Manual Serviço Diferencial Amarok

Service
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Amarok 2011
Transfer box and final drive

Edition 05.2013
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Workshop Manual
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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
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
agen
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Vo
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AG.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification of gearbox g.en. A. G. ..V.o.lk.sw. a. g.e.n.A.G.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a
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Identification of final
. . . . . . . . . . . . . . . .s n. o.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vodrive
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Technical data
ris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n.tee. . . . . . . . . . . . . . . . . . . . . . . . . . .
o
h
ut rear final drive - engine/capacities . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . .
Allocations aof
c
s
Allocation of front final drive - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allocation of transfer box - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allocation of rear axle - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - power transmission - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
2.2
2.3
2.4
2.5
3
3.1
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing drive pinion and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking backlash and contact pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulling tapered roller bearing for drive pinion off and pressing it on . . . . . . . . . . . . . . . . . .
Pulling tapered roller bearing for differential off and pressing it on . . . . . . . . . . . . . . . . . .
Overview of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining shims for crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining shims for drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing propshaft flange seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear-axle differential lock components and their locations . . . . . . . . . . . . . . . . . . . . . . . .
Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - flexible coupling for propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - Tirsan propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - Dana propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling and assembling propshaft intermediate bearing, Dana propshaft . . . . . . . .
Dismantling and assembling propshaft intermediate bearing, Tirsan propshaft . . . . . . . .
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking gear oil level in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.1
Contents
1
1
1
1
3
3
3
3
4
4
6
6
7
7
7
7
7
8
8
8
9
10
10
13
13
14
24
26
27
30
32
34
35
36
39
43
49
51
51
51
53
53
54
55
56
57
60
63
67
67
Amarok 2011
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Volkswage
Removing and installing front final drive . . . . .ks.w.a.ge. n. A. G. . . . . . . . .n.A.G.d.oe. s.n. . . . . . . . . . . . . .
l
ot
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Renewing bonded rubber bush on rear ofdfinal
by drive . . . . . . . . . . . . . . . . . . g.u.ar. . . . . . . . . .
a
e
s
ri of final drive . . . . . . . . . . . . . . . . . . . . . n.te.e. . . . . . .
Renewing bonded rubber bush on front
tho
or
u
Renewing bonded rubber on left ofss afinal drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.c . . . .
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking level of gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing left flange shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing oil seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing dust cap for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing dust cap for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing needle bearing for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
68
73
75
77
79
79
81
81
82
84
87
88
90
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1
1.1
1.2
1.3
1.4
1.5
2
2.1
3
3.1
3.2
3.3
3.4
3.5
3.6
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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Contents
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Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box control unit J646 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box Hall sender G759 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box control motor V455 . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing propshaft flange seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
92
92
94
95
97
99
99
100
102
102
103
105
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Technical data
Identification
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(VRL005429; Edition 05.2013)

1.1 Identification of gearbox, page 1
1.2 Identification of final drive, page 1
1.1
Amarok 2011
drive - Edition 05.2013
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Transfer
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Identification of gearbox
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
I
I
Identifica
tion code
09
I
I
Day
12
I
I
Month
09
I
I
Year (2009)
of manufac
ture
Additional data depend on manufacture.
1.2
Identification of final drive
Location on front final drive -arrow-
1. Identification
Amarok 2011
Codes -arrow- and manufacturing data for front final drive
Identification
code
MGY
Year
Day
Serial number
xxx
xxxx
Additional data depend on manufacture.
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Rep. gr.00 - Technical data
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Amarok 2011
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

Identification code
0CC
MQA
Allocation
Model
Engine
Final drive
Ratio
Capacity
Amarok 2011
2.0 l - 120 kW
i = 4.1
2.0 l1)
. Volkswagen AG
1) 2.1 l for new fill wagen AG
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The following
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2.0 l1)
cata
Specification of gear oil
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Amarok 2011
2.0 l - 120 kW
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Allocation to corresponding vehicle
2.2
MQB
Allocation of front final drive - engine/capacities
Front final drive

Identification code
Allocation
0C1
MQL
Model
Engine
Capacity
Amarok 2011
2.0 l - 120 kW
0.8 l
The following data can be found in the Electronic parts cata

logue ETKA .
Allocation to corresponding vehicle by engine code
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Allocation of transfer box - engine/capacities

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Identification code
Allocation
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0C7
LEP
Model
Engine
Amarok 2011
2.0 l - 120 kW
1.25 l
0C7
NHY
Amarok 2011
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
Amarok 2011
Allocation of rear axle - engine/capaci

ties
2H0.500.025. 2H0.500.025. 2H0.500.025.
AH
AJ
AF
2H0.501.011. 2H0.501.011. 2H0.501.011.
AH
AJ
AF
Standard
2.0 l
120 kW TDI
2.0 l 11 kW
petrol
2.0 l 90 kW
TDI
2.1 l 0.1 l
2.1 l 0.1 l
2.1 l 0.1 l
VW part num
ber
(with brake)
VW part num
ber
(without brake)
2H0.500.025. 2H0.500.029. 2H0.500.029.

AG
D
E
2H0.501.011. 2H0.501.011. 2H0.501.011.
AG
AP
AQ
40094736
40101793
NAL
NAM
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37 : 10 = 3.70 37 : 10 = 3.70
Standard
Lockable
2.0 l
132 kW TDI
2.0 l
132 kW TDI
2.1 l 0.1 l
2.1 l 0.1 l
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
Catalogue (ETKA) .
Calculation of gear ratios
Example:
41 : 10 = 4.10
Z2 : Z1 = i 1)
Electronic Parts
AG.
Manufacturer's 40073723
part number
Rear-axle
MPZ
code
43 : 10 = 4.30
Gear ratio 1)
Z2 : Z1 = i
Differential
Lockable
type
Engine alloca 2.0 l 118 kW
tion
petrol
2.0 l 90 kW
TDI
Capacity (dry 2.1 l 0.1 l
axle) 2)
rrectness of i
t to the co
nform
spec
at
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41 : 10 = 4.10 43 : 10 = 4.30
Capacity (dry
axle) 2)
2.5
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Manufacturer's 40073724
part number
Rear-axle
MQA
code
41 : 10 = 4.10
Gear ratio 1)
Z2 : Z1 = i
Differential
Standard
type
Engine alloca 2.0 l
tion
120 kW TDI
AG. Volkswagen AG d
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40073722
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VW part num
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(with brake)
VW part num
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2.4
Amarok 2011
1)
Z1 = no. of teeth on drive gear

Z2 = no. of teeth on driven gear
i = gear ratio
rrectness of i
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spec
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2. Technical data
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Overview - power transmission
3.1
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spec
atio
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wit
3.1 Overview - power transmission - four-wheel drive,

page 6
Overview - power transmission - four-wheel drive
1 - Front final drive

Removing and installing
page 68 .
2 - Front propshaft
page 56 .
Prote
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by
AG.
6 - Rear final drive

Optionally with rear axle
differential lock
page 51
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5 - Rear propshaft
page 57 .
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4 - Transfer box
With reduction gearing
Changing between on
road range HIGH and
offroad range LOW is
performed using run
ning gear programme
switch - E631 page 94
page 95 .
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3 - From manual gearbox
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Amarok 2011
Amarok 2011
Transfer
box
and
final
drive
Edition 05.2013
. Volkswage
Repair instructions
es, in part or in w
l purpos
hole
ercia
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4.1 Gearbox, page 7
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4.2 Rear axle, page 7
4.3 Seals and sealing rings, page 7
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spec
atio
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wit
4.4 Locking devices, page 7

4.5 Nuts and bolts, page 8
4.6 Bearing, page 8
4.7 Shims, page 8
4.1
Gearbox
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
ing repair work.
AG.
Prote
cted
by
When installing mounting brackets or waxed components,

clean the contact surfaces. Contact surfaces must be free of
wax and grease.
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Always renew retaining rings for front propshaft on transfer

box and front final drive.
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When installing the transfer box, ensure that the dowel sleeves
between the gearbox and transfer box are correctly installed.
thi
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A number of generally applicable instructions for the various re

pair procedures which were previously repeated at numerous
places in the workshop manual are summarised here. They apply
to this workshop manual.
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
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
size
ris
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bearings.
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Shims
Install only flawless shims.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Measure shims at several points with a micrometer. The var

ious thicknesses make it possible to achieve the exact shim
thickness required.
Check for burrs and damage.
or
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4.7
ss
Note the shims' location. There must be no gap between the

shim and the adjacent surface.
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Amarok 2011
Final drive - rear differential
rrectness of i
t to the co
nf
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m
spec
atio
h re
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wit
es, in part or in w
l purpos
hole
ercia
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39
1. Final drive
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Amarok 2011
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
AG. 26
genpage
1.6 Removing and installing crown wheel,
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ing it on, page 30
1.9 Pulling tapered roller bearing for differential off and press
ing it on, page 32
rrectness of i
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wit
1.10 Overview of shims, page 34
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1.7 Checking backlash and contact
pattern,
page
27
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1.8 Pulling tapered roller bearing
for
drive
pinion
off
and
press
a
c
ss
k
Vol
1.11 Adjustment overview, page 35

1.12 Determining shims for crown wheel, page 36
1.13 Determining shims for drive pinion, page 39
1.14 Renewing propshaft flange seal, page 43
1.15 Repairing propshaft flange, page 49
1.1
Assembly overview - final drive
Prote
cted
by
3 - Bolt
Renew after removal
Apply locking fluid - D
185 410 A2- before
starting bolt.
44 Nm
4 - Seal
Renew after removal
5 - Bolt
85 Nm
10
Rep. gr.39 - Final drive - rear differential
AG.
Repair work which may

affect the function of the
tachograph must always
be carried out in certified
workshops.
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Caution
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2 - Final drive cover

Vehicles with a digital
tachograph have a sen
sor mounting on the
cover page 18 .
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1 - Oil filler plug

Renew after removal
33 Nm
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
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13 - Crown wheel
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ut
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Determining shims
ss page 36 .
14 - Actuator
rrectness of i
t to the co
nf
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spec
atio
h re
n in
wit
Caution
Handle actuator with ex

treme caution and do not
strike it against any other
object.
Risk of damage to the
sensor.
Removing and installing page 13
15 - Oil drain plug
Renew after removal
33 Nm
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18 - Propshaft flange
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17 - Flange nut
Renew after removal
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16 - Axle beam
Removing and installing Rep. gr. 42 ; Rear axle; Removing and installing rear axle .
19 - Dust cap
20 - Sealing sleeve
Renew after removal
21 - Seal
Renew after removal
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.
28 - Drive pinion
es, in part or in w
l purpos
hole
ercia
, is n
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27 - Shim
For adjusting drive pinion
Determining shims page 39 .
Prote
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12
AG.
26 - Inner tapered roller bearing

Pulling off and pressing on page 30 .
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25 - Compression sleeve
Remove to renew drive pinion.
Renewing page 20
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
24 - Outer ring
For inner tapered roller bearing
Remove and install using drift - 3138- .
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23 - Outer ring
For outer tapered roller bearing
Remove and install using drift - 3138- .
AG. Volkswagen AG d
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22 - Outer tapered roller bearing

Remove to renew drive pinion.
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
Renew after removal
Will be destroyed during
removal and installation
AG. Volkswagen AG d
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Only in vehicles with dif ised
nte
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ferential lock.
h
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Removing and installing actuator
Note
r
fo
ng
On vehicles with differential lock the guide ring may be damaged

during the removal of the actuator Item 10 (page 13) . Check
the guide ring for damage after the actuator has been removed.
For this, the differential must be dismantled page 24 .
agen
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Remove drive pinion and differential page 14 .
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Removing
rrectne
s
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i
t to the co
n
form
spec
atio
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1.3
urposes, in part or in wh
ole,
cial p
is n
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s
11 - Securing pin
Renew after removal
Will be destroyed during
removal and installation
process.
Remains of pin remain
in differential housing.
The depth of the hole allows for shearing off the pin twice as well as for two remnants to remain in the
hole (new version). In case of the old versions the securing pin must be removed completely.
1. Final drive
13
AG.
un
le
ility
ab
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an
pt
ce
Amarok 2011
Transfer box and final
es n
wage
s
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ran
ir se
tee
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or
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a
drive
ss - Edition 05.2013
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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Remove outer race -arrow- from tapered roller bearing -1- on

left and right.
The tapered roller bearing on the actuator end will be damaged

when being removed and must be renewed.
Press tapered roller bearing on actuator end off differential
page 32 .
Prote
cted
by
Installing
Install in reverse order of removal, observing the following:
Installing drive pinion and differential page 14
Specified torques
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.
14
AG.
Carefully remove actuator -arrow- from differential.
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Risk of damage to the sensor.
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Handle actuator with extreme caution and do not strike it

against any other object.
do
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um
en
Caution
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Remove circlip -1- of actuator with a screwdriver or circlip pli

ers.
Amarok 2011
Special tools and workshop
equipment required
Thrust piece - VW 554 Tube - VW 519 Thrust piece - VW 432-
Drift - 3138-
rrectness of i
t to the co
nf
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m
spec
atio
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wit
es, in part or in w
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hole
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Counter-hold tool - 3145(modify holes on old ver

sion page 44 )
AG. Volkswagen AG d
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Torque wrench - VAS

5088-
1. Final drive
15
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AG. Volkswagen AG d
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Amarok 2011
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Transfer box and tfinal
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Counter support Kukko

18-2
Separating tool Kukko 17-2
Fitting tool - T50023 Thrust piece - VW 433 Thrust piece - T50048/1-
AG.
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16
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Thrust piece - T50048/2-
rrectne
s
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f
i
t to the co
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form
spec
atio
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thi
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equipment required
2011
pe
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ac
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Support device - T10323-
rrectness of i
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spec
a
t
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wit
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es, in part or in w
l purpos
hole
ercia
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Thrust piece - T50018-
Socket 32 mm - T10209 Expander - T50021- (renew

washers and M8 securing
bolts with new bolts with
property class 12.9 before
each installation)
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
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Specified torque: 44 Nm
Fit spreader - T50021- on rear axle.
rrectness of i
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spec
at
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Part number for washers:
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WHT003198
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Amarok 2011
Mark installation side of tapered roller bearing outer races
-2- and shims -1-.
WARNING
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l purpos
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Fit a bearing bracket again to prevent differential falling out

when expanding axle beam.
Wear safety goggles. Securing bolts of expander - T50021- are

highly stressed when axle is expanded.
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
Tension spreader - T50021- until differential can be removed

from axle beam without significant effort.
Note
Handle differential with extreme caution and do not strike it
against any other object.
When driving connector out inwards, ensure that it does not
strike against actuator.
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Slacken spreader - T50021- and remove.
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Remove retainer for connector. Then, press connector in

wards out of axle housing and remove it together with differ
ential. Carefully pull connector out inwards.
thi
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Risk of damage to axle differential lock Hall sender 1 - G460- .
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
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Press tapered roller bearing Item 26 (page 12) off driveVpin
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If only the compression sleeve is to be removed, note

page 20 .
rrectness of i
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spec
a
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thi
s
If the compression sleeve is to be renewed together with the ta

pered roller bearings, do the following:
Drive in outer races and determine shim for drive pinion
page 39 .
Then, fit determined shim onto drive pinion and press on ta
pered roller bearing page 30 .
Note
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Continuation for all cases:
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Remove any sealant residue from splines of flange before insert

ing the drive pinion.
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 - T50018Note

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Remove sealant residue thoroughly from
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Apply Loctite 565
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to ainner
splines
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ara
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of flange.
Caution
rrectness of i
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nf
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spec
atio
h re
n in
wit
Determine friction torque with crown wheel removed.

Determining friction torque
Bolt counter-hold tool - 3145- to propshaft flange.
Tighten flange nut with socket 32 mm - T10209- until the bear
ing has zero play.
Remove counter-hold tool - 3145- .
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Install propshaft flange with new securing nut.
or
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1. Final drive
21
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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
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new, unoiled bearing: 2.25 Nm to 2.82
r
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used bearing: previously determined
value
+
0.1
s
Friction torque:
With
Nm to 0.5 Nm
Caution
rrectness of i
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spec
at
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If the determined friction torque is too low, tighten flange nut

further in small steps. Then, align propshaft flange again (ro
tate 15 times in clockwise and 15 times in anticlockwise direc
tion). After that, determine friction torque again. Repeat this
procedure until the friction torque is within the specified range.
It is very likely that this procedure has to be repeated several
times.
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
drive pinion must be removed for this purpose.
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22
Amarok 2011
Secure flange nut by peening.
If the final drive gear set has been
pression sleeve and tapered roller
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dismantled completely
(com
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bearing), do
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Continuation for all cases:
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Determine shims for crown wheel page 36 .
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
Part number for washers: WHT001323
Install spreader - T50021- .
Wear safety goggles. Securing bolts of expander - T50021- are

highly stressed when axle is expanded.
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Tension spreader - T50021- until differential can be fitted into

axle beam without significant effort complete with tapered roll
er bearings and determined shims.
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WARNING
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Specified torque: 44 Nm
Prote
cted
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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.
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Secure final drive cover with new gasket and new bolts. y Volks
b
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Install rear axle shafts Rep. gr. 42 ; Rear axle shafts
ho
un
le
Secure wiring harness bracket to rear axle.

Specified torques

3.2 Assembly overview - Tirsan propshaft, page 54
Rear axle shafts, Assembly overview rear axle shafts Run
ning gear, axles, steering; Rep. gr. 42 ; Assembly overview rear axle shafts .
Component
Sender to gearbox housing
13 Nm
r
fo
ng
Dismantling and assembling differential
Convert two arm puller - T10040- with claw - T40001 /2- .
Special tools and workshop equipment required

-handelsblicher ZweiarmabzieherRemoving
Remove differential page 14 .
24
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1.5
Specified torque
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
h re
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wit
i
n
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Connect wiring harness to sender.
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Fill with gear oil page 67 .
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Install propshaft page 57 .
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 -handelsblicher 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.
Note
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The securing pin breaks when removing pin -1- and a part re
mains in the pin -arrow a-.
When the pin is removed from the housing, the remaining part of
the securing pin -arrow b- must be removed in two parts from the
housing in the -direction of arrow- using a commercially available
driver. The lower part of the securing pin -arrow c- remains in the
housing hole.
Remove differential bevel gears and thrust washer from dif
ferential cage.
WARNING
The repair can be made 2 - 3 times.

When driving out the pin, a part of the securing pin remains in
the lower part of the differential housing.
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Note
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When a new securing pin is inserted it presses the remains of

the old securing pin into the housing.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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The hole is so deep that differential can be dismantled twice.
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 .
3.2 Assembly overview -
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Tirsan propshaft, page 54tho
eo
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s
differential, page 13 s
1.6
Removing and installing crown wheel
26
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AG.
The bolts have a left-hand thread.
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Note
Prote
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Remove differential page 14 .
do
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um
en
Removing
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Torque wrench - V.A.G 1332-
es, in part or in w
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hole
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Specified torques
AG. Volkswagen AG d
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d
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Transfer box and final drive - eEdition
05.2013
ut
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c
s
s
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l purpos
hole
ercia
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erm
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Loosen bolts -2- of crown wheel -1-.
Using light blows, release crown wheel from drive. Then re

move bolts and remove crown wheel.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Installing

Specified torques

1.7
Checking backlash and contact pattern

Dial gauge - VAS 6079-
do
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Universal dial gauge bracket - VW 387-
or
Without illustration:
Dial gauge extension - T 50047/3Checking 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 387with dial gauge
gen AG
AG. Volkswaon
en50047/3gT
- VAS 6079- and gauge extension
axledohous
a
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Backlash can be changed using shims Item 7 (page 11) . If a

thinner shim is installed on one side, a shim that is thicker by cor
responding amount must be installed on other side so as to
maintain bearing preload of differential bearings.
Checking contact pattern:
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.
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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.
28
ht
rig
py
Co
t.
r
fo
ng
Retaining tool - T50022-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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um
en
ole,
cial p
is n
mer
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or
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Note
un
le
ri
Measure backlash; specification:
0.102 0.177 mm
tho
Amarok 2011
Correct contact pattern
Note
Contact at tooth tip:

Note
Contact at tooth root:

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Note
do
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Reduce installation distance of crown wheel somewhat (crown

wheel closer to drive pinion) page 35 . This causes teeth to
engage somewhat more deeply whilst maintaining backlash.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
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es n
wage
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In practice, it is not possible
to
achieve
such
an
ideal
contact
ua pat
b
ran
ed no point touches outer edge of tooth
ir sthat
tern. It is important
tee
o
h
t
or
surface.
u
ac
a
ss
Increase installation distance of crown wheel somewhat (remove

crown wheel from drive pinion) page 35 . This causes teeth
to engage somewhat less deeply whilst maintaining backlash.
1. Final drive
29
AG.
Prote
cted
by
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 - 3118n AG. Volkswagen AG do
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c
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rig
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.
C
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Procedure:
Remove drive pinion page 14 .
Then press tapered roller bearing -arrow- off drive pinion -1-.
30
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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ot
com
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db
ise
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un
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wage
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Amarok 2011
Press tapered roller bearing inner race off drive pinion.
AG. Volkswagen AG d
Determine shim for drive pinion before pressing on tapered
agen
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roller bearing page 39 .
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t
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or
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rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
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Press tapered roller bearing onto drive pinion.

Note
Ensure that drive pinion shim is correctly seated on back of drive

pinion head. Bearing must be fully in contact with shim. There
must be no gap between them.
do
c
um
en
ht
rig
py
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t.
1. Final drive
31
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Amarok 2011
1.9
Pulling tapered roller bearing for differential off and pressing it on

equipment required
Tube - 2040 Thrust pad - VW 447 i Pressure plate - VW 401 Thrust piece - VW 473 Counter support Kukko
18-2
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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f
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AG.
32
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Open tapered roller bearing cage -arrowwith side cutters and
remove cage with rollers.
ht
rig
py
Co
t.
The tapered roller bearings are damaged beyond repair when

being removed and must be renewed.
thi
sd
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en
Note
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
Dismantling
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Amarok 2011
Pull off inner rings with thrust plate - VW 447 i- and tube 2040- .
1-
Counter support Kukko 18-2
2-
Assembling
Note
For pressing on 2nd tapered roller bearing, place thrust pad -
VW 447 i- under inner race of 1st tapered roller bearing.
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Co
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s
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t to the co
n
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spec
atio
h re
n
wit
i
n
thi
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Tapered roller bearings must make flush contact.
1. Final drive
33
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Prote
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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.
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34
rrectne
s
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form
spec
atio
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i
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thi
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4 - Shim
Opposite side of crown
wheel.
For adjusting crown
wheel
Fitting position: cham
fered side faces axle
tube.
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

A
AG do
agen
during production.
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The utmost care and cleanliness during all assembly
ise
r
measurements are essential to achieve a good
ho result.
ut
sa
Basic dimension to be set

2 - Crown wheel
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
1 - Drive pinion
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
or
e
t
a
itte
iv
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f
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ng
and shims page 7 .
ility
ab
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s
Observe the general repair notes for tapered
roller bearings
a - Nominal default value = 112 mm

b - Middle of crown wheel
Adjustment overview
Note
Prote
cted
by
1)
Renew tapered roller bearing of drive pinion as well.
2)
Renew all tapered roller bearings of final drive gear set.
AG.
Compression sleeve3)
Differential cage
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Axle beam1)
Final drive gear set
(drive pinion and
crown wheel)1)
Tapered roller bear
ing2)
ht
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Co
t.
Renewed component Adjusting drive pinion Adjusting crown

page 39
wheel
page 36
thi
sd
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cu
m
en
If repairs have been carried out on the final drive gear set it is only
necessary to adjust the drive pinion or crown wheel if components
have been renewed which have a direct effect on the adjustments
of the final drive. To prevent unnecessary adjustments, refer to
the following table:
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
ole,
cial p
is n
mer
m
ot p
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c
erm
or
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t
a
itte
v
i
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p
Note
To avoid mistakes when adjusting crown wheel, it is a good idea

to print out tables for calculating shim page 36 and enter
measured values.
Differential removed.
A - Measuring inside dimension of rear final drive housing:

Insert measuring piece - T50047/2- and measure gap using
feeler gauge .
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
36
AG.
212.50 mm
0.70 mm
213.20 mm
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Measuring piece dimension

+ Measured gap size
= Rear final drive housing inside dimension
ht
rig
py
Co
t.
Example:
r
fo
ng
Calculate rear axle housing inside dimension by adding to

gether measured gap and measuring piece.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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en
Feeler gauge
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Measuring piece - T50047/2-
Amarok 2011
A - Measuring inside dimension of
rear final drive housing:
Measuring piece dimension
Measured gap size
Rear final drive housing inside di
mension
Measured:
mm
mm
mm
A=
B - Measuring differential axle di

mension:
Differential axle dimension
Example:
Measured:
212.50 mm
+0.70 mm
213.20 mm
Example:
B=
mm
201.00 mm
Note
The size of the individual shims ncorresponds

approximately
to half
AG. Volkswagen
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Measured:
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of
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le
pe
rm
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hole
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C=
Note
Insert thinner shim on crown wheel side so as to achieve a
Shims page 37
1 mm shim thickness corresponds to approx. 1.4 mm back
Prote
cted
by
13
14
15
16
17
18
19
20
21
22
Thickness t (mm)
5.645
5.671
5.696
5.721
5.747
5.772
5.798
5.823
5.848
5.874
AG.
No.
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Crown wheel shims
ht
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Co
t.
lash.
213.20 mm
mm
mm
mm
mm
+0.03 mm
-201.00 mm
12.23 mm
6.115 mm
do
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n
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
mm.
mm
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Rear final drive housing inside di

mension (A)
Value for bearing preload
Differential axle dimension (B)
Total thickness of shims
1/2 C =
Example:
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db
ise
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o
C - Calculating
thickness
thtotal
au
s
shims:
s
VW part number
WHT 006 443
WHT 006 443 A
WHT 006 443 B
WHT 006 443 C
WHT 006 443 D
WHT 006 443 E
WHT 006 443 F
WHT 006 443 G
WHT 006 443 H
WHT 006 443 J
1. Final drive
37
Amarok 2011
5.899
5.925
5.950
5.975
6.001
6.026
6.052
6.077
6.102
6.128
6.153
6.179
6.204
6.229
6.255
6.280
6.306
6.331
6.356
6.382
6.407
6.433
6.458
WHT 006 443 K

WHT 006 443 L
WHT 006 443 M
WHT 006 443 N
WHT 006 443 P
WHT 006 443 Q
WHT 006 443 R
WHT 006 443 S
WHT 006 443 T
WHT 006 443 W
WHT 006 443 Y
WHT 006 443 Z
WHT 006 443 AA
olksw
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WHT
443
AB
AG. V
n006
does
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not
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V
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ris
WHT
006
443
AD
o
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t
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ra
a
c
WHT 006 443 AE
ss
WHT 006 443 AF
WHT 006 443 AG
WHT 006 443 AH
WHT 006 443 AJ
WHT 006 443 AK
WHT 006 443 AL
If the shims for the crown wheel have been determined, do the
following:
Reinstall drive pinion and differential page 20 .
Check backlash and contact pattern page 27 .
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Prote
cted
by
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Co
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38
do
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en
es, in part or in w
l purpos
hole
ercia
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erm
o
e
t
a
itte
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nl
f
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n
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
VW part number
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Thickness t (mm)
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No.
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-
r
fo
ng
Prote
cted
by
Drive pinion bearing shells must be pulled in.
AG.
Drive pinion removed.
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rrectne
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i
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form
spec
atio
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n
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i
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p
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Feeler gauge
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Depth gauge
Pull in outer races of tapered roller bearings as far as stop

using fitting tool - T50023- as well as thrust piece - T50048/1and thrust piece - T50048/2- .
1. Final drive
39
Amarok 2011
un
le
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AG. Volkswagen AG d
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Installation position of fitting tool - T50023- in rear final drive
d
e
nte
s
i
r
housing.
o
eo
h
ut
ra
a
c
s
Measuring basic dimension (production tolerance)s on rear axle
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
housing
This means measuring piece is set to nominal basic dimen
sion.
Use dial gauge extension - T50047/4- .
40
AG.
Contact surfaces must be clean and free of burrs.
agen
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Prote
cted
by c
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C
op
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Note
ht
rig
py
Co
t.
Adjust preload of dial gauge - VAS 6079- to 2 mm. Then, set

dial gauge - VAS 6079- to 0.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Secure dial gauge extension - T50047/4- on dial gauge - VAS

6079- , then insert it in measuring piece - T50047/2- and se
cure it using knurled screw. Secure tip of dial gauge - VAS
6079- on extension.
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.
ility
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rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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ot p
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c
erm
or
e
t
a
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f
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ng
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Insert the converted fitting tool - T50023- inbthe
y V rear final drive
ua
d
ran
housing. Insert tapered roller bearing with
ir se measuring piece tee
o
h
t
or
T50047/1- in rear final drive housingauand bolt the two parts
ac
together using the threaded rod. ss
Insert measuring piece - T50047/2- with dial gauge - VAS

6079- and dial gauge extension - T50047/4- in rear final drive
housing.
Caution
The dial gauge must be read anti-clockwise at the red figures.
ht
rig
py
Co
t.
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c
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Determine reversal point on dial gauge - VAS 6079- by turning

it slightly back and forth in -direction of arrow-. Note the de
termined value.
thi
sd
o
cu
m
en
The thickness of the required shim is read directly on the dial

gauge - VAS 6079- .
Prote
cted
by
Shims page 41
Drive pinion shims
No.
Thickness t (mm)
VW part number
20
21
22
23
24
25
0.508
0.533
0.559
0.584
0.610
0.635
WHT 006 444

WHT 006 444 A
WHT 006 444 B
WHT 006 444 C
WHT 006 443 D
WHT 006 443 E
1. Final drive
41
Amarok 2011
No.
Thickness t (mm)
VW part number
26
27
28
29
30
31
32
33
34
35
36
37
38
39
0.660
0.686
0.711
0.737
0.762
0.787
0.813
0.838
0.864
0.889
0.914
0.940
0.965
0.991
WHT 006 444 F

WHT 006 444 G
WHT 006 444 H
WHT 006 444 J
WHT 006 444 K
WHT 006 444 L
WHT 006 444 M
WHT 006 444 N
WHT 006 444 P
WHT 006 444 Q
WHT 006 444 R
WHT 006 444 S
WHT 006 444 T
WHT 006 444 W
es n
wage
s
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If the shim for the drive
do
y V pinion has been determined,
ua the fol
b
d
ran
lowing:
ir se
tee
o
h
t
or
au
Fit newssshim
onto drive pinion and press on tapered rollerac
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
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bearing page 30 .
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AG.
Prote
cted
by
c
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p
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.
C
op
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ht
rig
py
Co
t.
42
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
r
fo
ng
Reinstall drive pinion and differential into rear final drive hous
ing page 20 .
Amarok 2011
1.14
Renewing propshaft flange seal

equipment required
Counter-hold tool - 3145(modify holes)
1332 Thrust piece - T50018 Socket 32 mm - T10209 Separating tool Kukko 17-2
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18-2
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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nl
f
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ng
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ht
rig
py
Co
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Prote
cted
by
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rig
ht
.
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AG.
Bearing preload gauge - VAS 6523-
thi
sd
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cu
m
en
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.
AG. Volkswagen AG d
agen
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by to loosen and tighten secur
ara
d
Counter-hold tool - 3145- is used
e
nte
is
r
o
ing nut for propshaft flange.
In
case
of
an
unmodified
tool,
drill
eo
h
ut
ra
a
out both holes in counter-hold
tool
3145to
dimension
-a=
c
s
s
Modifying counter-hold tool - 3145
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
A new counter-hold tool - 3145- with 10.5 mm holes will be

supplied.
Removing
Note
The brake drums must be removed, in order to prevent a poten

tially dragging brake from falsifying the measurement and causing
incorrect values.
Remove rear brake drums Brake systems; Rep. gr. 46 ;
Rear brakes; Resetting drum brake .
Unbolt propshaft from rear axle page 57 .
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Check drive pinion bearing for axial play (no play permitted).
agen
lksw
Vo
by
Measure friction torque on propshaft flange with a commer

cially available 32 mm socket , bearing preload gauge - VAS
6523- and a cordless power driver 12 V/1.4 Ah - VAS 5825- ,
for example.
.
AG.
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.
44
ht
rig
py
Co
t.
Secure propshaft to body.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
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p
or
nl
f
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g
n
Note
ility
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10.5 mm .
AG. Volkswagen AG d
agen
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not
l
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nte
ise
r
o
Transfer
box
and
final
e drive
h
t
or
u
ac
a
s
s
un
le
pe
rm
itte
d
ility
ab
y li
an
pt
ce
Remove locking device for nut -arrows-.
Screw counter-hold tool - 3145- onto propshaft flange.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Loosen securing nut using 32 mm socket - T10209- .
Fit puller, as shown, and pull off propshaft flange.

do
c
um
en
ht
rig
py
Co
t.
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te o
iva
r
rp
fo
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n
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AG.
Prote
cted
by
Removing oil seal
Amarok 2011
- Edition 05.2013
c
o
p
yri
gh
t.
C
op
yi
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.
Component
Specified torque
30 Nm
rrectness of i
t to the co
nf
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m
spec
atio
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wit
Nut
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Initial tightening torque
Check drive pinion bearing for axial play (no play permitted).
Note
If bearing is not without play, specified torque can be increased

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
60 Nm.

AG.
46
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Mark position of drive pinion in relation to one edge of securing

nut.
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ut - T10209- .
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Tighten securing nut using 32 mm socket
a
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Amarok 2011
Tighten securing nut by further 15 using 32 mm socket T10209- .
rrectness of i
t to the co
nf
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spec
atio
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wit

Tighten securing nut 15 further using 32 mm socket T10209- .

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Remove counterhold tool - 3145- .
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1. Final drive
47
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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,
wagen AG
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e
determine friction torque again.
procedure
until the
g
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friction torque is within
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Secure securing nut by peening.

Install propshaft page 57 .
Install brake drums Brake systems; Rep. gr. 46 ; Rear
brakes; Resetting drum brake .
Operate brake pedal several times until brake shoes are in
contact with brake drum.
Check oil level and top up if necessary page 67 .
AG.
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48
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3.3 Assembly overview - Dana propshaft, page 55
do
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Specified torques
rrectness of i
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spec
a
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thi
s
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
drive pinion must be removed for this purpose.
ility
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ri this procedure has to be repeated several
It is very likely tthat
ho
or
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times.
ss
Amarok 2011
1.15
Repairing propshaft flange

equipment required
Pressure plate - VW 402 Thrust piece - 40-105 Thrust pad - VW 511 Thrust piece - VW 442 Counter support Kukko
18-2
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Propshaft flange removed page 43 .
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Tube - 30 - 14-
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1. Final drive
49
Amarok 2011
Press out propshaft flange using thrust piece - 40-105- .
1-
Counter support Kukko 18-2
2-
Pressing on
rrectness of i
t to the co
nf
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spec
atio
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wit
Press sealing sleeve onto dust cap using thrust plate - VW

511- .
Then reinstall propshaft flange page 43 .
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Press dust cap onto propshaft flange using thrust piece - VW

442- and tube - 30 - 14- .
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Amarok 2011
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
lkswagen AG
. Voon
only allowed to be engaged when moving
off
heavy ground
gen AG
does or
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if carriageway is very soft.
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In case of a selectable four-wheel
drive the rear differential lock
ho
ut
a
can be activated in offroad
range LOW.
s
ara
nte
e
Refer to Self-study programme No. 464 ; Power transmission

for more information about function.
Refer to Amarok owner's manual for more information and
notes on safety.
2.2
Rear-axle differential lock components

and their locations
Note
Electrical/electronic components and their locations for fourwheel drive page 94
do
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hole
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at
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in t
his
The differential lock is switched on or off via the rear differential

lock switch - E121- . The differential lock control unit - J187checks via the CAN-Bus if the conditions to switch the rear axle
differential lock on have been fulfilled. If they have, then rear axle
differential lock is activated via axle differential lock Hall sender 1
- G460- and control solenoid - N5- .
or
ac
ility
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2. Differential lock
51
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52
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4 - Hall sender 1 for axle differ

ential lock - G460 With control solenoid N5 Location: on rear axle
do
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3 - Rear differential lock switch

- E121 Rear axle differential
lock warning lamp in
transfer box operating
unit - K184 Remove by removing
selector mechanism
cover General body
repairs, interior; Rep.
gr. 68 ; Compartments,
covers and trims; Re
moving and installing
centre console .
c
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2 - Diagnostic connection
Location: in driver foot
well
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spec
at
i
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his
Remove by removing centre

console General body re
pairs, interior; Rep. gr. 68 ;
Compartments, covers and
trims; Removing and installing
centre console .
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1 - Differential lock control unit

- J187-
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Amarok 2011
Transfer box and final drive -
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Edition s05.2013
sa
Amarok 2011
Propshaft
3.1 Assembly overview - flexible coupling for propshaft, page

53
3.3 Assembly overview - Dana propshaft, page 55
3.4 Removing and installing front propshaft, page 56
. Volkswage
n AG d
AG
3.5 Removing and installing
rear
agenpropshaft, page
o57
es n
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propshaft intermediate bear
Assembly overview - flexible coupling for propshaft

rrectness of i
t to the co
nform
spec
a
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3.1
tee
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ot g
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propshaft intermediate bear
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3.6 Dismantling andiseassembling
r
ing, Dana propshaft,
ho page 60
ut
a
ss and assembling
3.7 Dismantling
1 - Bolt
Renew after removal
60 Nm +90
2 - Flexible coupling
Allocation Electronic
Parts Catalogue (ET
KA) .
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4 - Propshaft
Assembly overview Tirsan propshaft
page 54 .
Assembly overview Dana propshaft
page 55 .
page 57
do
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3 - Bolt
Renew after removal
For securing on gear
box.
90 Nm +90
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5 - Washer
6 - Nut
Renew after removal
3. Propshaft
53
Amarok 2011
3.2
Assembly overview - Tirsan propshaft

Note
Volkswa
k
l
o
shaft must be raised and secured or supported.
yV
db
ise
r
Keep propshaft straight; store and transport
fully extended on
tho
au
ly.
s
s
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If propshaft is disconnected only from the rearswaxle,
agen the prop
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rrectness of i
t to the co
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spec
at
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n
wit
in t
his
1 - Bolt
Renew after removal
50 Nm +90
2 - Rear propshaft
page 57
3 - Dust cap
Renew after removal
4 - Propshaft intermediate
bearing
Dismantling and assem
bling propshaft inter
mediate bearing
page 63 .
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6 - Bolt
Renew after removal
66 Nm
do
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en
5 - Nut
Renew after removal
20 Nm +90
7 - Dust cap
Renew after removal
8 - Washer
9 - Rear propshaft
page 57
10 - Bolt
Renew after removal
50 Nm +90
11 - Retaining ring
On front final drive
Renew after removal
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.
54
Amarok 2011
13 - Retaining ring
Renew after removal
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
Renew after removal
50 Nm +90
10 - Rear propshaft
page 57
11 - Bolt
Renew after removal
50 Nm +90
thi
sd
o
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en
9 - Dust cap
Renew after removal
es, in part or in w
l purpos
hole
ercia
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8 - Seal
Renew after removal
AG.
7 - Propshaft intermediate
bearing
Dismantling and assem
bling propshaft inter
mediate bearing
page 60 .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
6 - Nut
Renew after removal
20 Nm +90
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4 - Rubber ring
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3 - Dust cap
Renew after removal
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2 - Rear propshaft
page 57
12 - Retaining ring
On front final drive
Renew after removal
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
Renew after removal
3.4
Removing and installing front propshaft

Counter-hold tool - 3415-
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 .
AG. Volkswagen AG d
Check if there are markings (paint spots) -A- on front propshaft
agen
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and on front final drive.
V
gu
by
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d
se
i
or
If these markings are not present, then markthposition
of prop
u paint.
a
shaft flange in relation to front final drive with
s
or
ac
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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f
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Prise front propshaft -1- off final drive using assembly lever.
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thi
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56
pe
rm
itte
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Remove front propshaft.

Installing .
Amarok 2011
- Edition 05.2013
ility
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un
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Push front propshaft off

3415- .
AG. Volkswagen AG d
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Transfer box
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transfer
box
using
counter-hold
tool
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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ot
com
Renew oil seals -1- if damaged.

Renew retaining rings -2-.
do
c
um
en
ht
rig
py
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rp
fo
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Grease splines of shafts and oil seals -1- with drive shaft
grease Electronic Parts Catalogue (ETKA) .
agen
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ht
.
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Markings -A- must be aligned with one another as far as pos

sible.
AG.
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
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
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Brake pedal actuator wheel drive)
es n
wage
s
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ua
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ran
ir se
tee
o
h
t
or
V.A.G 1869/2(vehicles with rearu
ac
a
ss
AG.
Prote
cted
by
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 .
58
agen
lksw
Vo
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c
o
p
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t
.
C
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If possible, use a twin pillar lifting platform when working on
ht
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t.
Note
do
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um
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te o
iva
r
rp
fo
g
n
Counter-hold tool - T10172- (vehicles with four-wheel drive)
un
le

Unscrew securing bolts for propshaft on propshaft flanges, but
do not remove them yet.
Vehicles with four-wheel drive
Unscrew securing bolts for propshaft on propshaft flanges, but
do not remove them yet. Brace using counter-hold tool T10172- .
Caution
r
fo
ng
To prevent noises due to imbalance, mark the position of the

propshaft relative to the flanges.
Mark position of propshaft in relation to propshaft flanges.

Prote
cted
by c
o
p
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gh
t.
C
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agen
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AG.
Note
ht
rig
py
Co
t.
Install hexagon nuts for intermediate bearing -arrows-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Fit brake pedal actuator - V.A.G 1869/2- .
Amarok 2011
and final drive - Edition 05.2013
ility
ab
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an
pt
ce
AG. Volkswagen AG d
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Removing
o
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h
ut
ra
a
c
s
Vehicles with srear-wheel drive
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 piece - 3118 Thrust pad - VW 510 Separating tool Kukko 17-2
18-2
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Prote
cted
by
tion of the vehicle identification number.
H = Tirsan propshaft
A or 8 = Dana propshaft
Dismantling
Remove propshaft page 57 .
60
AG.
Sticker on propshaft or, if not legible anymore, the 11th posi
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Distinguishing features of propshafts:
ht
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do
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rrectness of i
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Thrust pad - VW 447 H-
Amarok 2011
Note
Mark position of propshaft before removing it.
The propshaft may also be installed reversed by 180.
es n
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rrectness of i
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nform
spec
a
t
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wit
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l purpos
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Release dust cap.
Pull seal -1- and dust cap -2- off shaft.
do
c
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r
te o
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rp
fo
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n
Clamp propshaft in a vice und pull shafts apart by hand.
3. Propshaft
61
ht
rig
py
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Amarok 2011
Remove retaining ring.
agenaAknife
Cut rubber ring in marked area
-arrowwith
AG. Volksw
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removal and pull it off.Volksw
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Assembling

Note
Use silicone lubricant - D 007 000 A2- to ease the installation
of the rubber ring.
Installation position of elastomer components in direction of
ht
rig
py
Co
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cted
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rig
ht
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travel.
Using thrust piece - 3118- and thrust plate - VW 510- drive

propshaft intermediate bearing onto propshaft as far as stop.
AG.
62
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Fit separating tool Kukko 17-2 and counter support Kukko 18-2
and press off propshaft using thrust plate - VW 447 H- .
do
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es, in part or in w
l purpos
hole
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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
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Thrust piece - VW 454-
r
fo
ng
Thrust pad - VW 447 H-
Prote
cted
by
Thrust piece - VW 433-
AG.

18-2
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equipment required
rrectne
s
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o
f
i
t to the co
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form
spec
atio
h re
n
wit
i
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thi
sd
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Dismantling and assembling propshaft intermediate bearing, Tirsan prop

shaft
ht
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3.7
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3.3 Assembly overview - Dana
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propshaft, page
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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.
H = Tirsan propshaft
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Dismantling
es, in part or in w
l purpos
hole
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, is n
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A or 8 = Dana propshaft
AG. Volkswagen AG d
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Remove propshaft page 57 .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
Mark position of propshaft before removing it.

Clamp propshaft in a vice.
Initially loosen bolt until the washer plate can be removed.
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.
64
AG.
edges of the spanner.
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Due to space restrictions it may be necessary to grind off the
ht
rig
py
Co
t.
Note
thi
sd
o
cu
m
en
Then, apply light pressure on the bolt head -arrow A- using a

commercially available assembly lever . Loosen bolt further
while doing so -arrow B-. This will cause the propshaft to be
pressed off.
Amarok 2011
Note
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Fit separating tool Kukko 17-2 and counter support Kukko 18-2
with thrust piece - VW 433- to propshaft as shown in illustration
and press propshaft out of intermediate bearing.
Remove dust cap from propshaft.
Assembling
The blue marking on the propshaft intermediate bearing must face

in direction of travel.
do
c
um
en
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te o
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Note
rrectness of i
t to the co
nform
spec
a
t
i
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o
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wit
thi
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es, in part or in w
l purpos
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AG. Volkswagen AG d
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Tighten separating tool
Kukko
17-2
only
slightly
(so
that
it uaran
e
is
tee
r
barely has zero play).
ho
or
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ac
a
ss
Otherwise the paintwork
of the propshaft may be damaged.
ht
rig
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Co
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Prote
cted
by c
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Drive new dust cap evenly onto propshaft as far as stop using
thrust piece - T10176- and a -Kunststoffhammer- .
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AG.
Drive propshaft intermediate bearing onto propshaft as far as

stop using thrust plate - VW 447 H- , thrust piece - VW 454and 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
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.
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thi
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66
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
or
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t
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AG. Volkswagen AG d
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Amarok 2011
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
. Volkswagen AG
edge of the filler hole; top up as required.
gen AG
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Screw in oil filler plug -arrow- and tighten.
db
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ht
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Specified torques
4. Gear oil
67
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Amarok 2011
39
Final drive - front differential
Final drive

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
AG do
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1.4 Renewing bonded rubber
page
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1.5 Renewing ubonded

rubber on left of final drive, page 77 ee or
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Assembly overview - final drive
ac
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1.1
rrectness of i
t to the co
nform
spec
a
t
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n in
wit
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com
1 - Front final drive

page 68 .
2 - Bolt
50 Nm +90
3 - Support bracket
4 - Hexagon collar bolt
90 Nm +90
5 - Retainer

50 Nm +90
AG.
Prote
cted
by
Removing and installing front final drive

Torque wrench - V.A.G 1331 Torque wrench - V.A.G 1332-
68
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1.2
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8 - Hexagon collar nut
Rep. gr.39 - Final drive - front differential
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90 Nm +90
Amarok 2011
Engine and gearbox jack - V.A.G 1383 A Retainer - T10149Removing
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.
e
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ht
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Turn right wheel hub until one of the wheel bolt holes is at the
top.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
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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.
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db
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WARNING
ho
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a
ss
1. Final drive
69
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.
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Amarok 2011
Attach support - T10149- to wheel hub using wheel bolt and
tighten.
Insert support - T10149- in engine and gearbox jack - V.A.G
es n
wage
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1383 A- .
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or
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es, in part or in w
l purpos
hole
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m
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or
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t
a
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ng
WARNING
b
ed
ris
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th
au
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Unscrew and remove securing bolt for front final drive.

Lower wheel suspension again with engine and gearbox jack
- V.A.G 1383 A- .
Turn steering wheel to right lock.
Place engine and gearbox jack - V.A.G 1383 A- under front

final drive.
Remove support -A- and support bracket -B-.
Lower front final drive with engine and gearbox jack - V.A.G
1383 A- .
A second mechanic is required to remove front final drive.
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- .
70
AG.
Note
agen
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Installing
Prote
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by
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rig
ht
.
C
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Remove front final drive downwards.
ht
rig
py
Co
t.
First pull right drive shaft off front final drive, followed by left
drive shaft.
thi
sd
o
cu
m
en
Remove 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-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
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ot p
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c
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erm
o
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1. Final drive
71
ht
rig
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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-.
Position new
tighten yet.
Tighten securing bolt for front final drive -1-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Lower wheel suspension again with engine and gearbox jack

- V.A.G 1383 A- .
First tighten securing bolt -2- and then securing bolt -3-.
Carefully push connection nipple of breather line -1- into front
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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Prote
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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
72
ht
rig
py
Co
t.
Clip breather hose -2- to earth cable -1-.
do
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um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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First tighten securing bolt -7- and then securing bolt -6-.
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Position new
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securing bolt
b
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a
securing
bolts -6- and -7-.
ss
Amarok 2011
1.3
Renewing bonded rubber bush on rear of final drive

equipment required
Assembly tool - T10435 Assembly tool - T10254 Foot pump - VAS 6179 Hydraulic press - VAS
6178-
ole,
cial p
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Set foot pump - VAS 6179- to lowest setting.

Pulling out bonded rubber bush.
Note
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Prote
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Pulling in
ht
rig
py
Co
t.
r
fo
ng
Washer -A- from assembly tool - T10435-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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Pulling out
AG. Volkswagen AG d
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Tube - 30 - 14-
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 Amust be at right angles to final drive.
Mark installation position -arrow B- of bonded rubber bush.
n AG. Volkswagen A
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Pull-in depth for bonded rubber bush
AG.
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74
ht
rig
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Dimension -a- = 47.4 mm
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
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i
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s
Pull in bonded rubber bush until dimension
-a- page 74 is
reached.
pe
rm
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Renewing bonded rubber bush on front of final drive
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
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com

equipment required
Amarok 2011
- Edition 05.2013
ility
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1.4
AG. Volkswagen AG d
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Transfer box and final
ntdrive
is
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ee
o
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a
s
s
Assembly tool - T10435 Assembly tool - T10254 Foot pump - VAS 6179 Hydraulic press - VAS
6178-
do
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ht
rig
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Co
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Tube - 30 - 14-
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Pulling out
Note
Washer -A- from assembly tool - T10435Pulling in
1. Final drive
75
un
le
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
pe
rm
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final drive.
Note
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AG. Volkswagen AG d
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Amarok 2011
gu
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Position bonded rubber bush in installation position
on front
Small recesses of bonded rubber bush -arrows B- must be at right

angles to final drive.
Mark installation position -arrow A- of bonded rubber bush.
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76
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Pull in bonded rubber bush until it is centred in front final drive

housing.
Amarok 2011
1.5
Renewing bonded rubber on left of final drive

equipment required
Assembly tool - T10435 Assembly tool - T10254 Foot pump - VAS 6179-
r
fo
ng
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Pulling out
Note
Washer -A- from assembly tool - T10435Pulling 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
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ht
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Pull in bonded rubber bush until it is centred in housing on left

of final drive.
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spec
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Mark installation position -arrow A- of bonded rubber bush.
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Gear oil
2.1 Checking level of gear oil, page 79
2.1
Checking level of gear oil

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Ring ratchet spanner, 13 mm AF - T10384-
rrectness of i
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Gear oil for the front final drive is available as a part Electronic
parts catalogue ETKA .
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Amarok 2011
final drive - Edition 05.2013
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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
Install oil filler plug -arrow- and tighten to 35 Nm.
With the component in its installed position
Unscrew the oil filler plug -arrowwith 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
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
c
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Screw in oil filler plug -arrow- in combination with 13 mm ring

ratchet spanner - T10384- and bit - T50039- and tighten.
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Specified torque
Oil filler plug
35 Nm
AG.
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Component
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Specified torque
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Danger of burning.
Amarok 2011
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
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Renewing left flangessshaft oil seal

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Multipurpose tool - VW 771-
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3.6 Renewing needle bearing for left flange

ise shaft,
or
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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 .
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Clamp flange shaft in vice using jaw protectors -B-.

Remove retaining ring -A- using pliers .
Insert new retaining ring in groove in flange shaft, being careful
not to overstretch ring.
Drive in flange shaft using a plastic head hammer .
Check oil in front final drive page 79 .
Install front final drive page 68 .
Renewing oil seal for right flange shaft
AG.
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Procedure
Amarok 2011
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Thrust piece -
AG. Volkswagen AG d
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Transfer
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T10259- horis
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Pull out right flange shaft using multipurpose tool - VW 771- .
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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
age and renew if necessary page 88 .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
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in t
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es, in part or in w
l purpos
hole
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ran
Transfer box and final drive - Edition
ir se
tee
o
h
t
or
u
ac
a
ss dust cap -arrow- for dam
Before installing flange shaft, check
Clamp flange shaft in vice using jaw protectors -B-.

Remove retaining ring -A- using pliers .
Insert new retaining ring in groove in flange shaft, being careful
not to overstretch ring.
c
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Prote
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by

Puller - T10055-
Thrust piece - T10430 Thrust piece - T10430/1 2 self-tapping screws with 4 mm diameter
Procedure
84
AG.
Renewing input shaft seal
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Drive in flange shaft using a plastic head hammer .
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.
olksw
Screw in self-tapping gscrews
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Pull out dustd cap
by using puller - T10055- .
e
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Screw in self-tapping screws with 4 mm diameter.

Note
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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ho to punch 2 holes in oil seal.

Use a drift
ut
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Do not screw in sheet metal screw too far to avoid damaging

bearing behind it.
Pull out seal using puller - T10055- .
Mask off splines of stub shaft with adhesive tape.
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rig
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Co
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On new seal, fill space between dust lip and sealing lip half full
with sealing grease Electronic Parts Catalogue (ETKA) .
c
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Push new oil seal as far as oil seal seat on final drive.
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Prote
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by
Drive in seal to stop with thrust piece - T10430- , being careful

not to cant seal.
3. Oil seals
85
AG.
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
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rig
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Prote
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by
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do
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86
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
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in t
his
es, in part or in w
l purpos
hole
ercia
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AG. Volkswagen AG d
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Amarok 2011
3.4
Renewing dust cap for left flange shaft

equipment required
Press tool - VW 412 Thrust piece - VW 432 Support rails - VW 457 Pulling ring - 2003/3 Assembly tool - 3301-
AG. Volkswagen AG d
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rrectness of i
t to the co
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spec
a
t
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wit
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s
es, in part or in w
l purpos
hole
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Sealing grease Electron

ic Parts Catalogue (ETKA)
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Flange shaft removed, removing page 81
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AG.
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-3- - Separating device Kukko 17-2
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
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es, in part or in w
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hole
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Assembly tool - 3301-
AG do
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Thrust piece - 3456-
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do
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88
Amarok 2011
-3- - Separating device Kukko 17-2
un
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AG. Volkswagen AG d
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Flange shaftthremoved,
removing page 82
eo
u
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a
c
s
Procedure s
Drive on new dust cap for flange shaft -A- using thrust piece 3456- and sleeve - 3301/3- .
Position sleeve - 3301/3- with notch facing dust cap -A-.
ht
rig
py
Co
t.
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Note
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
wit
i
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thi
sd
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mer
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or
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v
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Press dust cap -B- off flange shaft.
3. Oil seals
89
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Prote
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by
c
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C
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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-
ole,
cial p
is n
mer
m
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erm
or
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t
a
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v
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p
Remove left flange shaft and oil seal page 81 .
AG.
Prote
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by c
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90
agen
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rig
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Co
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A - Internal puller Kukko 21-6
r
fo
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Pull out left flange shaft needle bearing.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
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Procedure
AG. Volkswagen AG d
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22-2 -4-
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
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rig
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Co
t.
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fo
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rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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um
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mer
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or
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t
a
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v
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p
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ab
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un
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3. Oil seals
91
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AG.
Prote
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by
c
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p
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gh
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C
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yi
Amarok 2011
39
Final drive - differential
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
5 - Dowel sleeve
Qty. 2
For centring gearbox/
transfer box
6 - Transfer box inter-axle lockup switch - F438 27 Nm
7 - Seal
Renew if damaged
8 - Retaining ring
Renew after removal
On input shaft for front
propshaft
9 - Seal
On output shaft for front
propshaft
Renew if damaged
Rep. gr.39 - Final drive - differential
thi
sd
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4 - Seal
Renew after removal
Insert in groove in input
shaft page 94
AG.
3 - Seal
For input shaft
page 102 .
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2 - Breather pipe
Removing page 94
Driving in page 94
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
1 - Transfer box
page 95 .
92
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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c
erm
or
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t
a
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iv
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Assembly overview - transfer box
Prote
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1.1
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page 100
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AG. Volkswagen AG d
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1.6 Removing and installing transfer box Hall sender G759
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page 99
is
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1.7 Removing and installing transfer box control motor
V455
,
c
s
s
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
13 - Seal
Renew if damaged
Must lie in peripheral groove of transfer box control motor - V45514 - Oil drain plug
Renew after removal
27 Nm
15 - Oil filler plug
Renew after removal
27 Nm
AG.
18 - Bolt
7 Nm
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17 - Transfer box Hall sender - G759 Removing and installing page 99 .
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16 - Seal
Cannot be obtained individually
thi
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l purpos
hole
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m
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or
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t
a
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iv
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f
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ng
11 - Transfer box control motor - V455 Removing and installing page 100 .
12 - Bolt
12 Nm
Amarok 2011
Edition 05.2013
ility
ab
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ce
10 - Seal
For output shaft for front
2-piece
Transfer
and final drive olkswagenbox
AG. V
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propshaft
t
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ss
19 - Nut
Renew after removal
Unscrewing page 106
Screwing on page 107
150 Nm
20 - Seal
Renew after removal
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
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tee
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wa-1Inserting oil seal into groove in input shaft
olks
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing breather pipe
Use pliers to move breather pipe -1- in directions of both ar

rows and pull out.
agen
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Before driving in breather pipe -1-, coat it with Loctite locking

fluid Electronic Parts Catalogue (ETKA) .
AG.
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.
94
ht
rig
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Co
t.
Driving in breather pipe
do
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hole
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, is n
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1 - Transfer box
J646 Location: under dash
panel
page 99 .
Amarok 2011
2 - Diagnostic connection
Location: in driver foot
well
do
c
um
en
3 - Running gear programme

switch - E631 Deactivate for fourwheel drive
Remove by removing
selector mechanism
cover General body
repairs, interior; Rep.
gr. 68 ; Compartments,
covers and trims; Re
moving and installing
centre console
4 - Transfer box operating unit

With reduction gearing
warning lamp in transfer
box operating unit K182 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 Remove by removing
selector mechanism
cover General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing centre console
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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 Location: on transfer box
8 - Transfer box Hall sender - G759 Location: on transfer box
1.3
Removing and installing transfer box
1. Transfer box
95
Amarok 2011
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Engine and gearbox jack - V.A.G 1383 A-
Drive shaft grease Electronic Parts Catalogue (ETKA)

Removing
Remove rear propshaft page 57 .

AG.
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96
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Pull breather line -arrow- off transfer box.
do
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Detach connector -arrows- and unclip wiring harness from

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
rrectness of i
t to the co
nform
spec
at
i
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wit
in t
his
Push transfer box completely onto gearbox, ensuring that

transfer box input shaft splines are centred as they are guided
onto the gearbox output shaft.
Caution
Do not use securing bolts to pull transfer box onto the gearbox.
Otherwise transfer box will cant.
If splines are correctly positioned and shafts are centred, then
transfer box will slide to stop against gearbox.
Install rear propshaft page 57 .
Check oil level in transfer box page 97 .
Prote
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Component
Specified torque
Transfer box to gearbox
45 Nm
AG.
1.4
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Specified torques
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Grease transfer box input shaft splines and gearbox output

shaft splines with drive shaft grease Electronic Parts Cata
logue (ETKA) .
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Always renew oil seal torisseal
transfer box and gearbox -1- and rante
o
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h
lubricate lightly.
t
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au
c
s
s
Checking gear oil level
Gearbox oil specification Electronic parts catalogue ETKA

1. Transfer box
97
Amarok 2011
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Note
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Make a tool to check oil level.

Dimension -a- = 37 mm
Dimension -b- = 60 mm
Procedure

Remove oil filler plug -1-.
Pull out tool and check oil level on tool. Top up oil if necessary.
The oil level must be within a range of 32 to 37 mm below lower
edge of filler hole.
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by c
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AG.
Remove oil filler plug -1-.
agen
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When filling with oil, note the following:

Fill 1.25 l of gear oil.
Tighten new oil filler plug.
Specified torques
98
ht
rig
py
Co
t.
Tighten new oil filler plug.
do
c
um
en
r
te o
iva
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fo
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n
Insert locally manufactured tool into filler hole downwards as

far as possible.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Oil level is below oil filler hole.
Amarok 2011
1.5

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.
1.6

Hall sender - G759-

Removing
es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
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Pull off connector -1-.
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Place drip tray under transfer box.
Installing
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Remove bolts -arrows- and pull transfer box Hall sender G759- off transfer box.
do
c
um
en
1. Transfer box
99
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Amarok 2011
Renew oil seal -1- if damaged.lkswagen
pe
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itte
d
The drive for the transfer box Hall sender - G759- -arrow Bes, in part or in w
l purpos
hole
ercia
, is n
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ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
and the mounting for the transfer box -arrow A- are offset. The
drive only fits in one position in the mounting for the transfer
box.
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When positioning transfer box Hall sender - G759- , insert
centring pin into hole in transfer box -A-.

Caution
It must be possible to insert transfer box Hall sender G759- without exerting great pressure, if necessary check
whether driver -arrow B- has been turned through 180 to
mounting -arrow A-.
Tighten bolts of transfer box Hall sender - G759- -arrows-.

c
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Check oil in transfer box page 97 .

Prote
cted
by

control motor - V455-

Removing
100
AG.
1.7
agen
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Specified torques
ht
rig
py
Co
t.
Push on connector -1-.
do
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fo
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n
Insert transfer box Hall sender - G759- .
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.
es, in part or in w
l purpos
hole
ercia
, is n
m
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c
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erm
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Tighten bolts -2- for transfer box control motor - V455- .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Push on connector -1-.

Specified torques
do
c
um
en
ht
rig
py
Co
t.
1. Transfer box
101
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Amarok 2011
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-
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l purpos
hole
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spec
at
i
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his
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Remove transfer box page 95 .
AG.
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102
ht
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Co
t.
Removing
do
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en
Sheet metal screw, approx. 4 mm in diameter
Amarok 2011
To pull out seal, screw sheet metal screw of about 4 mm di
ameter -arrow- into seal.
Caution
Pull out seal using puller - T10055- .

Installing

Drive in new seal to stop with thrust piece - T10184- , being
careful not to cant seal.
Install transfer box page 95 .
2.2
Renewing output shaft seal
ht
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py
Co
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s
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spec
atio
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i
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thi
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cial p
is n
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Do not screw in sheet metal screw too far to

bearing behind it.
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avoid
damaging
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Hub grease cap puller - VW 637/2-
2. Oil seals
103
Amarok 2011
AG. Volkswagen AG d
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spec
a
t
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wit
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hole
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extractor lever - VW 681-

Removing
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Prote
cted
by
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rig
ht
.
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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.
104
ht
rig
py
Co
t.
Pull out seal using hub grease cap puller - VW 637/2- .
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Lift inner part of seal in three places using a screwdriver, offset

120
Amarok 2011
2.3
Renewing propshaft flange seal

equipment required
Counter-hold tool - 3145 Thrust piece - VW 442 Removal and installing tool
- VW 459/2 Puller hooks - T20143/2 Torque wrench - V.A.G
1332 Sealing grease Electron
ic Parts Catalogue (ETKA)
Bolts M10 x 25 (Qty. 2)
If leaks are detected during repair work on the flange, always
renew the seal Item 23 (page 12) and the sealing sleeve
Item 20 (page 11) .
Always renew oil seal and propshaft flange together.

Removing
Remove rear propshaft page 57 .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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or
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2. Oil seals
105
ht
rig
py
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Prote
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by c
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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.
es, in part or in w
l purpos
hole
ercia
, is n
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c
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erm
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If necessary, pull off propshaft flange using puller Kukko 18-1

-A- and adapter - VW 295 A- .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Pull out seal using puller hooks - T20143/2- .

Installing
Lightly oil outer circumference of new oil seal.
Prote
cted
by
106
AG.
Insert new propshaft flange.
agen
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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.
ht
rig
py
Co
t.
do
c
um
en
Amarok 2011
Install new nut for propshaft flange and tighten. Screw counterhold tool - 3145- onto propshaft flange using two M10 x 25
bolts -arrows- in order to counter-hold tool.
Install rear propshaft page 57 .
Specified torques
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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cial p
is n
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Moisten new oil seal -1- with gear oil and insert.
2. Oil seals
107
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AG.
Prote
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Service

Transfer box and final drive

Service Department. Technical Information

All rights reserved.

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

(VRL005429; Edition 05.2013)

A reduction gearing is integrated into the transfer box.

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

Additional data depend on manufacture.

Identification of final drive

Location on front final drive -arrow-

Additional data depend on manufacture.

Rep. gr.00 - Technical data

2.1 Allocation of rear final drive - engine/capacities,

Allocation of rear final drive - engine/capacities

Rear final drive

Specification of gear oil

Allocation to corresponding vehicle

Allocation of front final drive - engine/capacities

Front final drive

The following data can be found in the Electronic parts cata

Allocation of transfer box - engine/capacities

Specification of gear oil

The following data can be found in the Electronic parts cata

Allocation of rear axle - engine/capaci

2H0.500.025. 2H0.500.029. 2H0.500.029.

Data shown on axle type plate.

If the oil was merely drained, the capacity is 2.0 l.

3) For current part numbers and codes refer to

Calculation of gear ratios

Rep. gr.00 - Technical data

Z1 = no. of teeth on drive gear

Overview - power transmission

3.1 Overview - power transmission - four-wheel drive,

Overview - power transmission - four-wheel drive

1 - Front final drive

Rep. gr.00 - Technical data

6 - Rear final drive

3 - From manual gearbox

4.1 Gearbox, page 7

4.2 Rear axle, page 7

4.3 Seals and sealing rings, page 7

4.4 Locking devices, page 7

To ensure flawless and successful gearbox repairs, the greatest

When installing mounting brackets or waxed components,

Always renew retaining rings for front propshaft on transfer

A number of generally applicable instructions for the various re

Allocate bolts and other components using Electronic parts

Seals and sealing rings

Thoroughly clean joint surfaces.

Do not overstretch retaining rings.

Nuts and bolts

Note the installation position of the sealed wheel bearings: the

Install only flawless shims.

Measure shims at several points with a micrometer. The var

Note the shims' location. There must be no gap between the

Rep. gr.00 - Technical data

Final drive - rear differential

1.1 Assembly overview - final drive, page 10

ing it on, page 30

1.10 Overview of shims, page 34

1.11 Adjustment overview, page 35