Removing transfer box: VW Touareg I

🧭 Before you start

Vehicle raised, noise insulation and skid plate off, rear exhaust section and any V10 TDI catalytic converters removed, rear propshaft out, front propshaft unbolted and any balance weight removed from the transfer box. The gearbox is supported on the engine and gearbox jack with the gearbox support and adjustment plate, the gearbox carrier is unbolted from the body and the transfer box bracket, the front propshaft is removed and the side and lower connecting bolts and the motor connectors come off. The assembly is lowered approximately 60 mm, the engine is secured to the body with the retaining tool, thrust pad and a wooden block, then the upper bolts and breather line are removed and the transfer box is pressed off the gearbox and lowered.

Fits: VW Touareg I (7L, 2002–2010)

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• Adjustment plate for the OAD gearbox fits the support one way only; align the arms to its holes.
• Remove the balance weight from the transfer box if one is fitted, and refit it on the same box.
• Lower engine and gearbox approximately 60 mm, then brace the engine to the body before the upper bolts come out.
• Grease the retaining tool pressure plate; thrust pad smaller diameter towards the plate, wooden block against the gearbox.
• Unclip the breather line from the transfer box before pressing it off.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Raise vehicle.
2. Remove noise insulation below gearbox.
3. If there is a skid plate beneath transfer box, remove it 50Skid plate.
4. Remove rear section of exhaust system and, if necessary, catalytic converters (V10 TDI) 26Removing and installing parts of the exhaust system.
5. Remove rear propshaft .

6. Remove securing bolts for front propshaft at front final drive and at transfer box.
7. If balance weight (A) is installed, remove balance weight (bolts (B)) from transfer box.
8. Assemble engine and gearbox supportV.A.G 1383/A, gearbox support3282, adjustment plate3282/37 for "“OAD”" gearbox and mounting elements as follows:
9. Fit adjustment plate3282/37 on gearbox support3282 (adjustment plate only fits in one position).
10. Align arms of gearbox support according to holes in adjustment plate.
11. Position engine and gearbox jackV.A.G 1383/A with gearbox support3282 under vehicle, align adjusting plate parallel to gearbox and support gearbox.
12. Secure gearbox to gearbox support3282 using bolt (A).
13. Remove gearbox carrier (B) from body.
14. Then remove gearbox carrier from transfer box bracket (arrows).
15. Remove front propshaft.
16. Remove side and lower connecting bolts for gearbox/transfer box.
17. Pull connectors (A) and (B) off transfer box motor.
18. Lower engine and gearbox assembly approx. 60 mm using engine and gearbox jackV.A.G 1383/A.
19. Secure engine and gearbox assembly to body (arrows) with retaining toolVW 785/1B as follows:
20. Grease contact surfaces of pressure plate of VW 785/1B with multi-purpose grease.
21. Seat thrust pad3062 on pressure plate. The smaller diameter of 3062 faces towards the pressure plate.
22. Place a wooden block(A) between gearbox and pressure plate3062.
23. Remove upper connecting bolts (A) for transfer box/gearbox.
24. Remove breather line (B) from transfer box (arrow 1) and unclip (arrow 2).
25. Press transfer box off gearbox.
26. Lower transfer box.

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