Installing Sensor Module

Tap out sealing ring on front output shaft on the transmission side with a screwdriver. → Sealing ring on front output shaft on transmission side

Sealing ring on front output shaft on transmission side
Insert sensor module and secure it -arrow- . Tightening torque 8 Nm (6 ftlb.)

Inserting sensor module
Insert oil collection pan -arrows- .

Inserting oil collection pan
Prepare electric plug connection for sensor module.
1. 4.1. Engage electric plug connection -2- on the holder -1- .
2. 4.2. Push connector housing -3- onto the electric plug connection -2- and engage it.
  
  Preparing electric plug connection
Position transmission housing so that it is vertical on the mounting bracket. → Positioning transmission housing vertically

Positioning transmission housing vertically
Shift gearshift lever as far as it will go in direction of travel -arrow- .

Gearshift lever shifted as far as it will go
Clean sealing faces on transmission housing flange.
Check that dowel sleeves -1, 2- are fitted and coat differential housing flange -arrow- with sealant.

Transmission housing flange
Check that magnet -arrow- is fitted.

Magnet in transmission housing
Insert oil guide for front-wheel drive -arrows- .

Oil guide for front-wheel drive
Guide pin, M8 T10273 must be screwed into the threaded bore under the dowel sleeves. → Screwing in guide pins

Screwing in guide pins
Suspend centre transmission housing on the workshop crane WE 1188 and install it. → Suspending centre transmission housing
1. 12.1. Retainer T10014 must be secured to the centre transmission housing.
2. 12.2. Secure VW771/40 from tool set Multi-purpose tool VW771 on the centre transmission housing.
3. 12.3. Eye-head bolt 3368 must be secured to VW771/40.
4. 12.4. Retainer T10014 and eye-head bolt 3368 must now be connected to the lifting tackle 2024 A.
5. 12.5. Lifting tackle 2024 A must be connected to the workshop crane WE 1188.
6. 12.6. Raise centre transmission housing and lower it into the transmission housing. → Suspending centre transmission housing
  
  Suspending centre transmission housing
Secure centre transmission housing with new fastening screws. → Fastening screws for centre transmission housing Initial tightening 8 Nm (6 ftlb.) Final tightening +120°

Fastening screws for centre transmission housing
Turn connector housing using bit T40228 (-arrow- ) and engage it.

Engaging connector housing
Install new sealing ring for front output shaft. → 387055 REPLACING SEALING RING FOR FRONT OUTPUT SHAFT
Fit spur gear -1- and needle-roller bearing -2- on the output shaft -3- .

Fitting spur gear and needle-roller bearing
Insert side shaft -2- with a new fastening screw -1- .

Inserting side shaft
Tighten new fastening screw -A- for side shaft -B- . Initial tightening 100 Nm (74 ftlb.) Final tightening +120° +30°
1. 18.1. Fit bi-hexagonal socket insert (a/f 21) -C- with extension -D- .
2. 18.2. Counter-hold tool T40217 must be inserted into the side shaft -arrows 1, 2- and screwed to the centre transmission housing.
  
  Fastening screw for side shaft
Install oil guide -arrow- for drive shaft.

Oil guide for drive shaft
Clean sealing faces on transmission housing cover.
Install transmission housing cover.
1. 21.1. Coat sealing face on transmission housing cover with sealant.
2. 21.2. Fit transmission housing cover.
3. 21.3. Tighten new fastening screws -1- . Initial tightening 20 Nm (15 ftlb.) Final tightening +90° +/-20°
4. 21.4. Tighten new fastening screws -2- . Initial tightening 15 Nm (11 ftlb.) Final tightening +90° +/-20°
  
  Transmission housing cover