2024846

Technical Bulletin
Model(s)
Routan
Year(s)
2010
Eng.
Code(s)
Trans.
Code(s)
All
6 spd.
Automatic
VIN Range From
VIN Range To
All
All
(LGG)
Condition
38 13 02 July 16, 2013 2024846 Supersedes T. B. V381301 dated January 11, 2013 to adjust the transmission
fluid quantity in the required parts and tools section.
Transfer Gear Bearing Noise
Customers may indicate that they hear a high pitch noise or growl coming from the left side of the vehicle. If the
symptom is present, perform the following Repair Procedure.
Technical Background
Some vehicles may have been built with transmission transfer gear bearings that have an incorrect bearing
preload, which can result in transfer gear bearing noise.
Production Solution
th
Improved preload specification introduced into production as of July 28 2010.
Page 1 of 40
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Technical Bulletin
Service
Procedure
• Open hood
• Disconnect and isolate the negative battery cable.
• Remove the battery.
• Disconnect the radiator overflow hose from the
radiator filler neck.
• Remove the engine coolant overflow bottle (1).
The bottle is secured to the radiator support by bayonet
style attachments. Remove the coolant recovery
container by pulling the coolant bottle upwards off of the
radiator fan shroud.
• 3.8L vehicles, remove the exhaust cross over pipe,
see repair manual group 26 Exhaust System,
Emission Control in ElsaWeb.
• Place a drain pan under the transmission.
• Disconnect the oil cooler lines (1) from transaxle
using Trans Cooler Disconnect tool 8875A.
• Allow residual transmission fluid to drain into the
drain pan and then move the lines out of the way.
Page 2 of 40
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove shift cable (1) from manual valve lever (2).
• Remove the solenoid pack connector (1) at the valve
body oil pan.
Page 3 of 40
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the engine coolant heater tube hold down
clamp bolt located at the left side of the engine.
• Remove the engine coolant heater tube hold down
clamp attached at the front of the engine
• Position the engine coolant heater tube out of the
way.
• Remove the three valve body oil pan sound
deadener retaining clips (1), and remove the sound
deadener (2).
• Take note of each sound deadener stud (1) location
(x3) for reference later, and remove each stud.
• Remove the wiring harness retaining clip (2) from
the valve body oil pan.
• Remove the top valve body oil pan bolts.
• Raise the vehicle on a hoist.
• If the vehicle is equipped with wheel center caps that cover the wheel nuts, remove the left front wheel’s cap
with an appropriate removal tool utilizing the notch located between the wheel and outer edge of the cap. Use
care not to damage the wheel coating.
• Remove left front wheel.
Page 4 of 40
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the two bolts (3) securing disc brake caliper
and adapter bracket (1) to the steering knuckle (2).
• Remove brake caliper and bracket (1) from steering
knuckle (2) and rotor (4) as a unit, and hang the
assembly out of the way. Use care not to over
extend the brake hose.
• Rotate steering fully left, and if equipped, remove the
bolt (2) at the ground cable.
• If equipped, remove the ground cable clip (1) at the
valve body pan and position the cable (3) away from
the valve body pan.
• Position a drain pan under the lower oil pan.
• Loosen the lower oil pan bolts and tap the pan at
one corner to break it loose allowing the fluid to
drain, and then remove the pan.
Page 5 of 40
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the nuts at the oil filter and discard filter.
• Remove the lower valve body oil pan bolts.
• Remove the valve body oil pan.
• Remove the electrical connector (1) at the valve
body.
• Remove the screw (3) at the detent arm (1) and
remove arm.
Page 6 of 40
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the 21 valve body to case bolts (1). One
valve body bolt is hidden by the manual valve
rooster comb.
• Pull the valve body away from the underdrive
compounder oil transfer tubes (2).
Page 7 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Lift up on the valve body to clear the manual valve
pin (1) past the slot in the rooster comb.
• Separate the underdrive coumpounder transfer
tubes (1) from the underdrive compounder.
Page 8 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove tubes (1).
• Remove transfer gear cover-to-case bolts (2) and
remove cover (1).
Page 9 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the oil scavenger (2).
Note:
The scavenger is secured to the transmission case with
small tabs. These tabs break easily. Use extreme care
when removing the scavenger from the transmission.
• Grind the staked tabs (3) from the transfer gear (2)
(underdrive coumpounder side). Take care not to
damage the transfer shaft threads.
Page 10 of 40
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install the gear holder (2) P/N 9739 onto the transfer
gear (3) (underdrive compounder side) and remove
the nut.
• Remove the snap ring (1) at the underdrive
compounder assembly (2).
Note:
The underdrive compounder snap ring is tapered. Note
the direction of the snap ring taper before removal so
that upon reassembly, it will be installed properly.
Page 11 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Using an impact driver (2), loosen all transfer gear
bearing retainer screws (1).
• Remove the four screws (1) shown.
• Install puller adaptor (1) P/N 9908 to the
compounder bearing retainer.
Page 12 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install slide hammer P/N C-3752 to puller adaptor
P/N 9908 and pull the underdrive compounder
assembly (1) from the case.
• Remove the underdrive compounder assembly.
• Remove the slide hammer from the adaptor P/N
9908 and clamp the adaptor into a vise to support
the underdrive compounder (3) during the
disassembly process.
Note:
The planetary gear set/output hub may still be in the
transmission case. If the planetary gear set/output hub
is in the transmission, remove it and continue.
• Remove the planetary gear set/output hub (1).
Page 13 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the helical shim (1).
Note:
If the helical shim is not on the sun gear, it may still be
located in the planetary gear set.
It will not be necessary to remove the helical shim from
the planetary gear set/output hub.
• Using two small picks (2), remove retaining clip (1)
from transfer/underdrive shaft. A new retaining clip
will be used during assembly.
• Remove the sun gear from the shaft.
Page 14 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the split bearing (2) using a small pick.
• Remove the underdrive compounder direct clutch (1)
from the low clutch (2).
Page 15 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the thrust bearing (1) from the transfer
shaft.
• Remove the overrunning clutch (1) from the low
clutch (2).
Page 16 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Carefully clamp the underdrive compounder low
clutch (2) into a soft jaw vise.
Note:
• Care must be taken not to overtighten the vise as
damage to the underdrive compounder low clutch
may result.
• Remove puller adapter P/N 9908 (1) from the low
clutch.
• Remove remaining fasteners securing the transfer
shaft bearing retainer and remove the retainer (2).
Page 17 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Remove the transfer shaft (1) from the low clutch
(2).
• Using a bearing splitter P/N 1130 (VW Tool 15/3)
and a press, remove the transfer shaft bearing.
Page 18 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Using installer P/N 6756 and a press, install the
transfer bearing Part. No. 7B0323415 onto the
transfer shaft.
• Using press puller P/N C-293-PA , Adaptors P/N
9738 and a press plug P/N 9678, remove
compounder transfer gear bearing cone.
Page 19 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install the transfer gear bearing cone Part No.
7B0323415 using installer Part No. 6756.
• Using a suitable tool drive the transfer shaft bearing
inner race (1) from the transfer shaft bearing retainer
(2).
Page 20 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Using a suitable tool drive the transfer shaft bearing
outer race (2) from the transfer shaft bearing
retainer (1).
• Install the new bearing inner race into the transfer
shaft bearing retainer (2) using Bearing Race
Installer 9952 and Handle C4171 (1).
Page 21 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install the new bearing outer race into the transfer
shaft bearing retainer (2) using Bearing Race
Installer 9952 and Handle C4171 (1).
• Install the transfer shaft (1) onto the low clutch (2).
• Lube the transfer shaft and transfer gear bearings
with clean ATF Part No. GUS 0001621Q (VW
ATF+4).
Page 22 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install transfer bearing retainer onto the low clutch.
• Install all of the bearing retainer screws and tighten
to 12 Nm (105 in. lbs.).
• Install the selectable shim.
Note:
The selectable shim will determine turning torque.
• Install the transfer gear onto the transfer shaft (1)
and Holder Part No. 9739 onto the transfer gear (2).
Page 23 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Note:
Care must be taken not to overtighten the vise as
damage to the underdrive compounder low clutch may
result.
• Install transfer gear nut (1).
• Clamp Holder 9739 into vise as shown.
• Tighten transfer gear (2) nut to 271 Nm (200 ft. lbs.).
• Remove holder 9739 from transfer gear.
• Carefully clamp the underdrive compounder low
clutch into a soft jaw vise.
Page 24 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Rotate the transfer gear (2) four complete
revolutions clockwise, and then four complete
revolution counter-clockwise to seat the new
bearings.
• Check turning torque using an inch pound beam
style torque wrench (1). Initial break away torque
should be disregarded. Turning torque should be
between 4.0 and 12.0 in. lbs. (drag). If more than
12.0 in. lbs. (drag), choose a larger shim and
recheck turning torque. If less than 4.0 in. lbs.
(drag), choose a smaller shim and recheck turning
torque.
• Install Holder 9739 (1) onto transfer gear and clamp
the holder into a vise.
• Remove transfer gear nut and gear.
• Install the Bearing Retainer Assembly Adaptor 9908
onto the low clutch.
• Clamp adapter into a vise to support the underdrive
compounder during assembly process.
Page 25 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install overrunning clutch (1) into low clutch (2).
• Install thrust bearing (1) onto transfer shaft.
Page 26 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install the direct clutch (1) onto the low clutch (2).
• Install split bearing (2) and lock into place.
Page 27 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install sun gear onto the shaft.
• Install the new sun gear retaining clip (1) Part No.
7BO323433AE onto the transfer/underdrive shaft.
• If necessary, install the helical shim (1).
Note:
• If the helical shim is not on the sun gear, then it still
may be located in the planetary gear set. It will not
be necessary to remove the helical shim from the
planetary gear set/output hub.
Page 28 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install the planetary gear (1) set/output hub onto the
direct clutch (2).
• Install the underdrive compounder (1) assembly into
the tranaxle case.
• Remove Adaptor 9908 from compounder bearing
retainer.
• Install all the bolts at the compounder bearing
retainer and tighten to 12 Nm (105 in. lbs.)
Page 29 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install underdrive compounder snap ring at top of
the compounder bearing retainer
1= Tapered side
2=Flat side
• Make sure select fit shim (2) is located on the
transfer shaft (1) prior to installing the transfer gear.
Page 30 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install transfer gear (3) onto transfer shaft.
• Install Holder (2) 9739 onto the transfer gear
(underdriver compounder side).
• Install new transfer gear (underdrive compounder
side) nut Part No. WHT004510 and tighten to 271
Nm (200 ft. lbs.).
• Use stake tool 9721 and stake new nut.
• Clean the transfer gear cover sealing surface and
mating surface.
• Install the oil scavenger (2).
Page 31 of 40
© 2013 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Spread a bead of sealant Part No. D 1763211O
onto the transfer gear cover sealing surface.
• Install transfer gear cover (1) to case bolts (2) and
tighten to 12 Nm (105 in. lbs.).
• Install the underdrive compounder oil transfer tubes
(1) into the underdrive compounder.
Page 32 of 40
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No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Position the valve body near the underdrive
compounder oil transfer tubes and slide the valve
body manual valve pin (1) into the slot in the rooster
comb.
• Slide the valve body onto the underdrive
compounder transfer tubes (2).
Page 33 of 40
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install the twenty one valve body to case bolts and
tighten to 6 Nm (50 in. lbs.).
Note:
Valve body to case bolt torque is critical during valve
body installation. Failure to torque bolts could result in
improper operation.
• Install the detent arm (1) onto the pin at the valve
body.
• Install the screw (3) at the detent arm and tighten to
6 Nm (50 in. lbs.).
Page 34 of 40
© 2013 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Install the electrical connector at the valve body.
• Install new transmission filter and nuts, tighten to 5
Nm (40 in. lbs.).
• Clean the oil pan and magnet.
• Spread a bead of Sealant Part No. D 1763211O
onto the oil pan sealing surface.
• Install oil pan and tighten oil pan bolts to 6 Nm (50
in. lbs.).
• Spread a bead of Sealant Part No. D 1763211O
onto the valve body oil pan sealing surface.
• Install the valve body oil pan and tighten bolts to 12
Nm (105 in. lbs.).
Note:
Install the three oil pan studs in the locations recorded
in removal procedure.
• If equipped, install the ground cable and tighten bolt.
• If equipped, install the ground cable clip at the valve body pan.
• Install the disc brake caliper and adaptor bracket assemble over the rotor and knuckle.
• Install the mounting bolts securing the caliper adapter bracket to the knuckle and tighten bolts to 169 Nm (125
ft. lbs.).
• Place wheel and tire into position on hub and lightly snug all five wheel mounting nuts. DO NOT tighten wheel
at this time.
Page 35 of 40
© 2013 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Lower vehicle.
• Progressively tighten all wheel mounting nuts in the proper sequence. Tighten nuts to a final torque of 135 Nm
(100 ft. lbs.)
• If applicable, install wheel center cap.
• Install the wire harness retaining clip onto the valve body oil pan.
• Install the three valve body sound deadener retaining clips Part No. WHT004266.
• Reposition the engine coolant heater tube and secure the tube with the hold down bolt located on the left side
of the engine, and the hold down clamp bolt attached to the front of the engine.
• Attach the solenoid pack connector at the valve body oil pan and secure it with the connector lock.
• Install the shift cable onto the manual lever.
• Reconnect the oil cooler lines onto the transaxle.
• 3.8L vehicles, install the exhaust crossover pipe.
• Reconnect radiator over flow hose onto the radiator fill neck and install the recovery bottle.
• Install Battery.
• Top off transmission fluid with Part No. ATF Part No. GUS 0001621Q (VW ATF+4).
Page 36 of 40
© 2013 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Warranty
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)
Year(s)
Eng.
Code(s)
Trans.
Code(s)
Routan
2010
All
6 spd.
Automatic
VIN Range From
VIN Range To
All
All
(LGG)
Claim Type:
Use applicable Claim Type
1)
SAGA Coding
Service Number:
Damage
3911
HST
Code
CWM
2024846
0020
Damage Location
Parts Manufacturer
(Depends on Service No.)
(removed part)
Use applicable when
indicated in ElsaWeb
(L/R)
USM
2)
3)
39112099 = 470 TU (includes pre and post repair road test)
Labor Operation : 3.8L Only
3)
39116099 = 520 TU (includes pre and post repair road test)
Causal: 4.0L select labor operation
39112099
Causal: 3.8L select labor operation
39116099
Labor Operation : 4.0L Only
Diagnostic Time
GFF Time expenditure
01500000 = XX TU max.
Road Test
01210002 = 10 TU
01210004 = 10 TU
Technical Diagnosis
01320000 = XX TU max.
4)
NO
Included in Labor time
NO
Claim Comment: Input “As per Technical Bulletin 2024846” in comment section of Warranty Claim.
Page 37 of 40
© 2013 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
2)
Code per warranty vendor code policy.
3)
Labor Time Units (TUs) are subject to change with Elsa updates.
4)
Documentation required per Warranty Policy Procedures Manual.
Required Parts and Tools
Legend: AR = as required
Part Description
Part No:
Quantity
Nut, Transfer Gear Retaining
WHT004510
1
ATF-RTV
D 1763211O
1 (AR)
ATF+4
GUS0001621Q
8
Spacer, Transfer Shaft Bearing
7B0323345BD
1 (AR)
7B0323345BE
1 (AR)
7B0323345BF
1 (AR)
7B0323345CA
1 (AR)
7B0323345CB
1 (AR)
4.13-4.15 mm (0.1626-0.1634 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.16-4.18 mm (0.1638-0.1646 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.19-4.21 mm (0.1649-0.1657 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.22-4.24 mm (0.1661-0.1669 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.25-4.27 mm (0.1673-0.1681 in.)
(expected minimal usage)
Page 38 of 40
© 2013 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Spacer, Transfer Shaft Bearing
7B0323345CC
1 (AR)
7B0323345CD
1 (AR)
7B0323345CE
1 (AR)
7B0323345CF
1 (AR)
7B0323345DA
1 (AR)
7B0323345DB
1 (AR)
7B0323345DC
1 (AR)
7B0323345DD
1 (AR)
7B0323345DE
1 (AR)
7B0323345DF
1 (AR)
7B0323433AE
1
4.28-4.30 mm (0.1685-0.1693 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.31-4.33 mm (0.1697-0.1705 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.34-4.36 mm (0.1709-0.1717 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.37-4.39 mm (0.1720-0.1728 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.40-4.42 mm (0.1732-0.1740 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.43-4.45 mm (0.1744-0.1752 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.46-4.48 mm (0.1756-0.1764 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.49-4.51 mm (0.1768-0.1776 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.52-4.54 mm (0.1780-0.1787 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
4.55-4.57 mm (0.1791-0.1799 in.)
(expected minimal usage)
Snap ring
Page 39 of 40
© 2013 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Bearing and Cup
7B0323415
2
Filter kit
7B0325433
1
Gasket
7B0253315
2 (3.8L engine only)
Nut
WHT004266
3
Tool Description
Tool No:
Tube quick connect removal tool
8875A
Gear Holder
9739
Nut staking tool
9721
Impact driver
-
Underdrive compounder puller adapter
9908
Slide hammer
C-3752
Bearing splitter
1130 (VW tool #15/3)
Installer
6756
Press puller
C-293-PA
Adapters
9738
Press plug
9678
Installer
9952
Drive handle
C4171
Wiring terminal removal tool
6680-2
Wiring terminal removal tool
6680-3
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 40 of 40
© 2013 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.