V381501 2024846

Technical Bulletin
Model(s)
Year(s)
Eng. Code(s)
Routan
2010
All
Trans. Code(s)
VIN Range From
VIN Range To
All
All
6 spd. Automatic
(LGG)
Condition
38 15 01 February 3, 2015 2024846 Supersedes T. B. V381302 dated July 16, 2013 to update part and tool
numbers 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 33
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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 33
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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.
• 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).
Page 3 of 33
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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
• 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.
• 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.
Page 4 of 33
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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 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.
• 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 5 of 33
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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 6 of 33
© 2015 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.
• Remove tubes (1).
Page 7 of 33
© 2015 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 transfer gear cover-to-case bolts (2) and
remove cover (1).
• 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 8 of 33
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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 9 of 33
© 2015 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.
• 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.
Page 10 of 33
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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 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).
• 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.
Page 11 of 33
© 2015 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
• 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.
• Remove the split bearing (2) using a small pick.
• Remove the underdrive compounder direct clutch (1) from
the low clutch (2).
Page 12 of 33
© 2015 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).
• 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.
Page 13 of 33
© 2015 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 remaining fasteners securing the transfer shaft
bearing retainer and remove the retainer (2).
• 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 14 of 33
© 2015 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. 7B0323415A 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.
• Install the transfer gear bearing cone Part No.
7B0323415A using installer Part No. 6756.
Page 15 of 33
© 2015 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 inner
race (1) from the transfer shaft bearing retainer (2).
• 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 16 of 33
© 2015 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. G 0001621Q (VW ATF+4).
Page 17 of 33
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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).
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).
Page 18 of 33
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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
• 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.
• Rotate the transfer gear (2) four complete revolutions
clockwise, and then four complete revolution counterclockwise 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.
Page 19 of 33
© 2015 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 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.
• Install overrunning clutch (1) into low clutch (2).
• Install thrust bearing (1) onto transfer shaft.
Page 20 of 33
© 2015 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.
• Install sun gear onto the shaft.
• Install the new sun gear retaining clip (1) Part No.
7BO323433AE onto the transfer/underdrive shaft.
Page 21 of 33
© 2015 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
• 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.
• Install the planetary gear (1) set/output hub onto the direct
clutch (2).
Page 22 of 33
© 2015 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 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.)
• 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 23 of 33
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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).
• Spread a bead of sealant Part No. D 1763212O onto the
transfer gear cover sealing surface.
• Install transfer gear cover (1) to case bolts (2) and tighten
to 12 Nm (105 in. lbs.).
Page 24 of 33
© 2015 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 underdrive compounder oil transfer tubes (1) into
the underdrive compounder.
• 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.
Page 25 of 33
© 2015 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
• Slide the valve body onto the underdrive compounder
transfer tubes (2).
• 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 26 of 33
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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 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 1763212O 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 1763212O 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.
• 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.
Page 27 of 33
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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 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. G 0001621Q (VW ATF+4).
Page 28 of 33
© 2015 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
Warranty
All Routan pre and post road test, StarMOBILE and wiTECH time units are included in the labor operation.
Therefore, no road test time units will appear in the designated area within the warranty table.
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)
Year(s)
Routan
2010
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
All
6 spd.
Automatic
All
All
(LGG)
Claim Type:
Use applicable Claim Type
1)
SAGA Coding
Damage Location
Damage
HST
Service Number:
Code
(Depends on
Service No.)
0020
Use applicable
when indicated in
ElsaWeb (L/R)
3911
CWM 2024846
Parts Manufacturer
(removed part)
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
4)
NO
Included in Labor time
01210004 = 10 TU
Page 29 of 33
© 2015 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
Technical Diagnosis
01320000 = XX TU max.
NO
Claim Comment: Input “As per Technical Bulletin 2024846” in comment section of Warranty Claim.
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 1763212O
1 (AR)
ATF+4
G 0001621Q
8
Spacer, Transfer Shaft Bearing
7B0323345BD
1 (AR)
7B0323345BE
1 (AR)
7B0323345BF
1 (AR)
7B0323345CA
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)
Page 30 of 33
© 2015 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
7B0323345CB
1 (AR)
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)
4.25-4.27 mm (0.1673-0.1681 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
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
Page 31 of 33
© 2015 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
4.52-4.54 mm (0.1780-0.1787 in.)
(expected minimal usage)
Spacer, Transfer Shaft Bearing
7B0323345DF
1 (AR)
Snap ring
7B0323433AE
1
Bearing and Cup
7B0323415A
2
Filter kit
7B0325433
1
Gasket
7B0253315
2 (3.8L engine only)
Nut
WHT004266
3
4.55-4.57 mm (0.1791-0.1799 in.)
(expected minimal usage)
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
Page 32 of 33
© 2015 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
Drive handle
C4171
Wiring terminal removal tool
6682-2
(component of Electrical Terminal Tool Kit 8197A)
Wiring terminal removal tool
6682-3
(component of Electrical Terminal Tool Kit 8197A)
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 33 of 33
© 2015 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.