Caution: Avoid excessive stress and damage to the CV joint boots of the drive shafts; do not bend the shaft all the way; do not allow the drive shafts to drop, as this may cause damage to the inside of the CV joint boots without any external signs of damage.
The vehicles in question feature all-wheel drive (AWD). A transfer case is mounted at the rear of the AT, distributing torque between the front and rear wheels via a corresponding driveshaft, final drive with differential, and drive shafts (see illustration 1.1).
1.1. Components of the all-wheel drive system:
1 - AT;
2 - Transfer case;
3 - Rear propeller shaft;
4 - Rear final drive;
5 - Front propeller shaft;
6 - Front main gear.
Depending on the combination of engine and automatic transmission, different transfer boxes and final drives are used (see Specifications).
The variable angle of inclination of the drive shafts is achieved by means of constant velocity joints (CV joints) placed in protective corrugated boots. Outer CV joints are attached to the wheel hubs.
The data for identifying the transfer case is indicated on its bottom side, at the junction with the AT (see illustration 1.2a).
1.2a. Transfer case identification data location.
The purpose of the identification data is indicated in the captions to Figures 1.2b-c.
1.2b. Assignment of identification data for the "0AQ" transfer case:
A - Transfer case part number; the first three letters are its designation;
B - Transfer case code;
C - Date of manufacture (DDMMYY).
1.2c. Assignment of identification data for the transfer case "0BU":
A - Production date (DDMMYYYY);
B - Transfer case code;
C - Transfer case part number; the first three letters are its designation.
The identification data for the front final drive is indicated on its underside, between the output flanges (see illustration 1.3a).
1.3a. Front Final Drive Identification Data Location.
The purpose of the identification data is indicated in the captions to Figures 1.3b-c.
1.3b. Assignment of identification data of the front main gear "0AA":
A - Final drive part number; the first three letters are its designation;
B - Final drive code;
C - Date of production and serial number.
1.3c. Assignment of identification data of the front main gear "0BM" or "0C1":
A - Production date and serial number;
B - Final drive code;
C - Final drive part number;
the first three letters are its designation.
The production date with a serial number consists of a letter indicating the year (E - 2005, F - 2006, etc.), A 3-digit number indicating the day of the year and a 4-digit number indicating the serial number of the part produced on that day.
The identification data for the rear final drive is indicated on its underside, between the output flanges (see illustration 1.4a).
1.4a. Location of rear final drive identification data.
The purpose of the identification data for the rear final drive 0AB is the same as for the front final drive 0AA (see illustration 1.3b). The purpose of the identification data for the rear final drive 0AB is indicated in the captions to Figure 1.4b.
1.4b. Assignment of identification data for the rear main gear "0BN" or "0BP":
A - Final drive part number; the first three letters are its designation;F
B - Final drive code;
C - Date of production and serial number.
The production date and serial number are deciphered in the same way as for the front main gear (see above).
Features of repair work
1. When installing support brackets or waxed components, clean mating surfaces of wax and grease.
2. Thoroughly clean the separating surfaces and apply AMV 188 200 03 sealant to them.
3. Apply the sealant evenly and not in too thick a layer.
4. Before installing the radial seals (oil seals), fill the space between the sealing lips halfway with G052 128 A1 grease.
5. The open side of the seal must face the working fluid.
6. Lightly lubricate the sealing rings before installation to avoid damaging them during installation.
7. After replacing the seal, check and adjust the working fluid level (see Chapter 1).
8. Loosen and tighten the threaded fasteners of the covers and housings in a diagonal order.
9. The tightening torques given apply to unlubricated threaded fasteners.
10. Replace self-locking nuts and bolts.
11. Remove any remaining thread locking compound from the threaded holes using a tap before screwing the self-locking bolts into them. Otherwise, there is a risk of the bolts being cut off when they are subsequently unscrewed.
12. Install new tapered roller bearings as supplied; do not apply additional lubricant.
13. Install the needle bearings so that the side with the letters (a thicker layer of metal) was turned towards the installation device.
14. Tapered roller bearings mounted on a single shaft must be replaced as an assembly.
15. Before installation, heat the inner bearing races to approximately 100°C.
16. Do not interchange the outer and inner races of bearings of the same size, as they are matched in pairs.