Installing transfer box
1. Support main transmission on converter bell housing with a wooden block -Arrow- .
2. Gradually run in transfer box. Press vent line into holder -Arrow- and attach to transfer box.
3. Screw in fastening screws on main transmission. --> Tightening torque: 45 (33 ftlb.) Nm
4. Tighten holder -A- for Tiptronic line using fastening nut -Arrow-. --> Tightening torque: 10 (7.5 ftlb.) Nm. (Scheme 92)
5. Support transfer box with transmission jack and remove wooden block between converter bell housing and suspension subframe.
Note. Always observe the exact work sequence when installing/removing the transmission cross member. Screws which are tightened with a torque angle must be replaced with new ones.
6. Install transmission cross member.
7. Screw in two cross member screws -B- on transfer box holder. --> Initial tightening: 50 (37 ftlb.) Nm --> Final tightening: 90°
8. Screw in fastening screws for securing transmission cross member to body -A- . --> Initial tightening: 50 (37 ftlb.) Nm --> Final tightening: 90°
Note. Screws which are tightened with a torque angle must be replaced with new ones.
9. Connect front cardan shaft to transfer box. --> Initial tightening: 30 (22 ftlb.) Nm --> Final tightening: 90°
Note. The temperature sensor -1- on the transfer box is no longer used in model year 2004. see scheme 264 If there is no temperature sensor, secure cable plug on the servo motor with tie-wraps.
10. Connect cable plug -1 , 2- to the transfer box and secure the cable holder.