
by c lksw
cted
– Bolt on subframe -arrows- ⇒ Running gear, axles, steering;
agen
Prote AG.
Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar,
suspension links; Fixing subframe and brackets in position .
– If wheel alignment is performed, bolts must be renewed ⇒

Running gear, axles, steering; Rep. Gr. 40 ; Assembly over‐
view - subframe, anti-roll bar, suspension links; Fixing sub‐
frame and brackets in place .
– Tighten bolts to specified torque ⇒ Running gear, axles, steer‐
ing; Rep. Gr. 48 .
– Remove spindle -10 - 222 A /11- from assembly subframe.

Touareg 2003 ➤
– Push universal joint onto steering box and tighten bolt -B- to
specified torque ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Assembly overview - steering box .
– If a shield -A- was fitted to steering box, reinstall it ⇒ Running
gear, axles, steering; Rep. Gr. 40 ; Assembly overview of
steering box .
– If coolant pipes -1- were fitted, reinstall on left longitudinal

member. When doing this, tighten nut -arrow A- and bracket
-arrow B- ⇒ Rep. Gr. 82 ; Auxiliary heater .
– Reconnect front propshaft ⇒ page 107 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
– Install shield -arrows- and tighten bolts to 10 Nm. pt

an
d
itte
y li
erm
– Reconnect drive shafts to flange shafts ⇒ Running gear, ab

ility
ot p
axles, steering; Rep. Gr. 40 ; Repairing drive shafts . wit

is n
h re
– Remove spring tensioner -VW 552- .
ole,
spec
– Install wheel housing liners on left and right sides ⇒ General

t to the co
body repairs, exterior; Rep. Gr. 66 ; Removing and installing

wheel housing liner .
– Check oil in front final drive ⇒ page 83 .
rrectne
– If there was a skid plate beneath front final drive, install it ⇒

ss o
cial p
– Install front wheels ⇒ Running gear, axles, steering; Rep. Gr.

inform
44 ; Fitting wheel and tyre, fitting wheel .

mer
atio
m
– It may be necessary to check wheel alignment ⇒ Running

o
n
c
gear, axles, steering; Rep. Gr. 44 ; Wheel alignment .

i
or
n thi
te
sd
iva
o
r
2.3 Routing breather line for front final drive

p
cum
r
fo
en
ng
t.
yi
The breather line -1- runs from the front final drive -3- behind the
Co
op py
right engine mounting -4- to the air cleaner -2- and is clipped into
t. C rig
gh ht
yri
it. p by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
3 Renewing oil seals on front final drive
3.1 Renewing oil seal for left flange shaft
Special tools and workshop n AG. Volkswagen AG do

equipment required lkswage es n
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byV ua
♦ Press tool -VW 412- ir se
d ran
tee
tho
u or
♦ Thrust piece -VW 432- ss
a ac
ce
le
♦ Support rails -VW 457-
un
pt
an
d
itte
y li
♦ Multipurpose tool -VW 771- rm
ab
pe
ility
♦ Pulling ring -2003/3-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
A1-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ -3- - Kukko 17/2 Separating device

Touareg 2003 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
3.1.1 Removing
es, in part or in w
t to the co
– Remove front final drive ⇒ page 84 .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Pull out flange shaft oil seal using multi-purpose tool -VW 771- p by
co Vo
lksw
and puller hooks -771/37- .
by
cted agen
Prote AG.
3.1.2 Installing
052 128 A1- .
3. Renewing oil seals on front final drive 93

Touareg 2003 ➤
pliers .
– Install front final drive ⇒ page 88 .
3.1.3 Renewing flange shaft dust cap

– Press dust cap -B- off flange shaft.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
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pe
ility
ot
wit
, is n
h re

hole
spec
Position sleeve -3301/3- with notch -arrow- facing dust cap -A-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
3.2 Renewing seal for right flange shaft

s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
op
♦ Multipurpose tool -VW 771- C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Touareg 2003 ➤
♦ Sealing grease -G 052 128 A1-
3.2.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
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or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
and puller hooks -771/37- .

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
3.2.2 Installing
r
te o
thi
s
iva
do

r
rp
cum
fo
en
g
n
t.
yi Co
052 128 A1- . Cop py
t. rig
gh ht
yri
p by
o Vo
by c
lksw
cted agen
Prote AG.

Touareg 2003 ➤
pliers .
3.3 Renewing seal for propshaft flange on front final drive (final drive removed)

equipment required
♦ Puller hooks -771/37-
♦ Drift sleeve -40 - 20-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
AG. Volkswagen AG d
1576- ksw
agen oes
n ol ot g
yV ua
♦ Bearing preloaded gauge -
b ran
ris
VAS 6222-
ut
ho tee
or
sa ac
♦ Thrustspiece -T10183-
ce
le
un
pt
an
d
itte
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device
erm
ab
ility
ot p
wit
is n
A1-
h re
ole,
♦ Loctite -648-
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.3.1 Removing
– Place front final drive on a workbench.
– Measure friction torque before loosening drive pinion nut.
– Note this value. Friction torque must be restored to this value
after the seal is renewed.
Use bearing preload gauge -VAS 6222- .

Touareg 2003 ➤
– Remove propshaft flange hexagon nut.

A - Bolts M10 x 25 (Qty. 2)
When loosening propshaft flange hexagon nut counterhold using
– Mark installation position of propshaft flange -arrow A- relative

to drive pinion -arrow B-.
– Pull off propshaft flange. If it is difficult to move, use multipur‐
pose tool -VW 771- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Pull out seal.
ce
le
un
– Clean securing nut thread on pinion shaft. pt

an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
3.3.2 Installing
nform
ercia

m
a
com
tio
n in
r
052 128 A1- .

te o
thi
s
iva
do
Before installing propshaft flange, check dust cap for damage.

r
rp
cum
Renew dust cap if necessary ⇒ page 99 .

fo
en
ng
t.
yi Co
– Install propshaft flange, observing the marks made before re‐ Cop py
moval ⇒ page 98 .
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
– Tighten new drive pinion nut until torque friction measured be‐
fore removal is attained ⇒ page 97 .
A - Bolts M10 x 25 (Qty. 2)
When tightening propshaft flange hexagon nut counterhold using
Increase torque setting slowly and check friction torque at regular

intervals. The friction torque measured before removal must not
be exceeded! Otherwise front final drive must be renewed!
– Install front final drive ⇒ page 88 . agen
AG. Volkswagen AG d
oes
olksw not
– Check oil in front final drive ⇒ page d by V83 . gu
ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
3.3.3 Renewing dust cap for propshaft flange
hole
spec
es, in part or in w
– Press off dust cap for propshaft flange.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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f
– Press dust cap -A- onto propshaft flange.

en
ng
t.
yi Co
op py
Installation position: Recess in dust cap faces upwards towards
. C rig
ht ht
rig
drive sleeve -40 - 20- . py by
co Vo
by lksw
cted agen
Prote AG.

Touareg 2003 ➤
4 Renewing needle bearing for left flange shaft

equipment required
AG. Volkswagen AG d
♦ Press tool -30 - 505- ksw
agen oes
not
Vol
by gu
♦ Press tool -30 - 506 B- ised ara
nte
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h
♦ -1- - Kukko internal puller s aut ra
c
21/6 s
ce
le
un
pt
♦ -4- - Kukko 22/2 Counter‐
an
d
itte
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hold
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4.1 Removing needle bearing

– Remove left flange shaft and oil seal ⇒ page 92 .
– Pull out left flange shaft needle bearing.
A - Internal puller 37 … 46 mm, e.g. Kukko 21/6
B - Counterhold, e.g. Kukko 22/2

Touareg 2003 ➤
4.2 Installing needle bearing

– Drive in left flange shaft needle bearing -A- to stop.
– Install left flange shaft and oil seal ⇒ page 92 .
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Renewing needle bearing for left flange shaft 101

Touareg 2003 ➤
gen AG
. Volkswagen AG
d wa oes
olks not
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ara
ed
5 Renewing bonded rubber bush on front final drive ris nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
equipment required
y li
erm
ab
ility
ot p
wit
is n
♦ Tube -30 - 14-
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
♦ Thrust pad -VW 512-

♦ Assembly tool -T10030-
AG. Volkswagen AG d
agen oes
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au ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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5.1 Installation position of bonded rubber

hole
spec
bush
es, in part or in w
t to the co

– The notches -arrows- in bush must be vertical relative to final
rrectness of i
drive.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Renewing bonded rubber bush on front final drive 103

Touareg 2003 ➤

The smaller notches -arrows- and the smaller holes -A- of bush
must be vertical relative to final drive.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
5.2 Pulling bonded rubber bush on prop‐
itte
y li
rm
ab
shaft flange out and in
pe
ility
ot
wit
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h re
hole
spec
It is important to grease spindle -3346/2- with Molybdenum
es, in part or in w
grease before using.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Pull in bonded rubber bush -A-.
s
iva
do
r
rp
c
Pull in bonded rubber bush -A- only until dimension -a- has been
um
fo
en
g
attained ⇒ page 104 .

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Installation depth for bonded rubber bush on propshaft flange.

Dimension -a- = 47.5 mm

Touareg 2003 ➤
5.3 Pulling bonded rubber bush out of and

into front of housing
It is important to grease spindle -3346/2- with Molybdenum
grease before using.
– To do this, set special tool -3346/1- on spindle -3346/2- with
flat shoulder facing bonded rubber bush.
– Pull in bonded rubber bush -A- until it is centred in front final

drive housing. wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5.4 Pulling bonded rubber bush out of and
into left flange shaft extension tube
rrectness of i
Removing and installing bonded rubber bush on extension tube
l purpos
for left flange shaft is identical to the procedure for removing and
installing bonded rubber bush on rear final drive ⇒ page 81 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Renewing bonded rubber bush on front final drive 105

Touareg 2003 ➤
39 – Final drive - differential

AG. Volkswagen
agen AG do
ksw es n
Vol ot g
1 Removing and installing propshafts
ris
ed
by ua
ran
tee
tho
or
au ac
ss
ce
le
1.1 Assembly overview

un
pt
an
d
itte
y li
Removing and installing front propshaft ⇒ page 107 .
rm
ab
pe
ility
Removing and installing rear propshaft ⇒ page 110 .
ot
wit
, is n
h re
hole
spec
1 - Front final drive
es, in part or in w
t to the co
❑ Coloured markings on
propshaft flange and on
front propshaft must line
rrectness of i
up.
l purpos
2 - Locking plate
3 - Bolt, 30 Nm + turn 90° fur‐
nform
ercia
ther
❑ Always renew
m
a
com
tion in
4 - Front propshaft
r
te o
thi
❑ Installation position: s
iva
do
Coloured mark on front
r
rp
cum
propshaft must line up

fo
en
ng
with coloured mark on

t.
yi Co
op
front final drive.
C py
t. rig
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5 - Transfer box cop Vo
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cted agen
Prote
6 - Hexagon nut
AG.
❑ Always renew
7 - Flexible coupling
⇒ page 115
8 - Washer
9 - Bolt, 75 Nm
❑ Tighten bolt to specified
torque while counter‐
holding on hexagon nut
⇒ Item 6 (page 106) .
10 - Rear propshaft
❑ Installation position:
Coloured mark on rear
propshaft must line up
with coloured mark on
rear final drive.
❑ Rear propshaft may be flexed only slightly to avoid damage to bellows in the vicinity of the centre bearing
-arrow-.
11 - Multi-point socket head bolt, 30 Nm then turn 90° further
❑ Always renew
12 - Locking plate
13 - Rear final drive
14 - Bracket
❑ For centre bearing.
106 Rep. Gr.39 - Final drive - differential

Touareg 2003 ➤
15 - Bolt, 20 Nm
❑ On bracket for rear propshaft.
AG. Volkswagen G d
❑ To adjust propshaft centre bearing free of tension, w agen and tightenA⇒
loosen page
oes 114 .
olks no t gu
yV
16 - Bolt, 60 Nm db ara
rise nte
❑ Bracket to body. tho eo
au ra
c
ss
17 - Bolt
ce
e
nl
pt
du
an
itte
18 - Hexagon nut, 75 Nm
y li
erm
ab
❑ Always renew
ility
ot p
wit
, is n
h re
hole
spec
1.2 Removing and installing front propshaft
es, in part or in w
t to the co
equipment required
rrectness of i
l purpos
1331-
nf
ercia
o
1332-
rm
m
atio
m

o
n in
c

or
thi
e

t
sd
iva
-1359/2-
o
r
rp
cu
o
m
f
en
ng
♦ Brake pedal actuator - yi

t.
Co
V.A.G 1869/2- ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
A twin pillar lifting platform should be used when working on the

front propshaft.
1. Removing and installing propshafts 107

Touareg 2003 ➤
Before removing, mark positions of all parts relative to each other.

Reinstall in the same position otherwise imbalance will be exces‐
sive, the mountings could be damaged causing rumbling noises.
If droning noises occur when driving, unbolt front propshaft from
flange at front final drive, rotate one hole relative to flange and
bolt on again.
If droning noises are still audible, front propshaft can be rotated
one hole relative to flange a total of 5 times
1.2.1 Removing
– For vehicles with automatic gearboxes, select position “N” with
the selector lever.
– Fit brake pedal actuator -V.A.G 1869/2- .
– Raise vehicle.
– Remove noise insulation below gearbox.
– If there is a skid plate beneath prop shaft, remove it ⇒ Rep.
– Check if there is a coloured mark on front propshaft and prop‐
shaft flange on front final drive.
– If no markings can be found, mark position of propshaft flange
-arrow A- relative to front final drive -arrow B- with coloured
marks.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Remove the lower three securing bolts fromaufront propshaft at
th or
ac
front final drive -arrows A-. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Touareg 2003 ➤
– Remove lower three securing bolts from front propshaft at

transfer box output flange -arrows B-.
– Lower vehicle.
– Remove brake pedal actuator -V.A.G 1869/2- .
– Raise vehicle.
– Turn both front wheels in the same direction at the same time
so that the propshaft rotates 1/2 turn (180°).
– Lower vehicle.
– Raise vehicle.
– Remove the remaining three bolts from front propshaft at front
final drive and at transfer box.
Remove gearbox carrier as follows:

– Position engine and gearbox jack -V.A.G
olkswa1383 A- with univer‐
en AG. V gen AG
sal mounting -1359/2- and
olkswa wooden
ag block -A- under
does transfer
not
box. d byV gu
ar
e an
ris tee
Do not loosen bolts
ut -arrows-.
ho or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove gearbox carrier -A- from body -arrows-.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
– Now unbolt gearbox carrier from transfer box bracket

o
m
f
en
ng
-arrows-.
t.
yi Co
Cop py
– Remove front propshaft.
t. rig
gh ht
pyri by
Vo
o
If the front propshaft cannot be removed, lower engine/gearbox
c by lksw
cted agen
assembly slightly, whereby the engine must not contact the bulk‐
Prote AG.
head.
1.2.2 Installing

Touareg 2003 ➤
Always renew securing bolts for front propshaft.

– Marks -arrow A- and -arrow B- must be aligned as nearly as
possible.
Install gearbox carrier as follows:

– Use new bolts.
– First tighten gearbox carrier to transfer box bracket -arrows-
to specified torque.
– Then bolt gearbox carrier -A- to body -arrows- to specified tor‐

que ⇒ page 110 .
– Screw in front propshaft bolts and tighten to specified torque
⇒ page 110 .
– If there was a skid plate beneath prop shaft, install it ⇒ Rep.
Torque settings
Bracket to gearbox carrier 50 Nm + 90° agen
AG. Volkswagen AG d
oes
♦ Always renew bolts Volksw not
gu
d by ara
ise nte
r
Gearbox carrier to body 50 Nm ut
ho+ 90° eo
ra
♦ Always renew bolts ss a c
ce
e
nl
pt
du
Front propshaft to front final drive flange 30 Nm + 90°

an
itte

y li
erm
ab
ility
ot p
Front propshaft to transfer box flange 30 Nm + 90°

wit
, is n

h re
hole
spec
es, in part or in w
t to the co
1.3 Removing and installing rear propshaft

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
110
op Vo
by c lksw
Rep. Gr.39 - Final drive - differential Prote
cted AG.
agen
Touareg 2003 ➤

equipment required
1331-
1332-
-1359/2-
♦ Brake pedal actuator -
V.A.G 1869/2-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
A twin pillar lifting platform should be used when working on rear

erm
ab
propshaft.
ility
ot p
wit
, is n

h re

hole
spec
sive, the mountings could be damaged causing rumbling noises.

es, in part or in w
t to the co
If droning noises occur when driving, unbolt rear propshaft from

flange at rear final drive, rotate one hole relative to flange and bolt
on again.
rrectness of i
If droning noises are still audible, rear propshaft can be rotated

l purpos
one hole relative to flange a total of 5 times at rear final drive and
a total of 2 times at transfer box.
nform
ercia
Do not flex rear propshaft; store only extended with centre bearing
bracket facing upwards.
m
at
om
io
1.3.1 Removing
n
c
in t
or
his
ate

do
priv
the selector lever.

um
for
en
ng
t.
yi
Co
Cop py
t. rig
– Raise vehicle.
gh ht
pyri by
Vo
co lksw
by
– Remove rear section of exhaust system ⇒ Rep. Gr. 26 ; Re‐ cted agen
Prote AG.

Touareg 2003 ➤
– If there is a skid plate beneath prop shaft, remove it ⇒ Rep.

– Check if there is a coloured mark on the rear propshaft and
the propshaft flange of the rear final drive.
– If no marking can be found, mark position of propshaft flange
-arrow A- relative to rear final drive -arrow B- using coloured
marks.
AG. Volkswagen AG d
agen oes
– Mark position of rear propshaft relative to output flange at Volksw not
gu
transfer box -arrow-. se
db
y ara
nte
ri
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove the lower 3 securing bolts for rear propshaft at rear
rrectne
final drive.
– Lower vehicle.
ss o
– Remove brake pedal actuator -V.A.G 1869/2- .
cial p
f inform
– Raise vehicle.
mer
atio
m
– Turn both rear wheels in the same direction at the same time
o
n
c
so that the propshaft rotates 1/2 turn (180°).
i
or
n thi
te
sd
a
– Lower vehicle.
iv
o
pr
cum
r
fo

en
ng
t.
yi Co
op
– Raise vehicle. C py
t. rig
gh ht
yri by
– Remove the remaining securing bolts for rear propshaft at rear op Vo
by c lksw
final drive. cted agen
Prote AG.
– Remove bolts securing rear propshaft to transfer box

-arrows-. To do this, counterhold nuts with an open jaw span‐
ner.
sal gearbox support -1359/2- under rear axle subframe.

Touareg 2003 ➤
– Support assembly subframe with a wooden block

⇒ page 113 figure N39-10040.
– Unscrew both bolts -arrows- on assembly subframe.
– Lower assembly subframe approx. 50 mm (dimension -a-) us‐

. Volkswagen AG
ing engine and gearbox jack -V.A.G 1383
swa A- .
gen AG does
olk not
yV gu
1 - Wooden block edb ara
nte
ris
ho eo
To avoid damaging rear propshaft,
aut have a second mechanic as‐ ra
c
ss
sist in removing rear propshaft.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Loosen centre bearing bracket bolts -arrows B- about 2 turns.
– Unbolt centre bearing bracket from body -arrows A-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
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– Disconnect rear propshaft -1- from rear final drive -2- and
Co
Cop py
swing over the final drive flange.
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pyri by
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– Pull rear propshaft carefully off centralizing pin of transfer box by c lksw
cted agen
output flange. Prote AG.
– Remove rear propshaft.

– Place down rear propshaft with centre bearing bracket facing
upwards.
1.3.2 Installing

Touareg 2003 ➤
Always renew securing bolts for rear propshaft.

– Marks -arrow A- and -arrow B- must be aligned as nearly as
possible.
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When removing and installing, do not damage the seal in rear
ole,
spec
propshaft flange for transfer box flange.
t to the co
If damaged renew rear propshaft.
Do not cant rear propshaft, push horizontally onto guide pin.
rrectne
After loosening a flange on rear propshaft, install centre bearing
free of stress ⇒ page 114 .
ss o
cial p
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atio
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– Fit bolts -arrows- for assembly subframe and tighten ⇒ Run‐
sd
iva
o
r
ning gear, axles, steering; Rep. Gr. 42 ; Repairing rear sus‐

p
cum
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fo
pension; l - Assembly overview, assembly subframe, anti-roll
en
ng
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bar, swivel joint .
Co
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t. rig
– After installing rear propshaft, install centre bearing free of
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
– Screw in rear propshaft bolts and tighten to specified torque.
– If there was a skid plate beneath prop shaft, install it ⇒ Rep.
Torque settings
Rear propshaft to rear final drive flange 30 Nm + 90°
Rear propshaft to flexible joint 75 Nm

♦ Always renew nuts/bolts
Centre bearing bracket to body 60 Nm
1.4 Installing centre bearing for rear prop‐

shaft free of stress
moving and installing parts of exhaust system. .

Touareg 2003 ➤
– Remove bolts -arrows B-.

– Loosen bolts -arrows A- several turns.
– Align sides of centre bearing bracket centrally with indenta‐

tions on body -arrows-.
– Secure centre bearing bracket by tightening the two bolts
-A-.
– Check that threaded holes of centre bearing -B- align with
elongated holes of bracket.
For slight deviations:
– Move centre bearing bracket sideways until the threaded
holes and the elongated holes align.
Ensure that the centre bearing does not contact the body (prop‐
shaft tunnel).
For larger deviations or insufficient distance between centre bear‐

ing and body:
– Loosen bolts -arrows- for gearbox carrier approx. 3 turns.
– Move gearbox carrier sideways until the centre bearing threa‐
ded holes and the bracket elongated holes align.
Ensure that the centre bearing does not contact the body (prop‐
shaft tunnel). G. Volkswagen nA AG do
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– Renew gearbox carrierybolts
Vol
ks one after the other (individually)
s no
t gu
-arrows- and tighten
isedthem
b
to specified torque. ara
nt r ee
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– Install bolts -arrows B- and tighten bolts -arrows A- and

pt
an
d
itte
-arrows B-.
y li
rm
ab
pe
– If removed, reinstall rear section of exhaust system ⇒ Rep.

ility
ot
Gr. 26 ; Removing and installing parts of the exhaust system.

wit
, is n
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hole
Torque settings
spec
es, in part or in w
Centre bearing bracket to body 60 Nm

t to the co
Rear propshaft centre bearing to bracket 20 Nm

Gearbox carrier to body 50 Nm + 90°
rrectness of i

l purpos
1.5 Removing and installing flexible cou‐

nform
ercia
pling
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a
com
tion in

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115
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by lksw
cted
1. Removing and installing propshafts
agen
Prote AG.
Touareg 2003 ➤
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♦ Brake pedal actuator -V.A.G 1869/2- ot
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hole
spec
es, in part or in w
t to the co
rrectness of i
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A twin pillar lifting platform should be used when working on rear
r
te o
thi
propshaft.
s
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um
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n
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sive, the mountings could be damaged causing rumbling noises. ht. Cop py
rig
rig ht
Do not flex rear propshaft; store only extended with centre bearing py by
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bracket facing upwards.
by lksw
cted agen
Prote AG.
1.5.1 Removing
the selector lever.
– Raise vehicle.
– Unbolt flexible coupling from rear propshaft -arrows-.

Touareg 2003 ➤
1.5.2 Installing
When removing and installing, do not damage the seal in rear
propshaft flange for transfer box flange.
If damaged renew rear propshaft.
Do not cant rear propshaft, push horizontally onto guide pin.
– After installing rear propshaft, install centre bearing free of
Torque settings
Flexible coupling to transfer box flange 75 Nm
♦ Always renew nut, tighten bolt to specified tor‐
que while counterholding on hexagon nut.
AG. Volkswagen AG d
agen oes
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nl
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rrectness of i
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at
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ate
do
priv
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for
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Prote AG.

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg K0058960720

6.1 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7 Removing and installing transfer box motor V253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.1 Removing transfer box motor V253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.2 Installing transfer box motor V253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.1 Removing and installing differential lock control unit J647 . . . . . . . . . . . . . . . . . . . . . . . . 59

2 Check gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.1 Removing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3.2 Installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.3 Routing breather line for rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4 Removing and installing axle differential lock motor V304 . . . . . . . . . . . . . . . . . . . . . . . . 66

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

made by the transfer gearbox operating unit -E473- .

2.1 Location on transfer box

2.2 Identification code, assembly allocation, capacities

2 Rep. Gr.00 - Technical data

Transfer box 0AD

Identification code GJH GJJ GJK

4.9 l - 230 kW 2.5 l - 128 kW

Transfer box 0AD

Transfer box 0AD

2. Transfer box identification 3

Transfer box 0AD

Transfer box 0AD

Gearbox housing extension length 139.9 mm 127.4 mm 127.4 mm

The following data can be found in the ⇒ Electronic parts cata‐

Transfer box 0AD

Identification code HMW HMX HTD

Allocation Model Touareg 2003 ▸ Touareg 2003 ▸ Touareg 2003 ▸

Engine 6.0 l - 331 kW 3.2 l - 177 kW 3.0 l - 165 kW

Transfer box 0AD

4 Rep. Gr.00 - Technical data

Transfer box 0AD

Transfer box 0AD

Gearbox housing extension length 127.4 mm 158.2 mm 127.4 mm

The following data can be found in the ⇒ Electronic parts cata‐

♦ The allocation to the respective vehicle according to manual

or automatic gearbox code

Transfer box 0AD

Allocation Model Touareg 2003 ▸ Touareg 2003 ▸ Touareg 2003 ▸

Engine 6.0 l - 331 kW 4.2 l - 228 kW 3.0 l - 155 kW

4.2 l - 257 kW turbo diesel

2. Transfer box identification 5

Transfer box 0AD

2003 ▸ 2003 ▸2003 ▸

6 Rep. Gr.00 - Technical data

Transfer box 0AD

2. Transfer box identification 7

3 Identifying front final drive

3.1 Location on front final drive

Codes and manufacturing data for front final drive.

Identifica‐ Day Month Year (2002)

3.2 Identification code, assembly allocation, ratios, capacities en