Table of contents: Models with 6-speed automatic… ↓ Models with 8-speed AT ↓
Models with 6-speed automatic transmission
1. Set the selector lever to the "N" position.
2. Remove the rear sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
3. On 4.2L models, separate the exhaust system at the clamp (see illustration 35.32 Chapter 2). Disconnect the hose (1 in illustration 35.34 Chapter 2) differential pressure sensor No. 2 "G524" and unscrew temperature sensor No. 2 "G498" (2) before the diesel particulate filter. Unscrew the nuts (3), remove the bolts (4 and 5) and remove the right particulate filter.
4. If present, remove the right heat shield from the main transmission (see illustration 3.5).
5. Make sure that the factory color marks are present on the front propeller shaft and on the front final drive flange (see illustration).
6.5. Marks on the front propeller shaft and on the front main gear flange.
If these marks are not visible, apply them.
6. Remove the bolts (1 in the illustration) fastening the cardan shaft to the front main gear, holding it from turning using the T10172 device with T10172/6 adapters.
6.6. Unscrewing/tightening the front propeller shaft bolts.
7. Remove the bolts (arrows in illustration 4.65 Chapter 2) fastening the cardan shaft to the transfer case, holding it from turning using the T10172 device with T10172/6 adapters.
8. On 4.2L models, remove the bolts on the left main catalytic converter bracket (see illustration 4.58a in Chapter 2) and on the right (similarly).
9. On 4.2L models, slightly raise the transfer case using the VAG1383A transmission jack with the T10337 support (see illustration) and do not lower it until the work is completed.
6.9. Jack under the transfer case.
Remove the AT support (see illustration 4.43 Chapter 6), unscrew the bolts (arrows in illustration 2.32) and remove the AT support.
10. Lightly compress the front driveshaft by pushing it forward (the hinges can move in the axial direction) and remove the driveshaft.
11. Installation is carried out in reverse order. Use new driveshaft mounting bolts; tighten them to 30 Nm, then tighten them to a 90° angle. Make sure the marks are aligned.
Models with 8-speed AT
12. The front propeller shaft installation details are shown in the illustration.
6.12. Installation details of the front propeller shaft for models with 8-speed automatic transmission:
1 - Transfer case;
2 - Front propeller shaft;
3 - Retaining ring (silver, diameter 23 mm), subject to replacement;
4 - Sealing ring (green, diameter 23 mm), subject to replacement;
5 - Front final drive;
6 - Bolts, 6 pcs., to be replaced, 30 Nm, then tighten to an angle of 90°;
7 - Locking plate.
13. Set the selector lever to the "N" position.
14. Remove the rear sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
15. Slightly raise the transfer case with a VAG1383A transmission jack with a T10337 support (see illustration) and do not lower it until the work is completed.
6.15. Jack under the transfer case.
Remove the AT support (see illustration 4.43 Chapter 6), unscrew the bolts (arrows in illustration 2.32) and remove the AT support.
16. Remove the bolts (arrows in illustration 4.65 Gpav 2) fastening the cardan shaft to the transfer case, holding it from turning using the T10172 device with T10172/6 adapters.
17. Mark the position of the front propeller shaft relative to the front final drive (see illustration 4.11).
18. Using a suitable lever, press the front propeller shaft out of the front final drive (see illustration 4.12). When doing this, press the lever against the bushing, not the boot, since if the boot is damaged, the driveshaft will have to be replaced. The shaft is held in place by a retaining ring.
19. Replace the seal (1 in the illustration) and retaining (2) rings.
6.19. Sealing (1) and retaining (2) rings.
20. Installation is carried out in reverse order. Make sure the marks are aligned. If you cannot insert the cardan shaft into the front final drive with a sharp push of your hand, rest a wooden block against the shaft and hit it.