Rear - Axel Parte 1

Service
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by Volkswagen AG. Volkswagen AG does not guarantee or accept any
liability with respect to the correctness of information in this document. Copyright by Volkswagen
AG.
List of Workshop Manual Repair Groups
R e p a i r Gr o u p
00 - Technical data
34 - Controls, housing
39 - Final drive - front differential
39 - Final drive - differential
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0059031520
AG.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Rear axle type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Advantages of four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Function of permanent four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.4 Differential locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Technical data for rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Technical data for transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Overview - power transmission - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Transfer box, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview - transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Removing and installing rubber bush and rear bracket of transfer box . . . . . . . . . . . . . . . . 15
1.4 Removing and installing upper bracket for transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5 Removing and installing rubber bush and front bracket for transfer box . . . . . . . . . . . . . . 19
1.6 Removing and installing front bracket for transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Checking and replenishing gear oil level in transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.8 Removing and installing transfer box control motor V455 . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.9 Removing and installing pneumatic actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Front final drive, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . . . . . . . 26
1.1 Assembly overview - front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Checking and replenishing gear oil level in front final drive . . . . . . . . . . . . . . . . . . . . . . . . 30
1.4 Removing and installing flange shafts on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.5 Renewing oil seals on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Assembly overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Assembly overview - rear axle, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . 37
1.3 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.4 Removing and installing rear axle, Crafter 4MOTION with Achleitner four-wheel drive . . . . 42
1.5 Removing and installing actuator for differential lock, Crafter 4MOTION with Achleitner
fourwheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2 Checking gear oil level, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . 50
3 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Renewing seal for propshaft flange of rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Crafter 2006 ➤
Rear axle and rear final drive - Edition 12.2014
Contents i
AG.
4 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 Removing and installing drive pinion and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3 Pulling tapered roller bearing for drive pinion off and pressing it on . . . . . . . . . . . . . . . . . . 75
4.4 Pulling tapered roller bearing for differential off and pressing it on . . . . . . . . . . . . . . . . . . 77
4.5 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.6 Overview of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.7 Adjusting crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.8 Tables for printing out, crown wheel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.9 Adjusting drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.10 Tables for printing out, drive pinion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.1 Assembly overview - propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2 Assembly overview - propshaft, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . 98
5.3 Assembly overview - propshaft bearing with underride guard, Crafter 4MOTION with
Achleitner four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.4 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.5 Removing and installing front propshaft, Crafter 4MOTION with Achleitner four-wheel drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.6 Removing and installing rear propshaft, Crafter 4MOTION with Achleitner four-wheel drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.7 Aligning propshaft, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . . . . . 106
5.8 Removing and installing constant velocity joint shaft, Crafter 4MOTION with Achleitner
fourwheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.9 Renewing centre bearing of two section propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.10 Renewing centre bearing of three-section propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.11 Renewing front centre bearing of propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.12 Installing protective caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.13 Removing and installing flexible coupling with damper weight . . . . . . . . . . . . . . . . . . . . . . 124
5.14 Removing and installing damper weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6 Air compressor/pressure accumulator, Crafter 4MOTION with Achleitner four-wheel drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.1 Assembly overview - air compressor V534 /pressure accumulator . . . . . . . . . . . . . . . . . . 131
6.2 Removing and installing air compressor V534 and pressure accumulator . . . . . . . . . . . . 133
6.3 Releasing pressure before working on compressed air system . . . . . . . . . . . . . . . . . . . . . . 136

6.4 Repairing air line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.5 Removing and installing valve block for compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.6 Removing and installing pressure switch for air compressor F503 . . . . . . . . . . . . . . . . . . 139
6.7 Performing pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Crafter 2006 ➤
ii Contents
AG.
00 – Technical data
1 General notes
(VRL007631; Edition 12.2014)
⇒ “1.1 Rear axle type plate”, page 1
⇒ “1.2 Advantages of four-wheel drive”, page 1
⇒ “1.3 Function of permanent four-wheel drive”, page 1
⇒ “1.4 Differential locks”, page 2
1.1 Rear axle type plate
Gear ratio “i” -arrow A- ⇒ page 9
Manufacturer's part number -arrow BNote
Allocation of VW part number and manufacturer's part number
⇒ page 9
Additional data depend on manufacture.
1.2 Advantages of four-wheel drive
The frictional connection between tyres and road is decisive for
the driving behaviour of a motor vehicle on slippery or unpaved
roads. Slipping or spinning wheels can only transfer minimal lateral
grip.
Driven wheels can spin if only one axle is driven when accelerating
or driving up a hill.
The vehicle can break away or come to a standstill if the tractive
forces are lost.
Four-wheel drive transfers drive to all four wheels which greatly
increase the available lateral grip and tractive force.
The higher lateral forces and tractive grip with four-wheel drive
ensure on slippery and unpaved surfaces for:
♦ improved acceleration
♦ more stable behaviour when driving through bends
♦ improved pulling away and negotiation of inclines.
1.3 Function of permanent four-wheel drive
With permanent four-wheel drive the front and rear axles are always
driven.
The front and rear axles are connected by a transfer box.
The transfer box compensates the differing revolutions between
the axles (especially when driving though corners/bends) and
prevents stress and lock-up in the powertrain.
Crafter 2006 ➤
1. General notes 1
AG.
Note
When testing the vehicle, use a two-axle roller dynamometer
rather than a single-axle roller dynamometer as a performance
test stand due to the permanent four-wheel drive.
1.4 Differential locks
Differential locks improve the tractive forces of the vehicle.

Switch on differential locks:
♦ when offroad
♦ when wading through water
♦ on snowy, icy or muddy surfaces
WARNING
Never us locked differentials on paved/hard surfaces.
Do not lock front axle differential when driving through tight
bends/corners. The steerability of the vehicle is reduced dramatically.
As soon as a differential is locked, the function of the ABS is
restricted.
Accelerate only gently when pulling away with a locked differential.
To prevent damage to the transfer box the vehicle may only be
placed on a single axle roller dynamometer (rolling road) when:
• the non-driven axle is jacked up, or
• the respective drive shafts have been disconnected, and
• the differential lock of the transfer box is switched on.
Switch on differential lock:
A total of 3 differentials can be locked.
♦ the transfer box differential, which compensates the differences
between axles,
♦ the rear axle differential, which compensates the differences
between the rear wheels,
♦ the from axle differential, which compensates the differences
between the front wheels.
Note
The switches are on the dash panel on the left of the steering
wheel.
Crafter 2006 ➤
2 Rep. gr.00 - Technical data
AG.
2 Repair instructions
⇒ “2.1 Gaskets, seals”, page 3
⇒ “2.2 Locking devices”, page 3
⇒ “2.3 Nuts and bolts”, page 3
⇒ “2.4 Bearing”, page 3
⇒ “2.5 Shims”, page 4
2.1 Gaskets, seals
♦ Thoroughly clean parting surfaces and apply sealing paste -
AMV 188 200 03- .
♦ Apply sealant uniformly but not too thick.
♦ Renew O-rings.
♦ Renew radial oil seals.
2.2 Locking devices
♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ The retaining rings must locate properly in the grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.
2.3 Nuts and bolts
♦ Loosen and tighten bolts and nuts for covers and housings
diagonally.
♦ Specified torques settings are specified for unoiled bolts and
nuts.
♦ Always renew self-locking bolts and nuts.
2.4 Bearing
♦ Install needle bearings with lettered side towards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. As far as possible, use products from one manufacturer!
♦ Heat tapered roller bearing inner races to approx. 100 °C before
pressing on.
♦ Do not interchange the inner and outer races of same size
bearings.
Crafter 2006 ➤
2. Repair instructions 3
AG.
2.5 Shims
♦ Measure shims at several points with a micrometer. The various
thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
♦ Comply with possible installation direction.
Crafter 2006 ➤
AG.
3 Technical data
⇒ “3.1 Technical data for rear axle”, page 5
⇒ “3.2 Technical data for transfer box”, page 9
⇒ “3.3 Calculation of gear ratios”, page 9
3.1 Technical data for rear axle
⇒ “3.1.1 Rear axles, Crafter with rear-wheel drive”, page 5
⇒ “3.1.2 Rear axle, Crafter 4MOTION with Achleitner four-wheel
drive”, page 8
3.1.1 Rear axles, Crafter with rear-wheel drive
VW part number 2E0 501 011 B 2E0 501 011 C 2E0 501 011 G
Manufacturer's part number1)
A9063502800 A9063503000 A9063500700
Gear ratio1) Z2 : Z1 0 i 46 : 11 = 4.182 52 : 11 = 4.727 52 : 11 = 4.727
Crown wheel diameter 245 mm 245 mm 215 mm
Allocation Model Crafter 2006 ► Crafter 2006 ► Crafter 2006 ►
Engine
code
BJM, BJL, BJK, CEBB,
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
BJJ, BJK, BJL, BJM, CEBA,
CEBB, CECA, CECB,
CKTB, CKTC, CKUB
Capacity 2) 2.8 l 2.8 l 1.6 l
1) Data appear on the axle type plate ⇒ page 1 .
2) The specified quantity is the minimum fill quantity of the rear

axle. This quantity must always be topped up to the lower edge
of the filler hole ⇒ page 50 . Gear oil ⇒ Electronic Parts Catalogue
(ETKA)
VW part number 2E0 501 011 H 2E0 501 011 K 2E0 501 011 L
A9063500800 A906350100 A9063501100
Gear ratio1) Z2 : Z1 = ii 46 : 11 = 4.182 48 : 11 = 4.364 51 : 10 = 5.1
Engine
code
BJK, BJL, BJJ, CEBA,
CEBB, CECA, CKTB,
CKTC
CEBB, CECA, CECB,
CKTB, CKTC, CKUB
CEBB, CECA, CECB,
CKTC, CKTB, CKUB,
CKUC
Capacity 2) 1.6 l 1.6 l 1.6 l
(ETKA)
VW part number 2E0 501 011 M 2E0 501 011 P 2E0 501 019

A9063502700 A9063503100 A9063501400
Gear ratio1) Z2 : Z1 0 i 51 : 13 = 3.923 51 : 10 = 5.1 48 : 13 = 3.692
Crafter 2006 ➤
3. Technical data 5
AG.
VW part number 2E0 501 011 M 2E0 501 011 P 2E0 501 019
A9063502700 A9063503100 A9063501400
Engine
code
BJM, BJK, BJL, CEBB,
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
Capacity 2) 2.8 l 2.8 l 2.8 l

(ETKA)
VW part number 2E0 501 019 A 2E0 501 019 B 2E0 501 019 C
A9063501700 A9063502000 A9063502300
Gear ratio1) Z2 : Z1 0 i 51 : 13 = 3.923 46 : 11 = 4.182 48 : 11 = 4.364
Engine
code
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
Capacity 2) 2.8 l 2.8 l 2.8 l
(ETKA)
VW part number 2E0 501 019 D 2E0 501 019 E 2E0 501 020
A9063502400 A9063502500 A9063501800
Gear ratio1) Z2 : Z1 0 i 52 : 11 = 4.727 51 : 10 = 5.1 48 : 13 = 3.692

Engine
code
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
BJJ, BJM, BJK, BJL, CEBA,
CEBB, CECA, CECB,
CKTB, CKTC, CKUC,
CKUB
Capacity 2) 2.8 litre 2.8 litre 2.8 litre
(ETKA)
Crafter 2006 ➤
AG.
VW part number 2E0 501 020 A 2E0 501 020 B 2E0 501 020 C
A9063501900 A9063506700 A9063502100
Gear ratio1) Z2 : Z1 0 i 51 : 13 = 3.923 46 : 11 = 4.182 48 : 11 = 4.364

Engine
code
BJM BJK, BJL BJJ, BJK, BJL
Capacity 2) 2.8 l 2.8 l 2.8 l
(ETKA)
VW part number 2E0 501 020 D 2E0 501 020 E
Manufacturer's part number1) A9063502200 A9063506800
Gear ratio1) Z2 : Z1 0 i 52 : 11 = 4.727 51 : 10 = 5.1
Crown wheel diameter 245 mm 245 mm
Allocation Model Crafter 2006 ► Crafter 2006 ►
Engine code BJJ, BJK, BJL BJJ
Capacity 2) 2.8 l 2.8 l
(ETKA)
VW part number 2E0 501 011 A 2E0 501 011 N 2E0 501 011 J
A9063502600 A9063502900 A9063500900
Gear ratio1) Z2 : Z1 0 i 48 : 13 = 3.692 48 : 11 = 4.364 51 : 13 = 3.923
Engine
code
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
BJK, BJL, CEBB, CECA,
CKTB, CKTC
Capacity 2) 2.8 l 2.8 l 2.8 l
(ETKA)
VW part number 2E0 501 019 F 2E0 501 019 G 2E0 501 019 H
A9063508700 A9063508800 A9063508900
Gear ratio1) Z2 : Z1 0 i 48 : 13 = 3.692 51 : 13 = 3.923 46 : 11 = 4.182
Crafter 2006 ➤
3. Technical data 7
AG.
VW part number 2E0 501 019 F 2E0 501 019 G 2E0 501 019 H
A9063508700 A9063508800 A9063508900

Engine
code
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
Capacity 2) 2.8 l 2.8 l 2.8 l
(ETKA)
VW part number 2E0 501 019 J 2E0 501 019 K 2E0 501 019 L
A9063509000 A9063509100 A9063509200
Gear ratio1) Z2 : Z1 0 i 48 : 11 = 4.364 52 : 11 = 4.727 51 : 10 = 5.1
Engine
code
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
CECA, CECB, CKTB,

CKTC, CKUC, CKUB
CECA, CECB, CKTB,
CKTC, CKUC, CKUB
Capacity 2) 2.8 l 2.8 l 2.8 l
(ETKA)
3.1.2 Rear axle, Crafter 4MOTION with
Achleitner four-wheel drive
VW part number
2E0 501,019
2E0 501 019 N 2E0 501,019 P
Gear
ratio1)
Z2 :
Z1 0 i
i = 4.111 i = 4.375 i = 4.857
Allocation
Model
Rear axle,
Crafter 4MOTION
with
Achleitner
four-wheel
drive 2006 ►
Rear axle,
Crafter 4MOTION
with
Achleitner
four-wheel
drive 2006 ►
Rear axle,
Crafter 4MOTION
with
Achleitner
four-wheel
drive 2006 ►
Engine
code
BJM, BJL,
BJK, CEBB,
CECA,
CECB,
CKTB,
CKTC,
CKUC,
CKUB
BJM, BJL,
BJK, CEBB,
CECA, CECB,
CKTB, CKTC,
CKUC, CKUB
BJM, BJL,
BJK, CEBB,
CECA, CECB,
CKTB, CKTC,
CKUC, CKUB
Capacity 2) 2.1 l 2.1 l 2.1 l
Crafter 2006 ➤
AG.
(ETKA)
3.2 Technical data for transfer box
Technical data for transfer box
Type of transfer box Self-contained 3 shaft transfer box
for permanent drive and with reduction
gearing i = 2.5. 100% central
differential lock operated via
electric control motor
Type of drive Permanent four-wheel drive
Type of reduction gearbox Layshaft
Ratio high 1.000
low 2.488
Oil capacity 1.37 litre
Oil viscosity SAE 75W-90
Oil type ⇒ Electronic Parts Catalogue “ETKA”

The following data can be found in the ⇒ Electronic Parts Catalogue
“ETKA” :
♦ Gear oil
3.3 Calculation of gear ratios
Example: 48 : 11 = 4.364
Z2 : Z1 = “i” 1)
1) Z1 = no. of teeth on driving gear, Z2 = no. of teeth on driven
gear, i = gear ratio
Crafter 2006 ➤
3. Technical data 9
AG.
4 Overview - power transmission
⇒ “4.1 Overview - power transmission - four-wheel drive”,
page 10
4.1 Overview - power transmission - four-wheel drive
1 - Front final drive
❑ Removing and installing
⇒ page 27 .
❑ Optionally with differential
lock
2 - Front propshaft
⇒ page 102 .
3 - From manual gearbox
4 - Transfer box
❑ With reduction gearing
⇒ page 12 .
5 - Rear propshaft
⇒ page 104 .
6 - Rear final drive
⇒ page 42 .
Crafter 2006 ➤
AG.
34 – Controls, housing
1 Transfer box, Crafter 4MOTION with
Achleitner four-wheel drive
⇒ “1.1 Assembly overview - transfer box”, page 11
⇒ “1.2 Removing and installing transfer box”, page 12
⇒ “1.3 Removing and installing rubber bush and rear bracket of
transfer box”, page 15
⇒ “1.4 Removing and installing upper bracket for transfer box”,
page 17
⇒ “1.5 Removing and installing rubber bush and front bracket for
transfer box”, page 19
⇒ “1.6 Removing and installing front bracket for transfer box”,
page 20
⇒ “1.7 Checking and replenishing gear oil level in transfer box”,

page 21
⇒ “1.8 Removing and installing transfer box control motor V455 ”,
page 23
⇒ “1.9 Removing and installing pneumatic actuator”, page 24
1.1 Assembly overview - transfer box
Crafter 2006 ➤
1. Transfer box, Crafter 4MOTION with Achleitner four-wheel drive 11
AG.
1 - Rear bracket for transfer
box
⇒ page 15 .
2 - Bolts
❑ Qty. 5
❑ Renew after removal
❑ 40 Nm
3 - Shims
❑ Qty. 10
4 - Nuts
❑ Qty. 3
5 - Transfer box
⇒ page 12 .
6 - Front bracket for transfer

box
⇒ page 20 .
7 - Underride guard
8 - Bolts
❑ Qty. 2
❑ 69 Nm
9 - Bolts
❑ Qty. 2
❑ 72 Nm
10 - Rubber mounting
❑ Qty. 2
❑ Renew if damaged
❑ Removing and installing ⇒ page 19 .
11 - Bolt
❑ 21 Nm
12 - Pneumatic actuator
❑ Removing and installing ⇒ page 24
13 - Securing clip
❑ Must be heard and felt to engage.
14 - Transfer box control motor - V455-
❑ Removing and installing ⇒ page 23 .
1.2 Removing and installing transfer box
Special tools and workshop equipment required
Crafter 2006 ➤
12 Rep. gr.34 - Controls, housing
AG.
♦ Engine and gearbox jack - VAS 6931-
♦ Tensioning strap - T10038-
♦ Torque wrench - V.A.G 1331-
Removing
– Refer to general repair instructions ⇒ page 3 .
– Remove rear propshaft ⇒ page 104 .
– Remove front propshaft ⇒ page 102 .
– Remove constant velocity joint shaft ⇒ page 108 .
Crafter 2006 ➤
AG.
– Disconnect electrical connectors.
– Relieve pressure in air system ⇒ page 136 .
– Disconnect air lines -arrows- from pneumatic actuator -1-.
– Remove bolt -arrow- and release electrical wiring harness
from transfer box bracket.
– Release electrical wiring harness -arrow- from retainers on
transfer box.
– Pull breather line -arrow- off transfer box -1-.
Crafter 2006 ➤
AG.
– Position engine and gearbox jack - VAS 6931- -1- under transfer
box -arrow-, and secure it with a tensioning strap -
T10038- .
– Remove bolts -arrows- from front bracket -1- of transfer box.
– Remove bolts from rear mounting.
– Slowly lower front bracket with transfer box -arrow- and engine
gearbox jack - VAS 6931- -1-.
Installing
Install in reverse order of removal, observing the following:
Note
♦ Always renew self-locking nuts and bolts.
♦ Always renew corroded nuts and bolts.
♦ Cable retainers and clips which were removed or loosened
must be reinstalled in the same positions.
– Install rear propshaft ⇒ page 104 .
– Install front propshaft ⇒ page 102 .
– Install constant velocity joint shaft ⇒ page 108 .
Specified torque
Component Specified torque
Bolt for rear rubber bush of
transfer box
85 Nm
Bolts for securing rubber bush 30 Nm
1.3 Removing and installing rubber bush

and rear bracket of transfer box
Crafter 2006 ➤
AG.
♦ Engine and gearbox jack - VAS 6931-
Removing
– Remove rear propshaft ⇒ page 104 .
– Remove bolt -arrow-.
– Detach electrical wiring harness from transfer box bracket.
– Position engine and gearbox jack - VAS 6931- under transfer
box to support it.
Crafter 2006 ➤
AG.
– Remove bolt -arrow- for rear mounting -1-.
– Lower transfer box slightly to gain access to centre securing
bolt using engine and gearbox jack - VAS 6931- .
– Unscrew bolts -arrows- for bracket from transfer box.
– Remove retainer -1-.

– Unscrew bolts -arrows- from rubber bush.
– Remove rubber bush -1-.
Installing
Note
♦ Cable retainers and clips which were removed or loosened
must be reinstalled in the same positions.
– Install rear propshaft ⇒ page 104 .
Specified torques
♦ ⇒ “1.1 Assembly overview - transfer box”, page 11
Bolt for rear rubber bush of
transfer box
85 Nm
Bolts for securing rubber bush 30 Nm
Collar nut securing propshaft to
transfer box
85 Nm
Bolts for rear bracket on transfer
box
40 Nm
1.4 Removing and installing upper bracket
for transfer box
Crafter 2006 ➤

AG.
Removing
– Remove transfer box ⇒ page 12 .
– Unscrew bolts -arrows- from bracket -1-.
– Unscrew bolts -arrows- for front bracket.
– Remove bracket -1- at top.
Installing
Note
– Install transfer box ⇒ page 12 .
Specified torques
Crafter 2006 ➤
AG.
Number Designation Torque
1 Bolt M12 × 1.5 × 30 75 Nm
2 Bolt M10 × 1.5 × 25 61 Nm
3 Bolt M8 × 1.25 × 16 30 Nm
4 Bolt M12 × 1.5 × 30 75 Nm

5 Bolt M10 × 1.5 × 25 61 Nm
5 Bolt with spacer washer M10 × 1.5
× 60
61 Nm
1.5 Removing and installing rubber bush
and front bracket for transfer box
Removing
– Remove bolt -arrow- from rubber bush -1-.
Crafter 2006 ➤
AG.
– Unscrew bolts -arrows- of rubber bush on gearbox carrier
-1-.
– Take rubber bush off mounting.
Installing
Note
♦ Before installing a new rubber bush, thoroughly clean mounting
of dirt and soiling.
Specified torque

Bolts for securing rubber bush
to gearbox carrier
30 Nm
Bolt for rubber bush to transfer
box bracket
72 Nm
1.6 Removing and installing front bracket for
transfer box
Removing
– Remove transfer box ⇒ page 12 .
– Remove bolt -arrow- for side cover -1- on transfer box.
Crafter 2006 ➤
AG.
– Unscrew bolts -arrows- of side cover -1-.
– Remove cover.
– Unscrew bolt -arrow- from front bracket -1- for differential lock.
– Unscrew bolts -arrows- from front bracket -1-.
– Remove front bracket for transfer box.
Installing
Note

– Install transfer box ⇒ page 12 .
Specified torques
Bolts for securing rubber bush
to gearbox carrier
30 Nm
Bolts at front of bracket
M12 × 45
69 Nm
Bolt at rear of bracket
M10 × 1.25
40 Nm
1.7 Checking and replenishing gear oil level
in transfer box
Crafter 2006 ➤
AG.
♦ Used oil collection and extraction unit - V.A.G 1782-
♦ ATF filling unit - V.A.G 1924-
Gear oil for the final drive is available as a part ⇒ Electronic Parts
Catalogue “ETKA” .
Test precondition:
• Transfer box in installation position
– Clean area around filler plug with a cleaning cloth.
Crafter 2006 ➤
AG.
– Remove filler plug -1- and check that oil level is up to lower
edge of filler hole.
– Replenish oil as necessary.
Caution
Observe gear oil specification ⇒ Electronic Parts Catalogue
“ETKA” .
Never overfill, as this can cause leaks and damage to gearbox.
– Tighten oil filler plug with new seal.
Specified torque
Oil filler plug 37 Nm
1.8 Removing and installing transfer box
control motor - V455-
Removing:
– Release and pull off connector -arrow- of transfer box control
motor - V455- -1-.

Crafter 2006 ➤
AG.
– Unscrew bolts -arrows- from transfer box control motor - V455-
-1-.
– Remove transfer box control motor - V455- from transfer box.
Installing
Note
1.9 Removing and installing pneumatic actuator
Removing:
– Relieve pressure in air system ⇒ page 136 .
WARNING
Always wear eye protection, protective gloves and ear protectors
when working on compressed air system.
The air system works with approx. 10 bar.
Relieve air pressure before working on system ⇒ page 136 .
– Disconnect air lines -arrows- at pneumatic actuator -1-.
Crafter 2006 ➤

AG.
– Release retaining clip -1- in -direction of arrow- and remove
clip -arrow-.
– Unscrew bolt -arrow- on bracket -1-.
– Remove control cylinder.
Installing
Note
– Carry out pressure test ⇒ page 140 .
Specified torques
Crafter 2006 ➤

Rear - Axel Parte 1

Uploaded by

Copyright:

Available Formats

You might also like

Rear - Axel Parte 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rear - Axel Parte 1

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

List of Workshop Manual Repair Groups

39 - Final drive - front differential

39 - Final drive - differential

matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg K0059031520

1.1 Rear axle type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Advantages of four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Function of permanent four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Gaskets, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.1 Technical data for rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 Technical data for transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.1 Overview - power transmission - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Transfer box, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . . . . . . . . . 11

1.1 Assembly overview - transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.4 Removing and installing upper bracket for transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.6 Removing and installing front bracket for transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.7 Checking and replenishing gear oil level in transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.8 Removing and installing transfer box control motor V455 . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.9 Removing and installing pneumatic actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1 Front final drive, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . . . . . . . 26

1.1 Assembly overview - front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2 Removing and installing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.5 Renewing oil seals on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.1 Assembly overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.3 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.1 Renewing seal for propshaft flange of rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Rear axle and rear final drive - Edition 12.2014

4.1 Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.2 Removing and installing drive pinion and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.5 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.6 Overview of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.8 Tables for printing out, crown wheel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.9 Adjusting drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.10 Tables for printing out, drive pinion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5.1 Assembly overview - propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Achleitner four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

5.4 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

5.9 Renewing centre bearing of two section propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.10 Renewing centre bearing of three-section propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

5.11 Renewing front centre bearing of propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.12 Installing protective caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5.14 Removing and installing damper weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

6 Air compressor/pressure accumulator, Crafter 4MOTION with Achleitner four-wheel drive

6.1 Assembly overview - air compressor V534 /pressure accumulator . . . . . . . . . . . . . . . . . . 131

6.3 Releasing pressure before working on compressed air system . . . . . . . . . . . . . . . . . . . . . . 136

6.7 Performing pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140