Amarok 2011 Transfer Box and Final Drive PDF

Service
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Amarok 2011 ➤
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Transfer box and final drive
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Edition 05.2013
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
39 - Final drive - rear differential
39 - Final drive - front differential
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2013 Volkswagen AG, Wolfsburg D3E8028924F

Amarok 2011 ➤
Transfer box and final drive - Edition 05.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification of gearbox g.en. A. G. ..V.o.lk.sw. a. g.e.n.A.G.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Technical data oris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n.tee. . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 ut rear final drive - engine/capacities . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . .
Allocations aof 3
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2.2 Allocation of front final drive - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.3 Allocation of transfer box - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.4 Allocation of rear axle - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.5 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.1 Overview - power transmission - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.3 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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4.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.6 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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4.7 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.1 Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1.2 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.3 Removing and installing actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.4 Removing and installing drive pinion and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.5 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.6 Removing and installing crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.7 Checking backlash and contact pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.8 Pulling tapered roller bearing for drive pinion off and pressing it on . . . . . . . . . . . . . . . . . . 30
1.9 Pulling tapered roller bearing for differential off and pressing it on . . . . . . . . . . . . . . . . . . 32
1.10 Overview of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.11 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.12 Determining shims for crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.13 Determining shims for drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.14 Renewing propshaft flange seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.15 Repairing propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Rear-axle differential lock components and their locations . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Assembly overview - flexible coupling for propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Assembly overview - “Tirsan” propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3 Assembly overview - “Dana” propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.4 Removing and installing front propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.5 Removing and installing rear propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.6 Dismantling and assembling propshaft intermediate bearing, “Dana” propshaft . . . . . . . . 60
3.7 Dismantling and assembling propshaft intermediate bearing, “Tirsan” propshaft . . . . . . . . 63
4 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 Checking gear oil level in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
Amarok 2011 ➤
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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1.2 Removing and installing front final drive . . . . .ks.w.a.ge. n. A. G. . . . . . . . .n.A.G.d.oe. s.n. . . . . . . . . . . . . . 68
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1.3 Renewing bonded rubber bush on rear ofdfinal by drive . . . . . . . . . . . . . . . . . . g.u.ar. . . . . . . . . .
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1.4 Renewing bonded rubber bush on front ri of final drive . . . . . . . . . . . . . . . . . . . . . n.te.e. . . . . . .
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1.5 Renewing bonded rubber on left ofss afinal drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.c . . . . 77
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2 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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2.1 Checking level of gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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3 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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3.1 Renewing left flange shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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3.2 Renewing oil seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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3.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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3.4 Renewing dust cap for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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3.5 Renewing dust cap for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.6 Renewing needle bearing for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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1 Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1 Assembly overview - transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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1.2 Components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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1.3 Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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1.4 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1.5 Removing and installing transfer box control unit J646 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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1.6 Removing and installing transfer box Hall sender G759 . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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1.7 Removing and installing transfer box control motor V455 . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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2 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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2.1 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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2.2 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
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2.3 Renewing propshaft flange seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1 Identification
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(VRL005429; Edition 05.2013)
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⇒ “1.1 Identification of gearbox”, page 1
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⇒ “1.2 Identification of final drive”, page 1
1.1 Identification of gearbox
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A reduction gearing is integrated into the transfer box.

Location on transfer box -arrow-.
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Production date -arrow A- and identification code -arrow B- of

transfer box
Example LEP 09 12 09
I I I I
I I I I
Identifica‐ Day Month Year (2009)
tion code of manufac‐
ture
Additional data depend on manufacture.
1.2 Identification of final drive

Location on front final drive -arrow-
1. Identification 1
Amarok 2011 ➤
Codes -arrow- and manufacturing data for front final drive

Identification Year Day Serial number
code
MGY x xxx xxxx
Additional data depend on manufacture.
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2 Rep. gr.00 - Technical data

Amarok 2011 ➤
2 Technical data
⇒ “2.1 Allocation of rear final drive - engine/capacities”,
page 3
⇒ “2.2 Allocation of front final drive - engine/capacities”,
page 3
⇒ “2.3 Allocation of transfer box - engine/capacities”, page 3
⇒ “2.4 Allocation of rear axle - engine/capacities”, page 4
⇒ “2.5 Calculation of gear ratios”, page 4
2.1 Allocation of rear final drive - engine/capacities

Rear final drive 0CC
Identification code MQA MQB
Allocation Model Amarok 2011 ► Amarok 2011 ►
Engine 2.0 l - 120 kW 2.0 l - 120 kW
Ratio Final drive i = 4.1 i = 4.1
Capacity 2.0 l1) 2.0 l1)
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♦ Specification of gear oil

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2.2 Allocation of front final drive - engine/capacities

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Front final drive 0C1

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Identification code MQL

Allocation Model Amarok 2011 ►
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Engine 2.0 l - 120 kW

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Capacity 0.8 l
The following data can be found in the ⇒ Electronic parts cata‐
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♦ Allocation to corresponding vehicle by engine code

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2.3 Allocation of transfer box - engine/capacities
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Identification code Prote
LEP NHY
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Allocation Model Amarok 2011 ► Amarok 2011 ►

Engine 2.0 l - 120 kW
Capacity 1.25 l 1.25 l
The following data can be found in the ⇒ Electronic parts cata‐
logue “ETKA” .
♦ Allocation to corresponding vehicle by identification code of
manual gearbox
2. Technical data 3
Amarok 2011 ➤
2.4 Allocation of rear axle - engine/capaci‐

ties
VW part num‐ 2H0.500.025. 2H0.500.025. 2H0.500.025.
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(with brake)
VW part num‐ 2H0.501.011. 2H0.501.011. 2H0.501.011.
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Manufacturer's 40073724 40073725 40073722
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Gear ratio 1) 41 : 10 = 4.10 41 : 10 = 4.10 43 : 10 = 4.30
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Differential Standard Lockable Standard
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Engine alloca‐ 2.0 l 2.0 l 2.0 l 11 kW
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2.0 l 90 kW
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TDI
Capacity (dry 2.1 l ± 0.1 l 2.1 l ± 0.1 l 2.1 l ± 0.1 l
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axle) 2)
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VW part num‐ 2H0.500.025. 2H0.500.029. 2H0.500.029.

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Manufacturer's 40073723 40094736 40101793

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Gear ratio 1) 43 : 10 = 4.30 37 : 10 = 3.70 37 : 10 = 3.70 op Vo
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Z2 : Z1 = i
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Differential Lockable Standard Lockable

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Engine alloca‐ 2.0 l 118 kW 2.0 l 2.0 l
tion petrol 132 kW TDI 132 kW TDI
2.0 l 90 kW
TDI
Capacity (dry 2.1 l ± 0.1 l 2.1 l ± 0.1 l 2.1 l ± 0.1 l
axle) 2)
1) Data shown on axle type plate.
2) If the oil was merely drained, the capacity is 2.0 l.
3) For current part numbers and codes refer to ⇒ Electronic Parts
Catalogue (ETKA) .
2.5 Calculation of gear ratios

Example: 41 : 10 = 4.10
Z2 : Z1 = “i” 1)

Amarok 2011 ➤
1)
♦ Z1 = no. of teeth on drive gear

♦ Z2 = no. of teeth on driven gear
♦ i = gear ratio
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2. Technical data
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Amarok 2011 ➤ autho eo
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Transfer box and final drive - Edition 05.2013 ss c
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3 Overview - power transmission
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⇒ “3.1 Overview - power transmission - four-wheel drive”,
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3.1 Overview - power transmission - four-wheel drive
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1 - Front final drive
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❑ Removing and installing
⇒ page 68 .
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2 - Front propshaft
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⇒ page 56 .
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3 - From manual gearbox
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4 - Transfer box
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❑ With reduction gearing
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❑ Changing between on‐

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ning gear programme
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switch - E631-
⇒ page 94
⇒ page 95 .
5 - Rear propshaft
⇒ page 57 .
6 - Rear final drive
❑ Optionally with rear axle
differential lock
⇒ page 51

Amarok 2011 ➤
Transfer box
. Volkswage
and final drive - Edition 05.2013
AG n AG d
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4 Repair instructions tho
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⇒ “4.1 Gearbox”, page 7 ss c
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⇒ “4.2 Rear axle”, page 7
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⇒ “4.3 Seals and sealing rings”, page 7
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⇒ “4.4 Locking devices”, page 7
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⇒ “4.5 Nuts and bolts”, page 8 hole
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⇒ “4.6 Bearing”, page 8
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⇒ “4.7 Shims”, page 8
4.1 Gearbox
rrectness of i
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To ensure flawless and successful gearbox repairs, the greatest

care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
nf
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ing repair work.
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A number of generally applicable instructions for the various re‐

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pair procedures which were previously repeated at numerous

or
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♦ When installing the transfer box, ensure that the dowel sleeves
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between the gearbox and transfer box are correctly installed.
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♦ Always renew retaining rings for front propshaft on transfer
ht
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box and front final drive.
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Prote AG.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue (ETKA) .
♦ Capacity of transfer box ⇒ page 3 .
♦ Capacity of front final drive ⇒ page 3 .
4.2 Rear axle

♦ When a dry, clean rear axle is filled for the first time or refilled
(new or completely cleaned rear axle) the oil capacity is 2.1 l
± 0.1 l.
♦ If a used rear axle is filled after the oil was merely drained, the
capacity is 2.0 l ± 0.1 l.
♦ Axle must be in horizontal position while oil is drained.
4.3 Seals and sealing rings

♦ Thoroughly clean joint surfaces.
♦ Apply sealing paste ⇒ Electronic Parts Catalogue (ETKA) to
drive pinion splines or propshaft flange. Spread a 2-3 mm ∅
bead around drive pinion teeth.
♦ Renew O-rings if damaged.
♦ Renew cover seal.
♦ Renew both pinion seals if leaking.
4.4 Locking devices

♦ Do not overstretch retaining rings.
4. Repair instructions 7
Amarok 2011 ➤
♦ Retaining rings must locate properly in grooves. With opening

towards floor.
♦ Renew compression sleeve.
4.5 Nuts and bolts

♦ Loosen and tighten bolts and nuts for covers and housings
diagonally.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ Always renew M14 brake bolts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
4.6 Bearing
♦ Note the installation position of the sealed wheel bearings: the
flat metal oil seal facing the wheel and the rubber oil seal facinggen AG. Volkswagen AG d
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♦ Do not interchange the inner and outer races of same
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size tee
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bearings. au
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4.7 Shims
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♦ Measure shims at several points with a micrometer. The var‐
erm
ab
ious thicknesses make it possible to achieve the exact shim
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thickness required.
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♦ Check for burrs and damage.
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♦ Install only flawless shims.
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♦ Note the shims' location. There must be no gap between the
shim and the adjacent surface.
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Prote AG.

Amarok 2011 ➤
39 – Final drive - rear differential
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1. Final drive 9
Amarok 2011 ➤
1 Final drive
⇒ “1.1 Assembly overview - final drive”, page 10
⇒ “1.2 Assembly overview - differential”, page 13
⇒ “1.3 Removing and installing actuator”, page 13
⇒ “1.4 Removing and installing drive pinion and differential”, page
14
⇒ “1.5 Dismantling and assembling differential”, page 24
Volkswagen AG
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⇒ “1.8 Pulling tapered roller bearing
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⇒ “1.9 Pulling tapered roller bearing for differential off and press‐
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⇒ “1.12 Determining shims for crown wheel”, page 36
es, in part or in w
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⇒ “1.13 Determining shims for drive pinion”, page 39
⇒ “1.14 Renewing propshaft flange seal”, page 43
rrectness of i
⇒ “1.15 Repairing propshaft flange”, page 49
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1.1 Assembly overview - final drive
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1 - Oil filler plug

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❑ Renew after removal atio

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❑ 33 Nm
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2 - Final drive cover

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❑ Vehicles with a digital

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tachograph have a sen‐

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cover ⇒ page 18 .
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Caution
AG.
Repair work which may

affect the function of the
tachograph must always
be carried out in certified
workshops.
3 - Bolt
❑ Renew after removal
❑ Apply locking fluid - D
185 410 A2- before
starting bolt.
❑ 44 Nm
4 - Seal
5 - Bolt
❑ 85 Nm
10 Rep. gr.39 - Final drive - rear differential

Amarok 2011 ➤
6 - Bearing bracket
❑ Paired with axle beam
❑ Mark installation position
7 - Shim
❑ For adjusting crown wheel.
❑ Installation position: chamfered side faces axle tube.
❑ Determining shims ⇒ page 36 .
8 - Outer ring
❑ For tapered roller bearing
9 - Tapered roller bearing
❑ Pulling off and pressing on ⇒ page 32 .
10 - Retaining ring
11 - Bolt
❑ Left-hand thread
❑ 140 Nm
12 - Differential
❑ Removing and installing ⇒ page 14 .
❑ Dismantling ⇒ page 24 gen AG
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❑ Determining shims
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14 - Actuator pt
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Handle actuator with ex‐

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strike it against any other

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Risk of damage to the

sensor.
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❑ Removing and installing ⇒ page 13

15 - Oil drain plug
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❑ 33 Nm
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16 - Axle beam
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❑ Removing and installing ⇒ Rep. gr. 42 ; Rear axle; Removing and installing rear axle .
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❑ Removing and installing ⇒ page 43 . Prote AG.
19 - Dust cap
20 - Sealing sleeve
21 - Seal
1. Final drive 11
Amarok 2011 ➤
Caution
If the seal is renewed,
the friction torque must
be determined before
starting repair work
⇒ page 44 .
If the friction torque has
not been determined be‐
fore removal, the com‐
pression sleeve and the
drive pinion bearings will
have to be renewed.

22 - Outer tapered roller bearing
❑ Remove to renew drive pinion. agen
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❑ For outer tapered roller bearing ut
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❑ Remove and install using drift - 3138- . ss c
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24 - Outer ring
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❑ For inner tapered roller bearing
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❑ Remove and install using drift - 3138- .
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25 - Compression sleeve
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❑ Remove to renew drive pinion.
es, in part or in w
❑ Renewing ⇒ page 20
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26 - Inner tapered roller bearing
❑ Pulling off and pressing on ⇒ page 30 .
rrectness of i
27 - Shim
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❑ For adjusting drive pinion
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❑ Determining shims ⇒ page 39 .

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28 - Drive pinion
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Prote AG.

Amarok 2011 ➤
1.2 Assembly overview - differential
1 - Thrust washer
2 - Differential pinion
❑ “Large”
❑ “Small”
4 - Thrust washer
5 - Pin
❑ “Large”
7 - Return spring
8 - Thrust washer
❑ Only in vehicles with dif‐
ferential lock.
9 - Selector fork
❑ Only in vehicles with dif‐
ferential lock.
10 - Guide ring
❑ Will be destroyed during
removal and installation AG. Volkswagen AG d
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❑ Only in vehicles with dif‐ ised b ara
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ferential lock. ut
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11 - Securing pin s
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❑ Will be destroyed during

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❑ Remains of pin remain

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in differential housing.
urposes, in part or in wh
The depth of the hole allows for shearing off the pin twice as well as for two remnants to remain in the
t to the co
hole (new version). In case of the old versions the securing pin must be removed completely.
rrectne
1.3 Removing and installing actuator

ss
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On vehicles with differential lock the guide ring may be damaged

thi
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during the removal of the actuator ⇒ Item 10 (page 13) . Check

iv
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the guide ring for damage after the actuator has been removed.
um
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For this, the differential must be dismantled ⇒ page 24 .

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1. Final drive 13
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Amarok 2011 ➤ tho tee
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Transfer box and final drive
ss - Edition 05.2013
a ac
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un
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– Remove outer race -arrow- from tapered roller bearing -1- on
an
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left and right.
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Note
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The tapered roller bearing on the actuator end will be damaged
es, in part or in w
t to the co
when being removed and must be renewed.
– Press tapered roller bearing on actuator end off differential
rrectness of i
⇒ page 32 .
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– Remove circlip -1- of actuator with a screwdriver or circlip pli‐

ers.
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Handle actuator with extreme caution and do not strike it
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Risk of damage to the sensor.
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– Carefully remove actuator -arrow- from differential.

Installing
Install in reverse order of removal, observing the following:
– Installing drive pinion and differential ⇒ page 14
Specified torques
♦ ⇒ “1.1 Assembly overview - final drive”, page 10
1.4 Removing and installing drive pinion

and differential
Note
♦ The final drive gear set can be removed and installed with axle
installed.
♦ The final drive gear set (drive pinion and crown wheel) may
only be replaced as a complete unit.

Amarok 2011 ➤
Special tools and workshop

equipment required
♦ Thrust piece - VW 554-
♦ Tube - VW 519-
♦ Torque wrench - VAS
5088-
AG. Volkswagen AG d
♦ Drift - 3138- agen oes
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♦ Counter-hold tool - 3145- orise nte
(modify holes on old ver‐ aut
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sion ⇒ page 44 ) ss c
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1. Final drive 15
AG. Volkswagen AG d
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Amarok 2011 ➤ d by
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Transfer box and tfinal
ho
ris
drive - Edition 05.2013 eo
au ra
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equipment required
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♦ Counter support Kukko erm
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♦ Separating tool Kukko 17-2
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spec
♦ Fitting tool - T50023-
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♦ Thrust piece - T50048/1-
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AG. Volkswagen AG d
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s
s Transfer box and final drive - Edition 05.2013
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♦ Support device - T10323-
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♦ Thrust piece - T50018-
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♦ Socket 32 mm - T10209-
hole
spec
es, in part or in w
♦ Expander - T50021- (renew
t to the co
washers and M8 securing
bolts with new bolts with
property class 12.9 before
rrectness of i
each installation)
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♦ Torque wrench - V.A.G

1331-
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1332-
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♦ Loctite 565
Removing differential
– Drain gear oil ⇒ Item 15 (page 11) .
– Remove rear axle shafts ⇒ Rear suspension; Rep. gr. 42 ;
Rear axle; Removing and installing rear axle shaft .
– Mark position of propshaft in relation to propshaft flange.
– Unscrew propshaft -2- from rear axle -1-.
– Secure propshaft to body.
– If fitted, remove spare wheel.
Vehicles with tachograph
Caution
Repair work which may affect the function of the tachograph

must always be carried out in certified workshops.
1. Final drive 17
Amarok 2011 ➤
Tachograph
Continuation for all vehicles
– Unscrew final drive cover from axle beam.
Vehicles with lockable differential
– Disconnect connector of wiring harness from differential.
– Unscrew securing bolt for wiring harness from bearing brack‐
et.
– Mark installation position of bearing brackets -1 and 2- and

remove -arrows-.
Caution
Always renew M8 securing bolts of expander - T50021- with

new bolts with property class 12.9 and washers before instal‐
lation.
Part number for M8 × 35 bolts: N10534803 AG. Volkswagen AG d
agen oes
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Part number for washers: WHT003198 d by Vo gu
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Specified torque: 44 Nm utho eo
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– Fit spreader - T50021- on rear axle.
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Prote AG.

Amarok 2011 ➤
– Mark installation side of tapered roller bearing outer races

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Fit a bearing bracket again to prevent differential falling out ss c
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when expanding axle beam.
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Wear safety goggles. Securing bolts of expander - T50021- are
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highly stressed when axle is expanded.
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– Tension spreader - T50021- until differential can be removed
spec
from axle beam without significant effort. es, in part or in w
t to the co
rrectness of i
Note
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♦ Handle differential with extreme caution and do not strike it

against any other object.
nf
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orm
♦ When driving connector out inwards, ensure that it does not
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strike against actuator.

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♦ Risk of damage to axle differential lock Hall sender 1 - G460- .
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– Remove retainer for connector. Then, press connector in‐
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wards out of axle housing and remove it together with differ‐

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ential. Carefully pull connector out inwards. C py
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– Slacken spreader - T50021- and remove.
Prote AG.
– Carry out visual inspection of tapered roller bearings on dif‐

ferential. Renew them if necessary ⇒ page 32 .
Removing drive pinion
Caution
If the same drive pinion bearings are reinstalled, the friction

torque must be measured and recorded before dismantling
further. This is not necessary when installing new bearings.
Determining friction torque ⇒ page 44 .
– Remove locking device for nut -arrow-. If necessary, modify

counter-hold tool - 3145- ⇒ page 44 .
– Screw counter-hold tool - 3145- onto propshaft flange.
– Loosen securing nut using 32 mm socket - T10209- .
1. Final drive 19
Amarok 2011 ➤
– Mount puller and remove propshaft flange.

A - Separating tool Kukko 17-2
B - Counter support Kukko 18-2
– Carry out visual inspection of sealing sleeve. Renew it if nec‐
essary ⇒ page 49 .
– Use a plastic hammer for driving drive pinion out of housing.
If only the compression sleeve is to be renewed
⇒ Item 25 (page 12) , the last step that remains is to remove the
seal ⇒ Item 21 (page 11) .
– Drive out seal -1- using a chisel.

If the compression sleeve and the tapered roller bearings are to
be renewed, drive out outer races of tapered roller bearings.
– Use drift - 3138- to drive out outer race of tapered roller bearing
(flange side) with seal.
– Use drift - 3138- to drive out outer race of tapered roller bearing
(pinion side).
– Carry out visual inspection of tapered roller bearings. Renew
them if necessary.
AG. Volkswagen AG d
agen oes
– Press tapered roller bearing ⇒ Item 26 (page 12) off driveVpin‐
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If only the compression sleeve is to be removed, note

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⇒ page 20 .
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If the compression sleeve is to be renewed together with the ta‐

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pered roller bearings, do the following:

h re
hole
spec
– Drive in outer races and determine shim for drive pinion

es, in part or in w
⇒ page 39 .
t to the co
– Then, fit determined shim onto drive pinion and press on ta‐
pered roller bearing ⇒ page 30 .
rrectness of i
l purpos
Note
nform
ercia
Remove any sealant residue from splines of flange before insert‐

ing the drive pinion.
m
a
com
tion in
r
Continuation for all cases:

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
– Insert drive pinion and support it using support device -

T10323- and press tool - VW 432- .
– Fit new compression sleeve ⇒ Item 25 (page 12) on drive pin‐
ion.
– Drive in tapered roller bearing (flange side) using tube - VW

519- and press tool - VW 554- until axial play is approx 2 mm.
– Drive in new seal flush using thrust piece - T50018-
Note
Remove sealant residue thoroughly from

agensplines on flange
AG. Volkswagen AG dbefore
oes
applying the new sealant. olksw not
yV gu b ara
ed nte
oris e
– Apply Loctite 565 to ainner
ut
h splines of flange. or
ac
ss
– Install propshaft flange with new securing nut.
ce
e
nl
pt
du
an
itte
y li
Caution
erm
ab
ility
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wit
, is n
Determine friction torque with crown wheel removed.

h re
hole
spec
es, in part or in w
Determining friction torque

t to the co
– Bolt counter-hold tool - 3145- to propshaft flange.

rrectness of i
– Tighten flange nut with socket 32 mm - T10209- until the bear‐

l purpos
ing has zero play.

– Remove counter-hold tool - 3145- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Final drive 21
Amarok 2011 ➤
– To align tapered roller bearings, rotate propshaft flange 15

times clockwise and 15 times anticlockwise.
– Measure friction torque on propshaft flange with a commer‐

cially available 32 mm socket , bearing preload gauge - VAS
6523- and cordless power driver 12 V/1.4 Ah - VAS 5825- .
Note
To avoid incorrect measurements, measure friction value at ap‐

prox. 50 rpm and turning at least 5 times.
AG. Volkswagen AG d
agen
Friction torque: Volksw
oes
not
by gu
d ara
• With new, unoiled bearing: 2.25 Nm to 2.82oris Nm
e nte
eo
h
ut ra
• With used bearing: previously determined
ss a value + 0.1 c
Nm to 0.5 Nm
ce
e
nl
pt
du
an
itte
y li
erm
Caution
ab
ility
ot p
wit
, is n
If the determined friction torque is too low, tighten flange nut
h re
further in small steps. Then, align propshaft flange again (ro‐
hole
spec
tate 15 times in clockwise and 15 times in anticlockwise direc‐
es, in part or in w
tion). After that, determine friction torque again. Repeat this

t to the co
procedure until the friction torque is within the specified range.
It is very likely that this procedure has to be repeated several rrectness of i
times.
l purpos
It is not permitted for friction torque to be attained by loosening

securing nut. Renew the compression sleeve if the permissible
friction torque has been exceeded ⇒ Item 25 (page 12) . The
nform
ercia
drive pinion must be removed for this purpose.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Secure flange nut by peening. lkswage es n
o ot g
yV ua
If the final drive gear set has been dismantled completely
ir se
d b
(com‐ ran
tee
pression sleeve and tapered roller bearing), douth the following:
o
or
a ac
ss
– Determine shims for crown wheel ⇒ page 36 .
ce
e
nl
pt
du
Continuation for all cases:
an
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
Always renew M8 securing bolts of expander - T50021- with
spec
new bolts with property class 12.9 and washers before instal‐ es, in part or in w
lation.
t to the co
Part number for M8 × 35 bolts: N10534803
rrectness of i
Part number for washers: WHT001323
l purpos
Specified torque: 44 Nm
nform
ercia
– Install spreader - T50021- .

m
at
om
ion
c
in t
or
WARNING
his
ate
do
priv
cum
Wear safety goggles. Securing bolts of expander - T50021- are
for
en
g
highly stressed when axle is expanded.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Tension spreader - T50021- until differential can be fitted into
c by lksw
cted agen
axle beam without significant effort complete with tapered roll‐ Prote AG.
er bearings and determined shims.
– Plug electrical connector into gearbox housing, taking due
note of following:
• Wiring harness must not be kinked or pinched.
• The connector stop faces downwards.
Note
♦ Do not interchange shims and tapered roller bearing outer

races for left and right sides.
♦ Install chamfered side of shims towards axle tube.
♦ When installing new shims, insert thinner shim (crown wheel
side) so as to achieve a backlash in all cases.
1. Final drive 23
Amarok 2011 ➤
– Install bearing brackets -1 and 2- in accordance with marked

installation position. Screw in bolts -arrows- finger-tight.
– Slacken expander - T50021- and remove.
– Tighten bearing brackets -1 and 2- to final torque.
– Check backlash and contact pattern on newly adjusted final
drive gear sets ⇒ page 27 .
– Tighten bolt for wiring harness securing plate bracket and en‐
sure that wiring harness is not in contact with crown wheel
bolts.
– Clean sealing surfaces.
wage es n
– Secure final drive cover with new gasket and new bolts. y Volks ot g
ua
b
ed ran
– Install rear axle shafts ⇒ Rep. gr. 42 ; Rear axle shafts
ho
ris . tee
t or
au ac
– Install propshaft ⇒ page 57 . ss
ce
le
un
pt
– Fill with gear oil ⇒ page 67 .
an
d
itte
y li
erm
ab
ility
ot p
– Connect wiring harness to sender.
wit
is n
h re
ole,
– Secure wiring harness bracket to rear axle.
spec
Specified torques
t to the co
♦ ⇒ “3.2 Assembly overview - Tirsan propshaft”, page 54
rrectne
♦ Rear axle shafts, Assembly overview rear axle shafts ⇒ Run‐
s
ning gear, axles, steering; Rep. gr. 42 ; Assembly overview -
s o
rear axle shafts .
cial p
f inform
mer
Component Specified torque
atio
m
Sender to gearbox housing 13 Nm

o
n
c
i
or
n thi
te
sd
a
1.5 Dismantling and assembling differential

iv
o
pr
cum
r
fo
en
ng
Special tools and workshop equipment required

t.
yi Co
Cop py
♦ Convert two arm puller - T10040- with claw - T40001 /2- .
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
or
♦ -handelsüblicher Zweiarmabzieher-
Removing
– Remove differential ⇒ page 14 .

Amarok 2011 ➤
Note
♦ When pressing out pin, securing pin breaks between pin and
housing. Remove remains of securing pin, then, remove re‐
mains from housing as described below.
♦ Fit a commercially available M6 nut between the two arm puller
- T10040- and stud -3- in order to prevent the tool from being
damaged.
– Convert two arm puller - T10040- with claws - T40001 /2- .

– Fit two arm puller - T10040- (or a -handelsüblicher Zweiar‐
mabzieher- ) on housing -1- and press pin -2- in
-direction of arrow- out of housing.
WARNING
The securing pin is removed in three parts. The first part is

removed when driving out the pin, the remaining part must be
“sheared” off into two parts, the two parts must then be re‐
moved from the housing.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Note orise nte
eo
th
au ra
s c
The hole is so deep that differential can be dismantled twice. s
ce
le
un
pt
an
d
itte
The securing pin breaks when removing pin -1- and a part re‐
y li
erm
ab
mains in the pin -arrow a-.
ility
ot p
wit
is n
When the pin is removed from the housing, the remaining part of
h re
ole,
the securing pin -arrow b- must be removed in two parts from the
spec
housing in the -direction of arrow- using a commercially available
t to the co
driver. The lower part of the securing pin -arrow c- remains in the
housing hole.
– Remove differential bevel gears and thrust washer from dif‐
rrectne
ferential cage.
ss
WARNING
o
cial p
f inform
mer
The repair can be made 2 - 3 times.

atio
m
When driving out the pin, a part of the securing pin remains in
o
n
c
i
or
the lower part of the differential housing.

thi
te
sd
va
When a new securing pin is inserted it presses the remains of

i
o
pr
cum
r
the old securing pin into the housing.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
♦ The guide ring will be destroyed during removal.

♦ Renew guide ring if it is damaged.
♦ If a damaged guide ring is used, the proper function of the lock
is no longer guaranteed.
1. Final drive 25
Amarok 2011 ➤
– Release guide ring -1- at locking lugs -arrows- and remove

selector fork from housing.
– Remove guide ring and check it for damage.
Installing
– Use new guide ring.
– Install thrust washers (qty. 4).
Note
♦ Turn bevel gears by hand and check if they rotate freely before
installing the securing pin.
♦ Drive new securing pin “flush” into differential housing.
– Install differential ⇒ page 14 .

Specified torques . Volkswagen AG
gen AG does
swa
♦ ⇒ “1.1 Assembly overview - final drive”, page 10 byV
olk not
gu
d ara
ise nte
♦ ⇒ “3.2 Assembly overview - Tirsan propshaft”, page 54thor eo
au ra
♦ ⇒ “1.2 Assembly overview - differential”, page 13 ss c
ce
le
un
pt
an
d
1.6 Removing and installing crown wheel

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
♦ Torque wrench - V.A.G 1332-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
Removing
do
r
rp
cum
fo
– Remove differential ⇒ page 14 .

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
The bolts have a left-hand thread.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara Amarok 2011 ➤
ed
ris nt
ut
ho Transfer box and final drive - eEdition
eo
ra
05.2013
s a c
s
– Loosen bolts -2- of crown wheel -1-.
ce
e
nl
pt
du
an
itte
– Using light blows, release crown wheel from drive. Then re‐
y li
erm
ab
move bolts and remove crown wheel.
ility
ot p
Installing
wit
, is n
h re
hole
spec
es, in part or in w
Specified torques
t to the co
rrectness of i
l purpos
1.7 Checking backlash and contact pattern
nform
ercia

m
at
om
ion
♦ Dial gauge - VAS 6079-
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Universal dial gauge bracket - VW 387-
or
Without illustration:
♦ Dial gauge extension - T 50047/3-
Checking backlash:
Note
♦ Only required for readjusting final drive gear set.

♦ Align tip of dial gauge - VAS 6079- at a 90° angle with tooth
flank.
– Adjust preload of dial gauge - VAS 6079- .
1. Final drive 27
Amarok 2011 ➤
– Install universal dial gauge bracket - VW 387- with dial gauge

- VAS 6079- and gauge extension -gT AG. Volkswaon
en50047/3- axledohous‐
gen AG
wa es n
ing. Volks ot g
by ua d ran
se
– Measure backlash; specification:
tho
ri 0.102 … 0.177 mm tee
or
au ac
ss
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
Backlash can be changed using shims ⇒ Item 7 (page 11) . If a
ility
ot p
thinner shim is installed on one side, a shim that is thicker by cor‐
wit
is n
responding amount must be installed on other side so as to
h re
ole,
maintain bearing preload of differential bearings.
spec
t to the co
Checking contact pattern:
rrectne
♦ Retaining tool - T50022-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Spotting ink
Note
Only required for readjusting final drive gear set.
– To check contact pattern, apply spotting ink to two teeth of

crown wheel offset by 180°.
– Mount retainer - T50022- and brake differential using setscrew
-arrow-.
– Rotate differential at propshaft flange in both directions.
– Check contact pattern.

Amarok 2011 ➤
Correct contact pattern
Note
lkswage es n
In practice, it is not possible
byV
o
to achieve such an ideal contact
ot g
ua pat‐
tern. It is important o
ir sthat
ed no point touches outer edge of tooth ran
tee
surface. auth or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Contact at tooth tip:
hole
spec
es, in part or in w
t to the co
Note
Reduce installation distance of crown wheel somewhat (crown
rrectness of i
wheel closer to drive pinion) ⇒ page 35 . This causes teeth to
l purpos
engage somewhat more deeply whilst maintaining backlash.
nform
mercia
a
com
tion in
r
te o
thi
s
Contact at tooth root:
iva
do
r
rp
cum
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
Increase installation distance of crown wheel somewhat (remove
cop Vo
by lksw
crown wheel from drive pinion) ⇒ page 35 . This causes teeth
cted agen
Prote AG.
to engage somewhat less deeply whilst maintaining backlash.
1. Final drive 29
Amarok 2011 ➤
1.8 Pulling tapered roller bearing for drive pinion off and pressing it on

equipment required
♦ Pressure plate - VW 401-
♦ Tube - VW 519-
♦ Thrust piece - 3118-
olks
wage es n
ot g
yV ua
db ran
rise tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Procedure:
– Remove drive pinion ⇒ page 14 .
– Then press tapered roller bearing -arrow- off drive pinion -1-.

Amarok 2011 ➤
– Press tapered roller bearing inner race off drive pinion.

– Determine shim for drive pinion before pressing on tapered
agen
AG. Volkswagen AG d
oes
roller bearing ⇒ page 39 . olksw not
yV gu b ara
ed nte
oris e
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Press tapered roller bearing onto drive pinion.
spec
es, in part or in w
t to the co
Note
rrectness of i
Ensure that drive pinion shim is correctly seated on back of drive
pinion head. Bearing must be fully in contact with shim. There
l purpos
must be no gap between them.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Final drive 31
Amarok 2011 ➤
1.9 Pulling tapered roller bearing for differential off and pressing it on

equipment required
♦ Tube - 2040-
♦ Thrust pad - VW 447 i-
♦ Counter support Kukko
18-2
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Dismantling
o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
The tapered roller bearings are damaged beyond repair when

t.
yi Co
op
being removed and must be renewed.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Open tapered roller bearing cage -arrow- with side cutters and Prote
cted AG.
agen
remove cage with rollers.

Amarok 2011 ➤
– Pull off inner rings with thrust plate - VW 447 i- and tube -
2040- .
1- Counter support Kukko 18-2
2- Separating tool Kukko 17-2
Assembling
Note
♦ For pressing on 2nd tapered roller bearing, place thrust pad -

VW 447 i- under inner race of 1st tapered roller bearing.
♦ Tapered roller bearings must make flush contact.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Final drive 33
Amarok 2011 ➤
1.10 Overview of shims
1 - Compression sleeve
❑ Renew
2 - Shim
❑ For adjusting drive pin‐
ion
3 - Shim
❑ On crown wheel side
❑ For adjusting crown
wheel
❑ Fitting position: cham‐
fered side faces axle
tube.
4 - Shim
❑ Opposite side of crown
wheel.
❑ For adjusting crown
wheel
❑ Fitting position: cham‐
fered side faces axle
tube.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
1.11 Adjustment overview
Note
♦ Careful adjustment of the crown wheel and drive pinion is es‐

sential to ensure that the final drive gives long service and runs
silently. Therefore, the drive pinion and crown wheel are
matched during manufacture, and checked to ensure a good
mesh pattern and quiet running in both directions of rotation.
The position of quietest running is found by moving the drive
pinion axially while simultaneously lifting the crown wheel from
the zero-play mesh position by the amount necessary to main‐
tain the backlash within the specified tolerance.
♦ The purpose of this adjustment is to re-establish the position
offering the quietest running as calculated on the test device G. Volkswagen
during production. lksw
agen
A AG do
es n
o ot g
yV
♦ The utmost care and cleanliness during all assembly
d b work and ua
ran
ise
measurements are essential to achieve a good
ut
ho result.
r tee
or
sa ac
♦ Observe the general repair notes for tapered
s roller bearings
ce
e
and shims ⇒ page 7 .

nl
pt
du
an
itte
y li
erm
ab
Basic dimension to be set
ility
ot p
wit
1 - Drive pinion
, is n
h re
hole
2 - Crown wheel
spec
es, in part or in w
a - Nominal default value = 112 mm
t to the co
b - Middle of crown wheel
rrectness of i
Adjustment overview
l purpos
Note
nf
ercia
o
If repairs have been carried out on the final drive gear set it is only
rm
m
atio
necessary to adjust the drive pinion or crown wheel if components
om
have been renewed which have a direct effect on the adjustments
n in
or c
of the final drive. To prevent unnecessary adjustments, refer to

thi
te
sd
a
the following table:

iv
o
r
rp
cu
o
m
f
en
ng
t.
Renewed component Adjusting drive pinion Adjusting crown
yi Co
op
⇒ page 39 wheel
C py
t. rig
gh
⇒ page 36
ht
pyri by
Vo
co lksw
by
Axle beam1) X X cted agen
Prote AG.
Final drive gear set X X

(drive pinion and
crown wheel)1)
Tapered roller bear‐ X X
ing2)
Compression sleeve3) - -
Differential cage - X
1) Renew tapered roller bearing of drive pinion as well.
2) Renew all tapered roller bearings of final drive gear set.
3)If the required friction torque was not achieved when the seal
for the propshaft flange was renewed, and therefore only the
compression sleeve was renewed, there is no need to readjust
the final drive gear set.
1. Final drive 35
Amarok 2011 ➤
1.12 Determining shims for crown wheel

♦ Measuring piece - T50047/2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Feeler gauge
wit
is n
h re
ole,
spec
Note
t to the co
To avoid mistakes when adjusting crown wheel, it is a good idea
to print out tables for calculating shim ⇒ page 36 and enter
rrectne
measured values.
s
• Differential removed.
s o
cial p
f in
A - Measuring inside dimension of rear final drive housing:
form
mer
– Insert measuring piece - T50047/2- and measure gap using
atio
m
feeler gauge .
o
n
c
i
or
n thi
e
– Calculate rear axle housing inside dimension by adding to‐

t
sd
va
gether measured gap and measuring piece.

i
o
pr
cum
r
fo
en
Example:
ng
t.
yi Co
Cop py
Measuring piece dimension 212.50 mm
t. rig
gh ht
pyri by
+ Measured gap size 0.70 mm
o Vo
by c lksw
cted agen
Prote
= Rear final drive housing inside dimension 213.20 mm
AG.
B - Measuring differential axle dimension:
– Place differential with tapered roller bearing outer races -1- on

level surface and measure total height.
C - Calculating shims for differential
Note
♦ To achieve specified bearing preload, it is necessary to add a

constant value (pressure) to calculated basic dimension.
♦ This range must be achieved using shims ⇒ page 37 .
Bearing preload: 0.029 mm … 0.048 mm

Calculation:
Tables for printing out, crown wheel adjustment

Amarok 2011 ➤
A - Measuring inside dimension of Measured: Example:

rear final drive housing:
Measuring piece dimension mm 212.50 mm
Measured gap size mm +0.70 mm
Rear final drive housing inside di‐ A= mm 213.20 mm
mension
B - Measuring differential axle di‐ Measured: Example:

mension:
Differential axle dimension B= mm 201.00 mm
Note
The size of the individual shims ncorresponds approximately

AG. Volkswagen AG do to half
of dimension -C-. olkswage es no
yV t gu
db ara
rise nte
C - Calculating thtotal
o thickness of Measured: eo Example:
shims: s au ra
c
s ce
le
Rear final drive housing inside di‐ mm 213.20 mm

un
pt
an
d
mension (A)
itte
y li
rm
ab
Value for bearing preload mm +0.03 mm
pe
ility
ot
Differential axle dimension (B) - mm -201.00 mm

wit
, is n
h re
Total thickness of shims C= mm 12.23 mm

hole
spec
1/2 × C = mm 6.115 mm
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ Insert thinner shim on crown wheel side so as to achieve a

nform
ercia
backlash in all cases, e.g. for a total shim thickness of 12.23

mm: crown wheel side, 6.102 mm and opposite side 6.128
m
a
com
mm.
ion in
r
te o
♦ Shims ⇒ page 37
thi
s
iva
do
♦ 1 mm shim thickness corresponds to approx. 1.4 mm back‐

r
rp
cum
fo
lash.
en
ng
t.
yi Co
Cop py
Crown wheel shims
t. rig
gh ht
pyri by
Vo
co lksw
by
No. Thickness t (mm)
Prote
cted AG.
agen
VW part number
13 5.645 WHT 006 443
14 5.671 WHT 006 443 A
15 5.696 WHT 006 443 B
16 5.721 WHT 006 443 C
17 5.747 WHT 006 443 D
18 5.772 WHT 006 443 E
19 5.798 WHT 006 443 F
20 5.823 WHT 006 443 G
21 5.848 WHT 006 443 H
22 5.874 WHT 006 443 J
1. Final drive 37
Amarok 2011 ➤
No. Thickness t (mm) VW part number

23 5.899 WHT 006 443 K
24 5.925 WHT 006 443 L
25 5.950 WHT 006 443 M
26 5.975 WHT 006 443 N
27 6.001 WHT 006 443 P
28 6.026 WHT 006 443 Q
29 6.052 WHT 006 443 R
30 6.077 WHT 006 443 S
31 6.102 WHT 006 443 T
32 6.128 WHT 006 443 W
33 6.153 WHT 006 443 Y
34 6.179 WHT 006 443 Z
35 6.204 WHT 006 443 AA
36 6.229 WHT n006 443
AG. V AB
olkswagen AG
lkswage does
not
37 6.255 by Vo WHT 006 443 AC gu
ara
ed
nte
38 6.280 thoris WHT 006 443 AD eo
u ra
39 6.306 ss
a
WHT 006 443 AE c
ce
e
40 6.331 WHT 006 443 AF

nl
pt
du
an
itte
41 6.356 WHT 006 443 AG
y li
erm
ab
42 6.382 WHT 006 443 AH
ility
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wit
, is n
43 6.407 WHT 006 443 AJ
h re
hole
44 6.433 WHT 006 443 AK
spec
es, in part or in w
45 6.458 WHT 006 443 AL
t to the co
rrectness of i
If the shims for the crown wheel have been determined, do the
following:
l purpos
– Reinstall drive pinion and differential ⇒ page 20 .
nform
ercia
– Check backlash and contact pattern ⇒ page 27 .

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
1.13 Determining shims for drive pinion

equipment required
♦ Dial gauge - VAS 6079-
♦ Setting tool - T 50047-
♦ Fitting tool - T50023-
♦ Thrust piece - T 50048-
♦ Depth gauge
wage es n
♦ Feeler gauge yV
olks ot g
ua
d b ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
• Drive pinion removed. Prote AG.
• Drive pinion bearing shells must be pulled in.
– Pull in outer races of tapered roller bearings as far as stop

using fitting tool - T50023- as well as thrust piece - T50048/1-
and thrust piece - T50048/2- .
1. Final drive 39
Amarok 2011 ➤
Transfer box and final drive - Edition 05.2013 AG. Volkswagen AG d
agen oes
olksw not
V gu
Installation position of fitting tool - T50023- in rear final drive
ed by ara
nte
housing. horis
eo
aut ra
Measuring basic dimension (production tolerance)s on rear axle
s c
ce
le
housing
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Secure dial gauge extension - T50047/4- on dial gauge - VAS
6079- , then insert it in measuring piece - T50047/2- and se‐
l purpos
cure it using knurled screw. Secure tip of dial gauge - VAS

6079- on extension.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Adjust preload of dial gauge - VAS 6079- to 2 mm. Then, set by c lksw
cted agen
dial gauge - VAS 6079- to »0«.
Prote AG.
Note
♦ Contact surfaces must be clean and free of burrs.

♦ This means measuring piece is set to nominal basic dimen‐
sion.
♦ Use dial gauge extension - T50047/4- .

Amarok 2011 ➤
– Convert fitting tool - T50023- . To do this, turn thrust piece -

T50048/2- around and slide it onto fitting tool - T50023- .
Caution
To avoid incorrect measurements, the value must be deter‐

mined with tapered roller bearing installed.
Bolt measuring piece - T50047/1- to fitting tool - T50023- and
tighten it “so that it barely has zero play”.
lkswage es n
– Insert the converted fitting tool - T50023- inbthey V rear final drive
o ot g
ua
housing. Insert tapered roller bearing with
o
ir se measuring piece -
d ran
tee
T50047/1- in rear final drive housingauand bolt the two parts
th or
ac
together using the threaded rod. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Insert measuring piece - T50047/2- with dial gauge - VAS
rrectness of i
6079- and dial gauge extension - T50047/4- in rear final drive
l purpos
housing.
nf
ercia
Caution
orm
m
atio
m
The dial gauge must be read anti-clockwise at the red figures.

o
n in
or c
The thickness of the required shim is read directly on the dial

thi
te
gauge - VAS 6079- . sd

iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Determine reversal point on dial gauge - VAS 6079- by turning cop Vo
by lksw
it slightly back and forth in -direction of arrow-. Note the de‐ cted agen
Prote AG.
termined value.
Shims ⇒ page 41
Drive pinion shims

20 0.508 WHT 006 444
21 0.533 WHT 006 444 A
22 0.559 WHT 006 444 B
23 0.584 WHT 006 444 C
24 0.610 WHT 006 443 D
25 0.635 WHT 006 443 E
1. Final drive 41
Amarok 2011 ➤

26 0.660 WHT 006 444 F
27 0.686 WHT 006 444 G
28 0.711 WHT 006 444 H
29 0.737 WHT 006 444 J
30 0.762 WHT 006 444 K
31 0.787 WHT 006 444 L
32 0.813 WHT 006 444 M
33 0.838 WHT 006 444 N
34 0.864 WHT 006 444 P
35 0.889 WHT 006 444 Q
36 0.914 WHT 006 444 R
37 0.940 WHT 006 444 S
38 0.965 WHT 006 444 T
39 0.991 WHT 006 444 W
lkswage es n
If the shim for the drive
by V pinion has been determined,
o ot g
do
ua the fol‐
lowing: o
ir se
d ran
tee
th or
au
– Fit newssshim onto drive pinion and press on tapered rollerac
bearing ⇒ page 30 .
ce
le
un
pt
an
d
– Reinstall drive pinion and differential into rear final drive hous‐
itte
y li
ing ⇒ page 20 .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
1.14 Renewing propshaft flange seal

equipment required
♦ Counter-hold tool - 3145-
(modify holes)
1332-
♦ Socket 32 mm - T10209-
AG. Volkswagen AG d
♦ Counter support Kukko agen oes
olksw not
18-2 byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
Special tools and workshop equipment required rig ht
py by
co Vo
by lksw
♦ Bearing preload gauge - VAS 6523- Prote
cted AG.
agen
♦ e.g. cordless power driver 12 V/1.4 Ah - VAS 5825-

♦ Loctite 565
1. Final drive 43
Amarok 2011 ➤
Caution
If the seal is renewed, the friction torque must be determined

before starting repair work ⇒ page 44 .
If the friction torque has not been determined before removal,
the compression sleeve and the drive pinion bearings will have
to be renewed.
Modifying counter-hold tool - 3145- AG. Volkswagen AG d

agen oes
olksw not
V gu
• Counter-hold tool - 3145- is used ed by to loosen and tighten secur‐ ara
nte
is
ing nut for propshaft flange. horIn case of an unmodified tool, drill eo
aut
out both holes in counter-hold tool - 3145- to dimension -a- = ra
s c
10.5 mm ∅. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
A new counter-hold tool - 3145- with 10.5 mm ∅ holes will be
h re
supplied.
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
Note
l purpos
The brake drums must be removed, in order to prevent a poten‐

tially dragging brake from falsifying the measurement and causing
nform
ercia
incorrect values.
m
at
om
i
– Remove rear brake drums ⇒ Brake systems; Rep. gr. 46 ;
on
c
Rear brakes; Resetting drum brake .

in t
or
his
ate
– Unbolt propshaft from rear axle ⇒ page 57 .

do
priv
cum
or
– Secure propshaft to body.

f
en
ng
t.
yi Co
op
– Check drive pinion bearing for axial play (no play permitted).
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Measure friction torque on propshaft flange with a commer‐ Prote
cted agen
cially available 32 mm socket , bearing preload gauge - VAS
AG.
6523- and a cordless power driver 12 V/1.4 Ah - VAS 5825- ,

for example.
.
Caution
♦ To avoid incorrect measurements, measure friction torque

at approx. 50 rpm and turning at least 5 times.
♦ Perform measurements carefully and accurately to pre‐
vent replacement of axle body.
♦ Do not take any actions to alter friction torque before in‐
stalling seal on axle.
– Note reading.

AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Amarok 2011 ➤
ise nte
thor Transfer box and final e drive
or - Edition 05.2013
au ac
ss
– Remove locking device for nut -arrows-.
ce
le
un
pt
an
d
– Screw counter-hold tool - 3145- onto propshaft flange.
itte
y li
rm
ab
– Loosen securing nut using 32 mm socket - T10209- .
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Fit puller, as shown, and pull off propshaft flange.
nform
ercia

m
a
com
ti
on in
r
te o
thi
Removing oil seal
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Drive out seal -1- using a chisel.
Caution
Do not damage axle body when driving out seal.
Installing
Note
♦ Remove any sealant residue from drive pinion and propshaft

flange.
♦ If leaks are detected during repair work on the flange, always
renew the seal ⇒ Item 21 (page 11) .
♦ Check the contact surface of the propshaft flange seal for
traces of wear. Renew sealing sleeve if necessary
⇒ page 49 .
♦ Before fitting the flange, seal the splines between the drive
pinion and the flange with Loctite 565 .
1. Final drive 45
Amarok 2011 ➤
– Drive in new seal flush using thrust piece - T50018-

– Install propshaft flange with new securing nut.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
ised b ara
nte
or eo
h
– Tighten securing nut using 32 mm socket s aut - T10209- . ra
c
s
Initial tightening torque
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Nut 30 Nm
ot p
wit
, is n
h re
– Check drive pinion bearing for axial play (no play permitted).
hole
spec
es, in part or in w
t to the co
Note
If bearing is not without play, specified torque can be increased
rrectness of i
in 10 Nm steps to max. 60 Nm. Renew compression sleeve if
bearing is not yet without play after the nut has been tightened to
l purpos
60 Nm.
nf
ercia
o
rm
m
atio
om
n in
or c

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Mark position of drive pinion in relation to one edge of securing

nut.

Amarok 2011 ➤
– Tighten securing nut by further 15° using 32 mm socket -

T10209- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
– Tighten securing nut 15° further using 32 mm socket -

t
sd
iva
o
T10209- .
r
rp
cu
o
m
f
en
ng
– Remove counterhold tool - 3145- .

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Final drive 47
Amarok 2011 ➤

– Measure friction torque on propshaft flange with 32 mm socket
- T10209- , bearing preload gauge - VAS 6523- and e.g. cord‐
less power driver 12 V/1.4 Ah - VAS 5825- .
Note
To avoid incorrect measurements, measure friction value at ap‐

prox. 50 rpm and turning at least 5 times.
Friction torque:
• With new, unoiled bearing: 2.25 Nm to 2.82 Nm
• With used bearing: previously determined value + 0.1
Nm to 0.5 Nm
Caution
If the determined friction torque is too low, tighten nut in small

steps. Then, align propshaft flange again (rotate 15 times in
clockwise and 15 times in anticlockwise direction). After that,
determine friction torque again.
wagen Repeat
AG. Volksthis procedure
wagen AG
does until the
friction torque is within olks specified range.
Vthe
not
gu
by ara
d
se n
It is very likely tthat
ho
ri this procedure has to be repeated several
tee
or
times. ss
au ac
ce
le
It is not permitted for friction torque to be attained by loosening

un
pt
securing nut. Renew the compression sleeve if the permissible

an
d
itte
y li
friction torque has been exceeded ⇒ Item 25 (page 12) . The

rm
ab
drive pinion must be removed for this purpose.

pe
ility
ot
wit
, is n
h re
hole
spec
– Secure securing nut by peening.

es, in part or in w
t to the co
– Install propshaft ⇒ page 57 .

– Install brake drums ⇒ Brake systems; Rep. gr. 46 ; Rear
rrectness of i
brakes; Resetting drum brake .

l purpos
– Operate brake pedal several times until brake shoes are in

contact with brake drum.
nform
ercia
– Check oil level and top up if necessary ⇒ page 67 .

m
Specified torques
com
tion in
r

te o
thi
s
iva
do

r
rp
cum
fo
♦ ⇒ “3.3 Assembly overview - Dana propshaft”, page 55

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
1.15 Repairing propshaft flange

equipment required
♦ Thrust piece - 40-105-
♦ Thrust pad - VW 511-
18-2
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility

ot p
wit
is n
♦ Tube - 30 - 14-
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
Pressing out
sd
iva
o
pr
cum
r
• Propshaft flange removed ⇒ page 43 .

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Final drive 49
Amarok 2011 ➤
– Press out propshaft flange using thrust piece - 40-105- .

1- Counter support Kukko 18-2
2- Separating tool Kukko 17-2
Pressing on
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
– Press dust cap onto propshaft flange using thrust piece - VW
itte
y li
erm
442- and tube - 30 - 14- .
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Press sealing sleeve onto dust cap using thrust plate - VW

rm
m
511- .
atio
om
n in
c
– Then reinstall propshaft flange ⇒ page 43 .

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
2 Differential lock
⇒ “2.1 Functional check”, page 51
⇒ “2.2 Rear-axle differential lock components and their locations”,
page 51
2.1 Functional check

A mechanical rear axle differential lock is now available as an
option in the Amarok with four-wheel drive.
When driving offroad, rear axle differential lock improves propul‐
sion on heavy ground, in particular when performing a hill start.
All functions that assist braking are deactivated when rear axle
differential lock is engaged, therefore rear axle differential lock is
only allowed to be engaged when moving off
gen AG
. Voon heavy ground
lkswagen AG
does or
swa
if carriageway is very soft. yV
olk not
gu b ara
ed nte
In case of a selectable four-wheel
ho
ris drive the rear differential lock e
aut
can be activated in offroad range “LOW”.
or
ac
s s
ce
e
The differential lock is switched on or off via the rear differential

nl
pt
du
lock switch - E121- . The differential lock control unit - J187-
an
itte
y li
checks via the CAN-Bus if the conditions to switch the rear axle
erm
ab
differential lock on have been fulfilled. If they have, then rear axle
ility
ot p
differential lock is activated via axle differential lock Hall sender 1
wit
, is n
- G460- and control solenoid - N5- .
h re
hole
spec
Refer to ⇒ Self-study programme No. 464 ; Power transmission
es, in part or in w
for more information about function.
t to the co
Refer to ⇒ Amarok owner's manual for more information and
notes on safety.
rrectness of i
2.2 Rear-axle differential lock components
l purpos
and their locations

nform
mercia
Note
at
om
ion
c
in t
or
Electrical/electronic components and their locations for four-

his
ate
wheel drive ⇒ page 94

do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Differential lock 51
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Amarok 2011 ➤ thor eo
u ra
Transfer box and final drive - Edition s05.2013
sa c
ce
e
nl
pt
du
1 - Differential lock control unit
an
itte
y li
- J187-
erm
ab
ility
ot p
Remove by removing centre
wit
console ⇒ General body re‐
, is n
h re
pairs, interior; Rep. gr. 68 ;
hole
spec
Compartments, covers and
es, in part or in w
trims; Removing and installing
t to the co
centre console .
2 - Diagnostic connection
rrectness of i
❑ Location: in driver foot‐ l purpos
well
3 - Rear differential lock switch
nform
ercia
- E121-
❑ Rear axle differential
m
at
om
i
lock warning lamp in
on
c
transfer box operating
in t
or
his
e
unit - K184-
at
do
riv
❑ Remove by removing
p
cum
or
selector mechanism
f
en
ng
t.
yi
cover ⇒ General body
Co
op py
repairs, interior; Rep.
t. C rig
gh ht
yri
gr. 68 ; Compartments, p by
co Vo
covers and trims; Re‐
by lksw
cted agen
Prote
moving and installing
AG.
centre console .
4 - Hall sender 1 for axle differ‐
ential lock - G460-
❑ With control solenoid -
N5-
❑ Location: on rear axle

Amarok 2011 ➤
3 Propshaft
⇒ “3.1 Assembly overview - flexible coupling for propshaft”, page
53
⇒ “3.2 Assembly overview - Tirsan propshaft”, page 54
⇒ “3.3 Assembly overview - Dana propshaft”, page 55
⇒ “3.4 Removing and installing front propshaft”, page 56
AG . Volkswage
⇒ “3.5 Removing and installing rear
ksw
agenpropshaft”, page
n AG d
o57
es n
ol ot g
yV u
⇒ “3.6 Dismantling andiseassembling
db propshaft intermediate bear‐
ara
n
ing, Dana propshaft”,
ut
ho page 60
r tee
or
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ss and assembling
⇒ “3.7 Dismantling propshaft intermediate bear‐
ce
le
ing, Tirsan propshaft”, page 63

un
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itte
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3.1 Assembly overview - flexible coupling for propshaft
rm
ab
pe
ility
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wit
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1 - Bolt
hole
spec
es, in part or in w
t to the co
❑ 60 Nm +90°
2 - Flexible coupling
rrectness of i
❑ Allocation ⇒ Electronic
Parts Catalogue (ET‐
l purpos
KA) .
3 - Bolt
nform
ercia

m
a
❑ For securing on gear‐
com
tion in
box.
r
te o
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❑ 90 Nm +90°
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4 - Propshaft
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❑ Assembly overview -
yi Co
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“Tirsan” propshaft
C py
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⇒ page 54 .
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❑ Assembly overview - Prote
cted AG.
agen
“Dana” propshaft
⇒ page 55 .
⇒ page 57
5 - Washer
6 - Nut
3. Propshaft 53
Amarok 2011 ➤
3.2 Assembly overview - “Tirsan” propshaft
Note
Volkswa
♦ If propshaft is disconnected only from the rearswaxle,
agen the prop‐
AG. gen AG
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shaft must be raised and secured or supported. yV
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♦ Keep propshaft straight; store and transport
tho
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ly. ss au ra
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1 - Bolt
erm
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ility
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❑ 50 Nm +90°
h re
hole
spec
2 - Rear propshaft
es, in part or in w
t to the co
⇒ page 57
3 - Dust cap
rrectness of i
l purpos
4 - Propshaft intermediate
bearing
nform
ercia
❑ Dismantling and assem‐

m
bling propshaft inter‐
at
om
i
mediate bearing
on
c
in t
⇒ page 63 .
or
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ate
do
riv
5 - Nut
p
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or

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❑ 20 Nm +90° t. Cop py
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6 - Bolt yri
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❑ Renew after removal cted agen
Prote AG.
❑ 66 Nm
7 - Dust cap
8 - Washer
9 - Rear propshaft
⇒ page 57
10 - Bolt
❑ 50 Nm +90°
11 - Retaining ring
❑ On front final drive
12 - Front propshaft
❑ All-wheel drive only
❑ Coloured markings on pin of front final drive and front propshaft must be in alignment.
❑ Always renew retaining rings ⇒ Item 11 (page 54) and ⇒ Item 13 (page 55) after propshaft has been
removed.

Amarok 2011 ➤
13 - Retaining ring
3.3 Assembly overview - “Dana” propshaft
Note
♦ If propshaft is disconnected only from the rear axle, the prop‐

shaft must be raised and secured or supported.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
1 - Bolt
❑ 50 Nm +90°
2 - Rear propshaft
AG. Volkswagen AG d
❑ Removing and installing agen oes
olksw not
⇒ page 57 ed byV gu
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o
3 - Dust cap aut
h eo
ra
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❑ Renew after removal s
ce
e
nl
pt
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4 - Rubber ring
an
itte
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erm
ab
5 - Bearing bracket
ility
ot p
wit
6 - Nut
, is n
h re
hole
spec
❑ 20 Nm +90°
es, in part or in w
t to the co
7 - Propshaft intermediate
bearing
rrectness of i
❑ Dismantling and assem‐
bling propshaft inter‐
l purpos
mediate bearing
⇒ page 60 .
nf
ercia
8 - Seal
orm
m
❑ Renew after removal atio

om
n in
c
9 - Dust cap
or
thi
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10 - Rear propshaft
o
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⇒ page 57 ht. rig
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11 - Bolt by c lksw
cted agen
Prote AG.
❑ 50 Nm +90°
12 - Retaining ring
❑ On front final drive
13 - Front propshaft
❑ Four-wheel drive only
❑ Coloured markings on pin of front final drive and front propshaft must be in alignment.
3. Propshaft 55
Amarok 2011 ➤
❑ Always renew retaining rings ⇒ Item 12 (page 55) and ⇒ Item 14 (page 56) after propshaft has been
removed.
14 - Retaining ring
3.4 Removing and installing front propshaft

♦ Drive shaft grease ⇒ Electronic Parts Catalogue (ETKA)

Removing
Before removing, mark positions of all parts relative to each other.
Reinstall in the same position otherwise imbalance will be exces‐
sive, the mountings could be damaged causing rumbling noises.
– Raise vehicle ⇒ Maintenance ; Booklet 11 .
– Remove engine/gearbox guard ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Engine/gearbox guard .
– Check if there are markings (paint spots) -A- on front propshaft
agen
AG. Volkswagen AG d
oes
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and on front final drive. by
Vol not
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– If these markings are not present, then markthposition
or
i
of prop‐ e or
shaft flange in relation to front final drive with
s au paint. ac
s
ce
e
nl
pt
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itte
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erm
ab
ility
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, is n
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hole
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es, in part or in w
t to the co
– Prise front propshaft -1- off final drive using assembly lever.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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pyri by
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56
by c lksw
cted
Rep. gr.39 - Final drive - rear differential
agen
Prote AG.
AG. Volkswagen AG d Amarok 2011 ➤
agen Transfer box
oes and final drive - Edition 05.2013
o lksw not
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– Push front propshaft off transfer
hor box using counter-hold tool - eo
ut
3415- . ss a ra
c
ce
le
– Remove front propshaft.
un
pt
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itte
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Installing .
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Renew oil seals -1- if damaged.
l purpos
– Renew retaining rings -2-.
nform
ercia
– Grease splines of shafts and oil seals -1- with drive shaft
grease ⇒ Electronic Parts Catalogue (ETKA) .
m
a
com
tion in
r
te o
thi
s
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cum
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Cop py
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rig ht
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cted agen
Prote
– Markings -A- must be aligned with one another as far as pos‐
AG.
sible.
– Position front propshaft on front final drive.
Caution
Wear protective gloves!
– Then push front propshaft -1- onto shaft forcefully by hand until
it engages.
– Pull on front propshaft to check propshaft has engaged cor‐
rectly.
– Position front propshaft on transfer box.
– Push front propshaft onto shaft until it engages.
– Pull on front propshaft to check propshaft has engaged cor‐
rectly.
– Install engine/gearbox guard ⇒ General body repairs, exterior;
Rep. gr. 50 ; Engine/gearbox guard .
Specified torques
3.5 Removing and installing rear propshaft

3. Propshaft 57
Amarok 2011 ➤
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♦ Brake pedal actuator - V.A.G 1869/2-
auth (vehicles with rear- or
ac
wheel drive) ss
ce
le
un
pt
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rm
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pe
ility
ot
wit
, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
♦ Counter-hold tool - T10172- (vehicles with four-wheel drive)
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ If possible, use a twin pillar lifting platform when working on

the propshaft.
♦ Remove and install propshaft with the help of a second me‐
chanic.
♦ Before removing, mark positions of all parts relative to each
other. Reinstall in the same position otherwise imbalance will
be excessive, the mountings could be damaged causing rum‐
bling noises.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
♦ Do not let propshaft »hang« during removal; always support
it.
♦ Always pull propshaft from or push it onto drive flange hori‐
zontally .

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes Transfer box and final drive - Edition 05.2013
olksw not
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d by ara
e
Removing horis nte
eo
aut ra
Vehicles with srear-wheel drive
s c
ce
le
un
– Fit brake pedal actuator - V.A.G 1869/2- .
pt
an
d
itte
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erm
ab
ility
ot p
– Unscrew securing bolts for propshaft on propshaft flanges, but
wit
is n
do not remove them yet.
h re
ole,
spec
Vehicles with four-wheel drive
t to the co
– Unscrew securing bolts for propshaft on propshaft flanges, but
do not remove them yet. Brace using counter-hold tool -
rrectne
T10172- .
s
s o
cial p
f inform
Caution
mer
atio
om
n
To prevent noises due to imbalance, mark the position of the
c
i
or
n
propshaft relative to the flanges.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
– Mark position of propshaft in relation to propshaft flanges.

t.
yi Co
Cop py
t. rig
gh ht
– Install hexagon nuts for intermediate bearing -arrows-. yri
p by
o Vo
by c lksw
cted agen
Prote AG.
Note
A second mechanic is required for the further removal of the

propshaft.
Caution
To avoid damaging the protective boot in the intermediate

bearing, remove, store and install the propshaft with the joint
as straight as possible.
– Unscrew propshaft at propshaft flanges and remove propshaft

with joint positioned as straight as possible.
Installing
– Install all parts which were marked in relation to each other in
their original positions.
– Install propshaft with new bolts.
Installing intermediate bearing free of tension
• All propshaft bolts are tightened.
– Align intermediate bearing in its elongated holes so that nei‐
ther propshaft nor intermediate bearing is under tension.
– Tighten new hexagon nuts.
Specified torques
3. Propshaft 59
Amarok 2011 ➤
3.6 Dismantling and assembling propshaft intermediate bearing, “Dana” prop‐

shaft

equipment required
♦ Thrust pad - VW 510-
18-2
♦ Thrust pad - VW 447 H-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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op py
Note t. C rig
gh ht
pyri by
Vo
co lksw
by
♦ Distinguishing features of propshafts: cted agen
Prote AG.
♦ Sticker on propshaft or, if not legible anymore, the 11th posi‐

tion of the vehicle identification number.
♦ H = Tirsan propshaft
♦ A or 8 = Dana propshaft
Dismantling
Remove propshaft ⇒ page 57 .

Amarok 2011 ➤
Note
♦ Mark position of propshaft before removing it.

♦ The propshaft may also be installed reversed by 180°.
– Release dust cap.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Clamp propshaft in a vice und pull shafts apart by hand.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
– Pull seal -1- and dust cap -2- off shaft.

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Propshaft 61
Amarok 2011 ➤
– Remove retaining ring.
– Cut rubber ring in marked areaagen

-arrow- with
AG. VolkswagenaAknife
G do to ease
removal and pull it off.Volksw es n
ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit separating tool Kukko 17-2 and counter support Kukko 18-2
and press off propshaft using thrust plate - VW 447 H- .
rrectness of i
Assembling
l purpos

nform
ercia
Note
m
at
om
ion
c
in t
♦ Use silicone lubricant - D 007 000 A2- to ease the installation

or
his
e
of the rubber ring.

at
do
priv
♦ Installation position of elastomer components in direction of

um
for
en
g
travel.
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
– Using thrust piece - 3118- and thrust plate - VW 510- drive
co Vo
by lksw
cted
propshaft intermediate bearing onto propshaft as far as stop.
agen
Prote AG.

Amarok 2011 ➤
– Then, install rubber ring by hand using silicone lubricant - D

007 000 A2- to ease installation.
– Renew dust cap and seal. Grease splines.
– Join parts of propshaft in area of splines and “abruptly” push
them together until the dust cap engages.
Specified torque AG. Volkswagen AG d
agen oes
olksw not
♦ ⇒ “3.3 Assembly overview - Dana propshaft”, page d by V55 gu
ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
3.7 Dismantling and assembling propshaft intermediate bearing, “Tirsan” prop‐
erm
ab
ility
ot p
shaft
wit
is n
h re
ole,
spec
t to the co
equipment required
rrectne
18-2
ss
o
cial p
f inform
♦ Thrust pad - VW 447 H-
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Propshaft 63
Amarok 2011 ➤
Note
♦ Distinguishing features of propshafts:

♦ Sticker on propshaft or, if not legible anymore, the 11th posi‐
tion of the vehicle identification number. AG. Volkswagen AG d
agen oes
♦ H = Tirsan propshaft olksw not
V gu
d by ara
e
♦ A or 8 = Dana propshaft ris nte
ho eo
aut ra
ss c
Dismantling
ce
e
nl
pt
du
an
Remove propshaft ⇒ page 57 .
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Mark position of propshaft before removing it.
es, in part or in w
t to the co
– Clamp propshaft in a vice.
– Initially loosen bolt until the washer plate can be removed.
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Then, apply light pressure on the bolt head -arrow A- using a

o
n in
c
commercially available assembly lever . Loosen bolt further

or
thi
e
while doing so -arrow B-. This will cause the propshaft to be

t
sd
iva
pressed off.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
by c
♦ Due to space restrictions it may be necessary to grind off the
lksw
cted agen
Prote
edges of the spanner.
AG.
♦ If the bolt is not long enough to press the propshaft parts apart
completely, the splines can be separated by light blows with a
-Kunststoffhammer- after the bolt has been loosened as far as
possible. Only strike against the joint section with inner
splines.
– Pull propshaft apart.

Amarok 2011 ➤
Note AG. Volkswagen AG d

agen oes
olksw not
yV g
♦ Tighten separating tool ised Kukko
b 17-2 only slightly (so that it uaran
barely has zero play).
ho
r tee
aut or
ac
♦ Otherwise the paintwork
ss of the propshaft may be damaged.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Fit separating tool Kukko 17-2 and counter support Kukko 18-2
t to the co
with thrust piece - VW 433- to propshaft as shown in illustration
and press propshaft out of intermediate bearing.
rrectness of i
– Remove dust cap from propshaft.
l purpos
Assembling
nform
mercia
a
com
t
Note
ion in
r
te o
thi
The blue marking on the propshaft intermediate bearing must face
s
iva
do
in direction of travel.
r
rp
cum
fo
en
ng
t.
yi Co
op py
– Drive new dust cap evenly onto propshaft as far as stop using t. C rig
gh ht
thrust piece - T10176- and a -Kunststoffhammer- . yri
p by
o Vo
by c lksw
cted agen
Prote AG.
– Drive propshaft intermediate bearing onto propshaft as far as

stop using thrust plate - VW 447 H- , thrust piece - VW 454-
and a -Kunststoffhammer- .
– Screw in bolt by several turns and join parts of propshaft (ob‐
serve marking). If necessary apply light blows with a plastic
hammer on the propshaft to join the parts.
3. Propshaft 65
Amarok 2011 ➤
Note
♦ If necessary, clamp the propshaft in a vice and strike it with a

plastic hammer at the marked positions -arrows-.
♦ Do not strike against the universal joint.
Specified torque
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
4 Gear oil
⇒ “4.1 Checking gear oil level in bevel box”, page 67
4.1 Checking gear oil level in bevel box

Gear oil for the rear final drive is available as a part ⇒ Electronic
parts catalogue “ETKA” .
Test precondition
• Vehicle standing on level ground
Procedure
– Remove oil filler plug -arrow-.
The oil level is correct when the rear final drive is filled to the lower
edge of the filler hole; top up as required. gen AG
. Volkswagen AG
d wa oes
olks not
– Screw in oil filler plug -arrow- and tighten.
db
yV gu
ara
e nte
ris
Specified torques utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Gear oil 67
Amarok 2011 ➤
39 – Final drive - front differential

1 Final drive
⇒ “1.1 Assembly overview - final drive”, page 68
⇒ “1.2 Removing and installing front final drive”, page 68
⇒ “1.3 Renewing bonded rubber bush on rear of final drive”, page
73
AG. Volkswagen
⇒ “1.4 Renewing bonded rubber
lksw bush on front of final edrive”,
agen AG do
s no page
75 db
yV
o t gu
a
e ran
ris t
⇒ “1.5 Renewing ubonded
tho rubber on left of final drive”, page 77 ee or
a ac
ss
1.1 Assembly overview - final drive
ce
le
un
pt
an
d
itte
y li
rm
ab
1 - Front final drive
pe
ility
ot
wit
, is n
⇒ page 68 .
h re
hole
spec
2 - Bolt
es, in part or in w
t to the co
❑ 50 Nm +90°
3 - Support bracket
4 - Hexagon collar bolt rrectness of i
l purpos
❑ 90 Nm +90°
5 - Retainer
nform
ercia
6 - Hexagon collar bolt

m
a
com
❑ 90 Nm +90°
ion in
r
te o
7 - Hexagon collar bolt

thi
s
iva
do
❑ 50 Nm +90°
r
rp
cum
fo
8 - Hexagon collar nut

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2 Removing and installing front final drive

68 Rep. gr.39 - Final drive - front differential

Amarok 2011 ➤
♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Retainer - T10149-
Removing
– Remove front right wheel.
– If fitted, remove engine/gearbox guard ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Engine/gearbox guard .
– Remove front propshaft ⇒ page 56 .
– Remove right and left drive shafts from front final drive ⇒
Running gear, axles, steering; Rep. gr. 40 .
– Remove front right transverse link ⇒ Running gear, axles,
steering; Rep. gr. 40 .
– Unclip breather hose
-2- at earth cable -1-.
Note
Illustration does not show engine to improve clarity.
– Carefully pull breather hose -1- off front final drive -arrow-.
Right wheel suspension must be raised in order to remove front
securing bolt for front final drive.
wage
e
olks s no
yV t gu
edb ara
WARNING ho
ris nte
eo
aut ra
ss c
Before the wheel suspension is raised, the vehicle must be
ce
le
un
strapped to the lifting platform arms on both sides using ten‐

pt
an
d
itte
sioning straps - T10038- ⇒ Maintenance ; Booklet 11 Raise

y li
rm
ab
vehicle.
pe
ility
ot
wit
, is n
h re
– Turn right wheel hub until one of the wheel bolt holes is at the
hole
spec
top.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Final drive 69
Amarok 2011 ➤
– Attach support - T10149- to wheel hub using wheel bolt and

tighten.
– Insert support - T10149- in engine and gearbox jack - V.A.G wage
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- V.A.G 1383 A- .
t to the co
– Turn steering wheel to right lock.
– Place engine and gearbox jack - V.A.G 1383 A- under front
rrectness of i
final drive.
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– Remove support -A- and support bracket -B-.
nf
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– Lower front final drive with engine and gearbox jack - V.A.G
orm
1383 A- .
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– Remove engine and gearbox jack - V.A.G 1383 A- .
or c
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A second mechanic is required to remove front final drive.
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– First pull right drive shaft off front final drive, followed by left
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Note
Always renew securing bolts and hexagon nuts.
– Check oil level in front final drive ⇒ page 79 .

– Turn steering wheel to right lock.
– Insert front axle drive with help from a second mechanic.
– First position left drive shaft on front final drive, followed by
right drive shaft.
– Support front final drive with engine and gearbox jack - V.A.G
1383 A- .

Amarok 2011 ➤
– Insert support bracket -B-.

– Position new securing bolts -2- and -3-, but do not tighten yet.
– Remove engine and gearbox jack - V.A.G 1383 A- .
Right wheel suspension must be raised in order to install front
securing bolt for front final drive.
WARNING
Before the wheel suspension is raised, the vehicle must be

strapped to the lifting platform arms on both sides using ten‐
sioning straps - T10038- ⇒ Maintenance ; Booklet 11 Raise
vehicle.
– Turn right wheel hub until one of the wheel bolt holes is at the
top.
– Attach support - T10149- to wheel hub using wheel bolt and

tighten.
– Insert support - T10149- in engine and gearbox jack - V.A.G
1383 A- .
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!
– Raise wheel suspension using engine and gearbox jack -

V.A.G 1383 A- until securing bolt for front final drive is acces‐
sible above transverse link -arrow-.
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1. Final drive
Amarok 2011 ➤
– Position new securing bolt for front final drive -1-, but do not
tighten yet.
– Position new securing bolt for front final drive -4-, but do not
tighten yet.
– Insert support -A-. n AG. Volkswagen AG do
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– First tighten securing bolt -7- and then securing bolt -6-.
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h re
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spec
es, in part or in w
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– First tighten securing bolt -2- and then securing bolt -3-.
rrectness of i
– Carefully push connection nipple of breather line -1- into front
l purpos
final drive. When doing this the connecting nipple must be in‐
serted between the raised portions of the housing and be
horizontal -arrow-.
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– Clip breather hose -2- to earth cable -1-.
Prote AG.
Note
Illustration does not show engine to improve clarity.
– Install front propshaft ⇒ page 56 .

– Attach drive shafts to flange shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 .
– Install engine/gearbox guard ⇒ General body repairs, exterior;
Rep. gr. 50 ; Engine/gearbox guard .
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Fitting wheel and tyre; Fitting wheel .
Specified torques

Amarok 2011 ➤
1.3 Renewing bonded rubber bush on rear of final drive

equipment required
♦ Assembly tool - T10435-
♦ Foot pump - VAS 6179-
♦ Hydraulic press - VAS
6178-
♦ Tube - 30 - 14-
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Pulling out
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– Set foot pump - VAS 6179- to lowest setting.

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– Pulling out bonded rubber bush.

form
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Note
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Prote AG.
1. Final drive 73
Amarok 2011 ➤
– Position bonded rubber bush in installation position on front

final drive.
Note
Corners and small recesses of bonded rubber bush -arrows A-

must be at right angles to final drive.
– Mark installation position -arrow B- of bonded rubber bush.

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– Pull in bonded rubber bush until dimension
s -a- ⇒ page 74 is
ce
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reached.
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Dimension -a- = 47.4 mm
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Transfer box and final ntdrive
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1.4 Renewing bonded rubber bush on front of final drive ss
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6178-
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Pulling out
Note
Pulling in
1. Final drive 75
AG. Volkswagen AG d
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Amarok 2011 ➤ by
Vol not
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Transfer box and final drive - Edition 05.2013 orise nte
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– Position bonded rubber bush in installation position
ss
on front
ce
le
final drive.
un
pt
an
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ab
pe
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Note
ot
wit
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h re
Small recesses of bonded rubber bush -arrows B- must be at right
hole
spec
angles to final drive.
es, in part or in w
t to the co
– Mark installation position -arrow A- of bonded rubber bush.
rrectness of i
l purpos
– Pull in bonded rubber bush until it is centred in front final drive

housing.
nform
mercia
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tion in
r
te o
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Amarok 2011 ➤
1.5 Renewing bonded rubber on left of final drive

equipment required
♦ Hydraulic press - VAS wage
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6178- yV
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♦ Tube - 30 - 14- ir se tee
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spec
t to the co
rrectness o
cial p
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c
i
or
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Prote AG.
Pulling out
Note
Pulling in
1. Final drive 77
Amarok 2011 ➤
– Position bonded rubber bush in installation position on left of

final drive.
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Small recesses of bonded rubber bush -arrows B- must be tat
ho right tee
or
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– Mark installation position -arrow A- of bonded rubber bush.
an
d
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– Pull in bonded rubber bush until it is centred in housing on left ole,
spec
of final drive.
t to the co
rrectness o
cial p
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mer
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Amarok 2011 ➤
AG. Volkswagen AG d
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2 Gear oil autho or
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⇒ “2.1 Checking level of gear oil”, page 79
nl
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2.1 Checking level of gear oil
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Gear oil for the front final drive is available as a part ⇒ Electronic
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parts catalogue “ETKA” .
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es, in part or in w
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♦ Ring ratchet spanner, 13 mm AF - T10384- ht. Cop py
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♦ Bit - T50039-
Note
♦ Front final drive has a fill-for-life oil fill. It is only necessary to

check oil level or to top up oil after renewal of oil seal or if final
drive is replaced. Due to poor accessibility of oil filler plug when
installed, oil level should be checked or oil should be replen‐
ished prior to installation.
♦ The special tool indicated is to be used.
2. Gear oil 79
Amarok 2011 ➤
Test precondition
• Front final drive in installation position
Procedure
– Remove oil filler plug -arrow-.
The oil level is correct when the front final drive is filled to the lower
edge of the filler hole; top up as required.
– Install oil filler plug -arrow- and tighten to 35 Nm.
With the component in its installed position
– Unscrew the oil filler plug -arrow- with a combination of ring
ratchet spanner, 13 mm AF, - T10384- and bit - T50039- .
The oil level is correct when the front final drive is filled to the lower
edge of the filler hole; top up as required.
– If necessary, replenish oil via breather hose, using a standard
funnel.
WARNING
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Exhaust system can berisehot.
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Allow exhaust system
aut to cool down before replenishing oil. ra
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– Screw in oil filler plug -arrow- in combination with 13 mm ring

y li
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ratchet spanner - T10384- and bit - T50039- and tighten.

ility
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Specified torque
wit
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spec
es, in part or in w
Oil filler plug 35 Nm

t to the co
rrectness of i
l purpos
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Prote AG.

Amarok 2011 ➤
3 Oil seals
⇒ “3.1 Renewing left flange shaft oil seal”, page 81
⇒ “3.2 Renewing oil seal for right flange shaft”, page 82
⇒ “3.3 Renewing input shaft seal”, page 84
⇒ “3.4 Renewing dust cap for left flange shaft”, page 87
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⇒ “3.5 Renewing dust cap for right flange shaft”, page
Vol
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⇒ “3.6 Renewing needle bearing for left flange
or
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3.1 Renewing left flangessshaft oil seal c
ce
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un
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an
d
itte
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ab
♦ Multipurpose tool - VW 771-
pe
ility
ot
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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t
ion in
r
te o
thi
s
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Prote AG.
♦ Sealing grease ⇒ Electronic Parts Catalogue (ETKA)

Procedure
– Remove front final drive ⇒ page 68 .
– Pull out left flange shaft using multipurpose tool - VW 771- .
3. Oil seals 81
Amarok 2011 ➤
– Pull out oil seal for flange shaft using multipurpose tool - VW
771- .
– Drive in new oil seal to stop using thrust piece - T10260- .

– Fill space between dust lip and sealing lip half full with sealing
– Before installing flange shaft, check dust cap for damage and
renew if necessary ⇒ page 87 . n AG. Volkswagen AG
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– Clamp flange shaft in vice using jaw protectors -B-.
wit
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h re
– Remove retaining ring -A- using pliers .
hole
spec
– Insert new retaining ring in groove in flange shaft, being careful
es, in part or in w
t to the co
not to overstretch ring.
– Drive in flange shaft using a plastic head hammer .
rrectness of i
– Check oil in front final drive ⇒ page 79 .
l purpos
– Install front final drive ⇒ page 68 .

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3.2 Renewing oil seal for right flange shaft

or c
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♦ Multipurpose tool - VW 771-

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Prote AG.

Amarok 2011 ➤
AG. Volkswagen AG d
agen Transfer
oes box and final drive - Edition 05.2013
olksw not
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♦ Thrust piece - T10259- horis nte
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es, in part or in w
t to the co
rrectness of i
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Procedure
nform
ercia

m
a
com
t
– Pull out right flange shaft using multipurpose tool - VW 771- .
ion in
r
te o
thi
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– Pull out oil seal for flange shaft using multipurpose tool - VW
771- .
– Drive in new oil seal to stop using thrust piece - T10259- .

3. Oil seals 83
wage es n
Amarok 2011 ➤ yV
olks ot g
b ua
Transfer box and final drive - Edition
ir se
d 05.2013 ran
tee
tho
u or
a ac
– Before installing flange shaft, check
ss dust cap -arrow- for dam‐
age and renew if necessary ⇒ page 88 .
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Clamp flange shaft in vice using jaw protectors -B-.
nform
ercia
– Remove retaining ring -A- using pliers .

m
– Insert new retaining ring in groove in flange shaft, being careful
at
om
io
not to overstretch ring.
n
c
in t
or
his
e
– Drive in flange shaft using a plastic head hammer .

at
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um
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3.3 Renewing input shaft seal

♦ Puller - T10055-

♦ 2 self-tapping screws with 4 mm diameter
Procedure

Amarok 2011 ➤
– Pull off oil seal -1- and retaining ring -2-.

– To be able to screw self-tapping screws -arrows- into sealing
cover, first use drift to punch 2 holes in sealing cover.
– Screw in self-tapping gscrews

en AG. V with a4gemm
olksw n AG diameter.
d wa oes
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– Pull out dustd cap
by using puller - T10055- .
V gu
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ris
– Use a drift
ut
ho to punch 2 holes in oil seal. eo
ra
a c
ss
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un
pt
an
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ole,
spec
t to the co
– Screw in self-tapping screws with 4 mm diameter.
rrectne
Note
ss o
Do not screw in sheet metal screw too far to avoid damaging

cial p
f in
bearing behind it.

form
mer
atio
m
– Pull out seal using puller - T10055- .

o
n
c
i
or
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– On new seal, fill space between dust lip and sealing lip half full
te
sd
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with sealing grease ⇒ Electronic Parts Catalogue (ETKA) .

iv
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– Mask off splines of stub shaft with adhesive tape.

en
ng
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– Push new oil seal as far as oil seal seat on final drive.
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– Drive in seal to stop with thrust piece - T10430- , being careful
Prote
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agen
not to cant seal.
3. Oil seals 85
Amarok 2011 ➤
– Drive on new dust cap with thrust piece - T10430/1- .
– Insert new oil seal -1- and new retaining ring -2-.
– Install front propshaft ⇒ page 56
AG. Volkswagen AG d
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Prote AG.

Amarok 2011 ➤
3.4 Renewing dust cap for left flange shaft

equipment required
♦ Press tool - VW 412-
♦ Support rails - VW 457-
♦ Pulling ring - 2003/3-
♦ Assembly tool - 3301-
♦ Sealing grease ⇒ Electron‐
ic Parts Catalogue (ETKA)
AG. Volkswagen AG d
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♦ -3- - Separating device Kukko 17-2

rrectness of i
l purpos
nform
mercia
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tion in
r
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• Flange shaft removed, removing ⇒ page 81 opyri
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3. Oil seals 87
Amarok 2011 ➤
Procedure
– Press dust cap -B- off flange shaft.
– Press on dust cap for flange shaft -A-.
Note
Position sleeve - 3301/3- with notch -arrow- facing dust cap -A-.
3.5 Renewing dust cap for right flange shaft

AG. Volkswagen n AG do
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t to the co
rrectness of i

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c
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Prote AG.

Amarok 2011 ➤
♦ -3- - Separating device Kukko 17-2
AG. Volkswagen AG d
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• Flange shaftthremoved,
or removing ⇒ page 82 eo
au ra
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Procedure ss
ce
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un
pt
– Press dust cap -B- off flange shaft.
an
d
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spec
t to the co
rrectness o
cial p
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– Drive on new dust cap for flange shaft -A- using thrust piece -
form
mer
3456- and sleeve - 3301/3- .

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te
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Position sleeve - 3301/3- with notch facing dust cap -A-.

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Prote AG.
3. Oil seals 89
Amarok 2011 ➤
3.6 Renewing needle bearing for left flange shaft

equipment required
♦ Press tool - 30 - 505-
♦ Press tool - 30 - 506 B-
♦ Internal puller Kukko 21-6
-1-
22-2 -4-
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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un
pt
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d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Procedure
ss o

cial p
f inform
– Remove left flange shaft and oil seal ⇒ page 81 .

mer
atio
m
– Pull out left flange shaft needle bearing.

o
n
c
i
or
A - Internal puller Kukko 21-6

thi
te
sd
iva

pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Drive in needle bearing for left flange shaft -A- to stop.

– Install left flange shaft and oil seal ⇒ page 81 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Oil seals 91
Amarok 2011 ➤
39 – Final drive - differential

1 Transfer box
⇒ “1.1 Assembly overview - transfer box”, page 92
⇒ “1.2 Components and their locations”, page 94
⇒ “1.3 Removing and installing transfer box”, page 95
⇒ “1.4 Checking gear oil level”, page 97
⇒ “1.5 Removing and installing transfer box control unit J646 ”,
page 99 AG. Volkswagen AG d
agen oes
lksw not
⇒ “1.6 Removing and installing transfer box Hall sender G759 by ”,
Vo gu
ara
page 99 rised
nte
ho eo
ut
⇒ “1.7 Removing and installing transfer box control motor
ss a V455 ”, ra
c
page 100
ce
e
nl
pt
du
an
1.1 Assembly overview - transfer box
itte
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erm
ab
ility
ot p
wit
, is n
1 - Transfer box
h re
hole
spec
⇒ page 95 .
es, in part or in w
t to the co
2 - Breather pipe
❑ Removing ⇒ page 94
rrectness of i
❑ Driving in ⇒ page 94
l purpos
3 - Seal
❑ For input shaft
nf
ercia
orm
⇒ page 102 .
m
atio
om
n in
4 - Seal
or c
thi
e

t
sd
iva
o
r
rp
cu
❑ Insert in groove in input
o
m
f
shaft ⇒ page 94
en
ng
t.
yi Co
op
5 - Dowel sleeve
C py
t. rig
gh ht
yri
❑ Qty. 2
p by
o Vo
by c lksw
cted
❑ For centring gearbox/
agen
Prote AG.
transfer box
6 - Transfer box inter-axle lock-
up switch - F438-
❑ 27 Nm
7 - Seal
❑ Renew if damaged
8 - Retaining ring
❑ On input shaft for front
propshaft
9 - Seal
❑ On output shaft for front
propshaft
92 Rep. gr.39 - Final drive - differential

Amarok 2011 ➤
Transfer
AG. Volkswagenbox and final drive -
AG do
Edition 05.2013
agen es n
olksw ot g
10 - Seal byV ua
ed ran
ris tee
❑ For output shaft for front propshaft
utho
or
a ac
❑ 2-piece ss
ce
e
nl
pt
11 - Transfer box control motor - V455-
du
an
itte
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erm
ab
ility
ot p
12 - Bolt
wit
, is n
h re
❑ 12 Nm
hole
spec
13 - Seal
es, in part or in w
t to the co
❑ Must lie in peripheral groove of transfer box control motor - V455-
rrectness of i
14 - Oil drain plug
l purpos

❑ 27 Nm
nf
ercia
15 - Oil filler plug
orm
m
atio
om
n in
❑ 27 Nm
or c
thi
te
sd
16 - Seal
iva
o
r
rp
cu
❑ Cannot be obtained individually
o
m
f
en
ng
t.
yi
17 - Transfer box Hall sender - G759-
Co
Cop py
ht. rig
❑ Removing and installing ⇒ page 99 . rig ht
py by
co Vo
by lksw
18 - Bolt Prote
cted AG.
agen
❑ 7 Nm
19 - Nut
❑ Unscrewing ⇒ page 106
❑ Screwing on ⇒ page 107
❑ 150 Nm
20 - Seal
❑ Coat with gear oil when installing
21 - Propshaft flange
❑ For rear propshaft.
22 - Seal
❑ For propshaft flange
❑ Renew with propshaft flange ⇒ page 105
1. Transfer box 93
Amarok 2011 ➤
Inserting oil seal into groove in input shaft
olks
wa-1-
ge es n
ot g
yV ua
db ran
rise tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing breather pipe
rrectness of i
– Use pliers to move breather pipe -1- in directions of both ar‐
rows and pull out.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
Driving in breather pipe rig ht
py by
co Vo
by lksw
– Before driving in breather pipe -1-, coat it with Loctite locking cted agen
Prote AG.
fluid ⇒ Electronic Parts Catalogue (ETKA) .
– Drive breather pipe to stop with thrust piece - T10203- .
1.2 Components and their locations
Note
♦ Electrical and electronic components of rear-axle differential

lock ⇒ page 51
♦ Refer to ⇒ Self-study programme No. 464 ; Power transmis‐
sion for more information about function.
♦ Refer to ⇒ Amarok owner's manual for more information and
notes on safety.

Amarok 2011 ➤
AG. Volkswagen AG d
ksw
agen Transfer
oes box and final
not
drive - Edition 05.2013
ol
byV gu
ara
d
1 - Transfer box control unitor-ise nte
eo
J646- aut
h
ra
ss c
❑ Location: under dash
ce
e
nl
panel
pt
du
an
itte
y li
erm
ab
⇒ page 99 .
ility
ot p
wit
2 - Diagnostic connection
, is n
h re
hole
❑ Location: in driver foot‐
spec
well
es, in part or in w
t to the co
3 - Running gear programme
switch - E631-
❑ Deactivate for four-
rrectness of i
wheel drive
l purpos
selector mechanism
cover ⇒ General body
nform
ercia
repairs, interior; Rep.

m
at
gr. 68 ; Compartments,
om
io
covers and trims; Re‐
n
c
in t
or
moving and installing
his
te
centre console
a
do
priv
cum
or
4 - Transfer box operating unit

f
en
ng
t.
yi
❑ With reduction gearing
Co
Cop py
warning lamp in transfer ht. rig
rig ht
box operating unit - py by
co Vo
lksw
K182-
by
cted agen
Prote AG.
❑ With inter-axle lock-up
warning lamp in transfer
box operating unit -
K183-
❑ With rear axle differen‐
tial lock warning lamp in
transfer box operating
unit - K184-
selector mechanism
cover ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing centre console
5 - Running gear programme switch - E631-
❑ Activate for four-wheel drive
❑ Remove by removing selector mechanism cover ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trims; Removing and installing centre console
6 - Transfer box control motor - V455-
❑ Location: on transfer box
7 - Transfer box inter-axle lock-up switch - F438-
8 - Transfer box Hall sender - G759-
1.3 Removing and installing transfer box

1. Transfer box 95
Amarok 2011 ➤
♦ Engine and gearbox jack - V.A.G 1383 A-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
♦ Drive shaft grease ⇒ Electronic Parts Catalogue (ETKA)
t to the co
Removing
rrectness of i
– Remove rear propshaft ⇒ page 57 .
l purpos
– Detach connector -arrows- and unclip wiring harness from nform

ercia
transfer box.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull breather line -arrow- off transfer box.

Amarok 2011 ➤
– Position engine and gearbox jack - V.A.G 1383 A- under trans‐

fer box.
– Unscrew and remove transfer box/gearbox connecting bolts.
– Press transfer box off gearbox.
– Lower transfer box with engine and gearbox jack - V.A.G 1383
A- .
Installing
– Check whether dowel sleeves for aligning gearbox and trans‐
fer box are fitted in gearbox; installgifennecessary.
AG. Volkswagen AG d
a oes
ksw not
Vol gu
by a
– Always renew oil seal torisseal
ed transfer box and gearbox -1- and rante
lubricate lightly. tho eo
s au ra
c
s
– Grease transfer box input shaft splines and gearbox output
ce
e
nl
shaft splines with drive shaft grease ⇒ Electronic Parts Cata‐
pt
du
an
logue (ETKA) .
itte
y li
erm
ab
– Push transfer box completely onto gearbox, ensuring that
ility
ot p
transfer box input shaft splines are centred as they are guided
wit
, is n
onto the gearbox output shaft.
h re
hole
spec
es, in part or in w
Caution
t to the co
Do not use securing bolts to pull transfer box onto the gearbox.
Otherwise transfer box will cant.
rrectness of i
l purpos
If splines are correctly positioned and shafts are centred, then

transfer box will slide to stop against gearbox.
nform
ercia

m
at
om
ion
– Install rear propshaft ⇒ page 57 .

c
in t
or
his
te
– Check oil level in transfer box ⇒ page 97 .

a
do
priv
cum
or
Specified torques
f
en
ng
t.
yi Co
♦ ⇒ “1.1 Assembly overview - transfer box”, page 92 Cop py
t. rig
gh ht
yri
♦ ⇒ “3.2 Assembly overview - Tirsan propshaft”, page 54 p by
o Vo
by c lksw
cted agen
Prote
AG.
Transfer box to gearbox 45 Nm
1.4 Checking gear oil level

Gearbox oil specification ⇒ Electronic parts catalogue “ETKA”
1. Transfer box 97
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
Note
d
itte
y li
rm
ab
pe
ility
♦ Oil level is below oil filler hole.
ot
wit
, is n
♦ Make a tool to check oil level.
h re
hole
spec
es, in part or in w
Dimension -a- = 37 mm
t to the co
Dimension -b- = 60 mm
Procedure
rrectness of i
l purpos
– Remove oil filler plug -1-. nform

ercia
– Insert locally manufactured tool into filler hole downwards as

m
far as possible.
com
tion in
r
– Pull out tool and check oil level on tool. Top up oil if necessary.
te o
thi
s
iva
do
The oil level must be within a range of 32 to 37 mm below lower

r
rp
cum
edge of filler hole.

fo
en
ng
t.
yi Co
– Tighten new oil filler plug. Cop py
t. rig
gh ht
yri
When filling with oil, note the following: p by
o Vo
by c lksw
cted agen
– Remove oil filler plug -1-. Prote AG.
– Fill 1.25 l of gear oil.

– Tighten new oil filler plug.
Specified torques
♦ ⇒ “1.1 Assembly overview - transfer box”, page 92

Amarok 2011 ➤

control unit - J646-
Removing
– Remove connectors -1- and -3- on transfer box control unit -
J646- -2-.
– Push locks on bracket in direction of arrow and remove trans‐
fer box control unit - J646- .
Installing
Transfer box control unit - J646- must engage in bracket.

Hall sender - G759-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
Removing aut
h eo
ra
ss c
– Pull off connector -1-.
ce
e
nl
pt
du
an
– Place drip tray under transfer box.

itte
y li
erm
ab
– Remove bolts -arrows- and pull transfer box Hall sender -

ility
ot p
G759- off transfer box.

wit
, is n
h re
Installing
hole
spec
es, in part or in w

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Transfer box 99
Amarok 2011 ➤
AG. Volkswagen AG d
– Renew oil seal -1- if damaged.lkswagen oes
not
o
yV gu
db ara
ir se nte
ho eo
Note aut ra
ss c
ce
le
♦ The drive for the transfer box Hall sender - G759- -arrow B-
un
pt
an
d
and the mounting for the transfer box -arrow A- are offset. The
itte
y li
drive only fits in one position in the mounting for the transfer
rm
ab
pe
ility
box.
ot
wit
, is n
♦ When positioning transfer box Hall sender - G759- , insert
h re
hole
centring pin into hole in transfer box -A-.
spec
es, in part or in w
t to the co
Caution
rrectness of i
♦ It must be possible to insert transfer box Hall sender -
G759- without exerting great pressure, if necessary check
l purpos
whether driver -arrow B- has been turned through 180° to

mounting -arrow A-.
nform
mercia
a
com
t
– Insert transfer box Hall sender - G759- .
ion in
r
te o
thi
– Tighten bolts of transfer box Hall sender - G759- -arrows-.
s
iva
do
r
rp
cum
– Push on connector -1-.
fo
en
ng
t.
yi Co
– Check oil in transfer box ⇒ page 97 . t. Cop py
rig
gh ht
yri
Specified torques p by
co Vo
by lksw
cted agen
♦ ⇒ “1.1 Assembly overview - transfer box”, page 92 Prote AG.

control motor - V455-
Removing

Amarok 2011 ➤
– Pull connector -1- off transfer box control motor - V455- .

– Remove bolts -2- and pull transfer box Hall sender - V455- off
transfer box.
Installing
– Renew oil seal -1- if damaged.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Tighten bolts -2- for transfer box control motor - V455- .
ility
ot p
wit
– Push on connector -1-.
, is n
h re
hole
– Check oil in transfer box ⇒ page 97 .
spec
es, in part or in w
Specified torques
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Transfer box 101

Amarok 2011 ➤
2 Oil seals
⇒ “2.1 Renewing input shaft seal”, page 102
⇒ “2.2 Renewing output shaft seal”, page 103
⇒ “2.3 Renewing propshaft flange seal”, page 105
2.1 Renewing input shaft seal

♦ Puller - T10055-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion

c
in t
or
his
te
♦ Sheet metal screw, approx. 4 mm in diameter

a
do
priv
cum
or
Removing
f
en
ng
t.
yi Co
– Remove transfer box ⇒ page 95 . Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– To pull out seal, screw sheet metal screw of about 4 mm di‐

ameter -arrow- into seal.
lkswage es n
o ot g
Caution byV ua
d ran
ir se tee
tho
or
Do not screw in sheet metal screw too far to avoid
ss
au
damaging ac
bearing behind it.
ce
le
un
pt
an
d
itte
y li
erm
ab
– Pull out seal using puller - T10055- .
ility
ot p
wit
Installing
is n
h re
ole,
spec
t to the co
– Drive in new seal to stop with thrust piece - T10184- , being
rrectne
careful not to cant seal.
– Install transfer box ⇒ page 95 .
ss o
cial p
f
inform
mer
2.2 Renewing output shaft seal
atio
om
n
c
i
or
n
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hub grease cap puller - VW 637/2-
2. Oil seals 103

Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
♦ extractor lever - VW 681- olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
nform
ercia
– Lift inner part of seal in three places using a screwdriver, offset

120°
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pull out seal using hub grease cap puller - VW 637/2- .
– Pull seal out with oil seal extractor lever - VW 681- .

Installing
– Position new seal on transfer box.
– Push inner part of seal onto output shaft as far as possible.
– Drive in new seal to stop with thrust piece - T10449- , being
careful not to cant seal.

Amarok 2011 ➤
2.3 Renewing propshaft flange seal

equipment required
♦ Removal and installing tool
- VW 459/2-
♦ Puller hooks - T20143/2-
1332-
♦ Sealing grease ⇒ Electron‐
ic Parts Catalogue (ETKA)
♦ Bolts M10 x 25 (Qty. 2)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
♦ If leaks are detected during repair work on the flange, always

hole
spec
renew the seal ⇒ Item 23 (page 12) and the sealing sleeve
es, in part or in w
⇒ Item 20 (page 11) .

t to the co
♦ Always renew oil seal and propshaft flange together.

rrectness of i
Removing
l purpos
– Remove rear propshaft ⇒ page 57 .

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
105
agen
Prote AG.
2. Oil seals
Amarok 2011 ➤
– Unscrew nut for propshaft flange. Screw counter-hold tool -

3145- onto propshaft flange using two M10 x 25 bolts
-arrows- in order to counter-hold tool.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
– If necessary, pull off propshaft flange using puller Kukko 18-1
itte
y li
erm
-A- and adapter - VW 295 A- .
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Pull out seal using puller hooks - T20143/2- .

m
at
om
i
Installing
on
c
in t
or
his
ate
do
riv
– Lightly oil outer circumference of new oil seal.

p
cum
for
en
ng
t.
– Fill space between dust lip and sealing lip half full with sealing op
yi Co
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Drive in new oil seal to stop with thrust piece - VW 442- and
removal and installing tool - VW 459/2- , being careful not to
cant oil seal.
– Insert new propshaft flange.

Amarok 2011 ➤
– Moisten new oil seal -1- with gear oil and insert.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Install new nut for propshaft flange and tighten. Screw counter-
ility
ot p
hold tool - 3145- onto propshaft flange using two M10 x 25
wit
is n
bolts -arrows- in order to counter-hold tool.
h re
ole,
spec
– Install rear propshaft ⇒ page 57 .
t to the co
Specified torques
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Oil seals 107

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Copyright © 2013 Volkswagen AG, Wolfsburg D3E8028924F

2.3 Allocation of transfer box - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Overview - power transmission - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1 Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.2 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.7 Checking backlash and contact pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.1 Renewing left flange shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.4 Renewing dust cap for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

1.2 Components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.3 Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.4 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1.5 Removing and installing transfer box control unit J646 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

⇒ “1.1 Identification of gearbox”, page 1

1.1 Identification of gearbox

A reduction gearing is integrated into the transfer box.

Production date -arrow A- and identification code -arrow B- of

1.2 Identification of final drive

Codes -arrow- and manufacturing data for front final drive

2 Rep. gr.00 - Technical data

2.1 Allocation of rear final drive - engine/capacities

♦ Specification of gear oil

2.2 Allocation of front final drive - engine/capacities

Front final drive 0C1

Identification code MQL

Engine 2.0 l - 120 kW

♦ Allocation to corresponding vehicle by engine code

♦ Specification of gear oil

Allocation Model Amarok 2011 ► Amarok 2011 ►

♦ Specification of gear oil

2.4 Allocation of rear axle - engine/capaci‐

Gear ratio 1) 41 : 10 = 4.10 41 : 10 = 4.10 43 : 10 = 4.30

Engine alloca‐ 2.0 l 2.0 l 2.0 l 11 kW

VW part num‐ 2H0.500.025. 2H0.500.029. 2H0.500.029.

VW part num‐ 2H0.501.011. 2H0.501.011. 2H0.501.011.

Manufacturer's 40073723 40094736 40101793

Differential Lockable Standard Lockable

2.5 Calculation of gear ratios

4 Rep. gr.00 - Technical data

♦ Z1 = no. of teeth on drive gear

❑ Removing and installing

3 - From manual gearbox

❑ Changing between on‐

6 Rep. gr.00 - Technical data

⇒ “4.6 Bearing”, page 8

To ensure flawless and successful gearbox repairs, the greatest

A number of generally applicable instructions for the various re‐

pair procedures which were previously repeated at numerous

to this workshop manual.

4.2 Rear axle

4.3 Seals and sealing rings

4.4 Locking devices

♦ Retaining rings must locate properly in grooves. With opening

4.5 Nuts and bolts

♦ Install only flawless shims.

8 Rep. gr.00 - Technical data

39 – Final drive - rear differential

⇒ “1.10 Overview of shims”, page 34