Installing Transfer Box

Support main transmission on converter bell housing with a wooden block -arrow- .

Fig 1: Supporting Transmission Using Wooden Block
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Gradually run in transfer box. Press vent line into holder -arrow- and attach to transfer box.

Fig 2: Locating Vent Line Retainers
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Tighten fastening screws on main transmission. → Tightening torque: 45 Nm (33 ft lbs.)

Fig 3: Locating Transfer Box To Main Transmission Fastening Screws
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Tighten support -A- for Tiptronic line using fastening nut -arrow- . → Tightening torque: 10 Nm (7.5 ft lbs.)

Fig 4: Locating Tiptronic Line Fastening Nut
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Support transfer box with transmission jack and remove wooden block between converter bell housing and suspension sub-frame.

Fig 5: Supporting Transmission Using Wooden Block
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Information

Always observe the exact work sequence when installing/removing the transmission cross member.

Information
- Screws which are tightened with a torque angle must be replaced with new ones.
Install transmission cross member.
Screw in two cross member screws -B- on transfer box support. → Initial tightening: 50 Nm (37 ft lbs.) → Final tightening: 90° (67 ft lbs.)

Fig 6: Identifying Transmission Cross Member Screws
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Screw in fastening screws for securing transmission cross member to body -A- . → Initial tightening: 50 Nm (37 ft lbs.) → Final tightening: 90° (67 ft lbs.)
Information
- Screws which are tightened with a torque angle must be replaced with new ones.
Connect front cardan shaft to transfer box. → Initial tightening: 30 Nm (22 ft lbs.) → Final tightening: 90° (67 ft lbs.)

Fig 7: Identifying Front Cardan Shaft To Transfer Box Fastening Screws
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Information
- The temperature sensor -1- on the transfer box is no longer used in model year 2004.
- If there is no temperature sensor, secure cable plug on the servo motor with tiewraps.
  
  Fig 8: Identifying Transfer Box Servo Motor Plug Sequence
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Connect cable plug -1, 2- to the transfer box and secure the cable holder.

Fig 9: Identifying Servo Motor Cable Plug
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Fit heat protection to the cable plugs on the servo motor.

Fig 10: Identifying Heat Protection Cover On Servo Motor
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