Whats Inside a Touareg Transfer Case?

[@rodcosta2345]

I don’t even own a Touareg and yet here I am. Thanks guys, great content.

[@MrTheHillfolk]

Me either. I just like to see broken stuff.

[@altergreenhorn]

Owned one much newer than this but no thanks. One was enough.

[@MrTheHillfolk]

@@altergreenhorn I'd like to get my mitts on one of those v10 diesels "to make something stupid go fast" like my high school shop teacher said some of us would end up doing in life.

[@namdar79]

"Found nothing, and know nothing". Brilliant! If only more people in life would be this realistic and humble, the world would be an even better place ;)

[@rbfokc3470]

Chain is stretched 100%. My 2009 Touareg 3.6 VR6 had the same issue. Same sounds and everything. Bought a chain off of Amazon. HV-082 part number $90. It's a NV235 transfercase. I actually separated the case with it still bolted to the transmission. Pull both drive shafts (drop crossmember to get the front shaft out of the way don't have to remove it) remove the front drive shaft yoke (12point 36mm) then all the case bolts and pull it apart. All the internals will stay with the rear case half your pulling off (it's heavy, have a friend or be strong lol) Old chain looked like it wasn't slipping no wear marks, no metal on the magnet. Holding it next to the new chain is was only slightly longer than the new one. I was concerned the chain wasn't the issue. Then trying to get the new chain on it was pretty tight and took more effort to get it around the gears, so yeah. Good as new no more noise. Didn't replace anything else. Cleaned all the internals. Cleaned out the oil pump. New oil (Triax DTF-1 requires .7QT but i dumped the whole QT in it) $40 on Amazon. Runs like a champ no more noise. Only "special" tool needed was the 36mm 12point socket for the yoke. You can use a regular torx sockets on the 12point torx that VW likes to use. Triple square I think they are called. I don't have any I just use regular torx sockets (drive shaft uses the triple square bolts) It's not a hard job, you can leave the rear yoke on unless you wanna take everything apart to clean it. It's also 36mm 12pt but you need a deep socket for the rear yoke. If you take everything apart make sure you put the thrust washers back where the belong. Just pay close attention when you're taking it apart and you'll be fine. Easy transfercase to work on. Nothing fancy. For about $150 and some time you can fix this issue in your driveway. I believe in you ❤️🤣

[@leoaranda2957]

Did you just replace the chain?

[@rbfokc3470]

@@leoaranda2957 yup! Still going strong.

[@leoaranda2957]

I also Will do on My cayenne 2010 tky buddy

[@tl6708]

Thank you so much for your advise. I have a 2010 Cayenne with 215K miles. The noise started around 195K.

[@BoneyBobsTreasure]

Brilliant, thank you a million times, I have been working at cars for thirty years or more but have not worked on 4WD before and just finished putting a refurb transfer case back in my Cayenne using your video and can declare you are the KZbin Transfer Case Kings, I searched all the other material and yours is the best AND it is packed with good details that mean I watched it three times to squeeze our all the use eg your camera work is detailed enough you don't need to explain the bolt/washer/nut set up on the driveshaft damper rubber, we can see all we need just from the footage. Thanks for this, a huge help.

[@now22207]

I've owned a 2012 Touareg for four years now. Geez! I don't have this issue, but your video was so through and engaging, I watched three more...then subscribed. Awesome and Knowledgeable

[@EAGLECO1994]

Thanks for posting this video! Your clip of the knocking on launch is exactly what my Cayenne GTS was doing. Really made me confident in tackling the swap myself! Love driving it after the replacement.

[@theblackknightmoore3250]

Did you get transfer case replaced? And did it fix it? my Porsche is doing the same thing

[@rossbowman202]

I prefer to use a grinder and reciprocating saw to take my transfer cases apart too. Great video.

[@davebalz4039]

Great job on the transfer case. Have some Bizzarre noises on ‘06 Cayenne Turbo S. Suspicion is transfer case related. Seemed perhaps caused by actuator. Have new actuator. Studying actuator positioning. Thanks! Enjoyed the sparks on the mystery disassembly. Side grinder, easy outs, mallets! I love precisión work. Back in my spherical roller bearing manufacturing days as engineer, our saying was “measure it with a tape, mark it with chalk, and cut it with a torch! Ha. Nice work. Thank you.

[@mmccorm11]

Whoever is putting the references in during editing is doing you a solid favor. “WHAT’s IN THE BOOOOXXXXX”

[@blackericdenice]

I rebuilt my 96 4x4 Tahoe transmission and had to remove a transfer case. I did it on my back alone twice. My transmission last 3 years until I installed a cam in my 5.7. This brings back many memories.

[@grenmastermike]

Definitely tore a Jeep transfer case apart that sounded the same. There was no carnage in that either. What is happening is the chain is stretching and the lubricating fluid is keeping the metal from chipping away when the chain skips a tooth.

[@Free76Thinker]

I'm hoping this is the case, I just started having this same issue. He is a video of mine making the same noise. A used transfer case is like $650. kzbin.info/www/bejne/mZmYqZxunpempsU

[@joseph8626]

Haha "What we learned about this thing is we didn't learn a god damn thing"-DAP

[@busrsq]

100% chain, I have had the same in a toyota gearbox, get the measurement from VW and you will find it has stretched

[@Super73VW]

Yup! Slappy Slap! Find where the chain was slapping the case

[@ml414skidoo]

Same as Mercedes V8's, they can stretch the chain.

[@campervan6668]

No idea what's going on here, but I do like to watch how you use all this stuff and like your shop!!!!

[@itskarl79]

probably stepper motor not fully engaging the selected hi or low mode... shifting fork seemed stuck when you disassembled the transfer case, maybe the linkage was overcammed (rotated too far) and had it stuck... It's possible that if you had removed the stepper, unstuck the shift linkage and reset the stepper to the correct position and reinstalled it would have been fine.... But still wouldn't have prevented it from happening again.. Replacing the transfer case with a good cheap used one was probably the most cost effective solution.

[@LandRoverDS2020]

They did check the stepper motor

[@volpswagen_marco]

After seeing all the internals, this theory seems most plausible

[@mikeoberle6413]

I realize this video is a couple of years old. My '05 made the same noise. The noise was coming from the incomplete shift selection of high/low. The actuator motor was removed, cleaned, new brushes, then assembled and installed to correct orientation after manually rotating the shaft to high position. Got in the car and ran the high/low through several cycles then drove. Noise gone. I agree. It looks like the high/low was over-rotated. Probably from the servo being misaligned.

[@Devocated]

I love the discussion of chains in front of a B6 S4

[@mannygsx]

Wolf auto is not far from me and their customer service is extremely excellent

[@jamesmcfaddin1789]

I had a Cadillac suv with a t-case sound exactly like what you had. Common issue on that caddy t-case: the chain stretches just enough to skip gears...won’t leave shavings or metal because it’s a softer metal than the gear itself.

[@josephwhiton1387]

Same thing happens on this case also. Chains will stretch by almost 3/4 inch! Popping under throttle.

[@joshuam7552]

You guys already had really informative videos before, but the added satire makes them entertaining as shit! Love watching the videos!

[@aniebrown2016]

Presentation was very well done, enjoyed it.

[@thesalvistyle5802]

my Touareg 2005 V8 was making the same noise, and I would get the blinking lights on the t-case selector switch. I replaced the stepper motor (transfer case motor) and has worked fine the noise went away and no more blinking light on the selector switch.

[@mongorie]

Send it to Charles,he loves that stuff

[@grumpydevildog1462]

Another quality video from DAP😍

[@scalley]

DIY Colonoscopy tutorial next?

[@hallkbrdz]

Awesome video (at least the how-to swap part, not sure about the destructive inspection LOL). Great reference for the near future as I have the same noise on my '06 v10, although it only does it briefly under WOT from a stop (so I don't do that). I would have guessed the noise is a stretched chain hitting the case, AND... it looks like there are some - look at 1:57 at the bottom of the case. Look at those worn ribs! The chain won't show wear, it's much harder than the aluminum case.

[@thelol1759]

Hey DAP, I think it may have been worth trying to change the fluid a few times and seeing if that got rid of the noise. It sounds a bit to me like when someone needs to add a limited slip additive to an EP lube.

[@thelol1759]

Commented this before I finished the video fyi

[@spinnetti]

Mine used to do that once in a while - was just stepper motor causing it - since you took the stepper out, could it still be whatever the stepper actuates? - or does the stepper just put the squeeze on the clutch pack? I know when I tried to pull the drive shaft it took two men and a boy to get the damn thing loose. It was like it was welded on.

[@jamest5149]

I guarantee the chain has stretched and jumps the teeth. It’s common on many vehicles with transfer cases like Land Rover/Range rovers, Jeep’s etc. Never start hitting things in a gear box with a hammer, I am surprised you didn’t end up getting shrapnel in the face or body.... Very dangerous, use a copper/hide/de blow hammer like you started using on the second day.

[@crescentandstarglory]

James T Wouldn’t a skipping chain show wear marks?

[@altergreenhorn]

Not necessary jumps the teeth. Maybe just banging on something because it's stretched or just vibrate with that sound

[@yungsta18]

mine is doing the same thing.... guess one day in the distant future i'll be able to fix it by getting another transfer case.... i wish yall would have figured out what happened to it but regardless good content for sure .... thanks

[@michaelp9061]

So HAPPY for YOU !! hard work do pay off

[@OsamahAlQaisi]

Thanks alot video came on time I have this issue from several months and I got tired searching for a good solution , keep us updated if you found what is the issue with the replaced transfer case

[@erikthie2253]

can you do a video on the kessey door locks? i mean when you touch the door to lock the car, and what the issues are if they stop working. also, how to fix and replace. thanks!

[@happy543210]

not finding a cause of failure is very concerning! with all that metal clanking, you should have seen shards somewhere.

[@MrTheHillfolk]

I guess they should reassemble and install it and keep grinding on it in the car until the wear is found 🤣

[@dailylife3975]

Probably front dif

[@dailylife3975]

Or drive line the rubber bushing wears out

[@luisa.hernandezc.7773]

On today episode of my home garage we finally do the Transmission service on this 2014 VW Touareg TDI with the Aisisn 8 speed Transmission . Little did we know we were low on fluid explains some of the weird cold shifts and shifting habits of vehicle,.

[@abdulnasserlawi7619]

Yes please and also the headliner removal

[@r.weaver3769]

What page of the service manual are the instructions for using grinder and sawzall? still looking...

[@fredygump5578]

It could be a worn syncro, preventing AWD from engaging. You wouldn't be able to figure that out without detailed specifications and the right size/ kind of micrometer.

[@OldWurlitzerMusic]

i had the same noise , in 4 low , in normal high it was fine , i changed the special transfer case fluid and all is ok now , identical sound while i was in the deep snow when it happened,,, 06 touareg v6 3.2 full air suspension

[@abdulnasserlawi7619]

What oil you have used can you share part number?

[@garyjacobs3110]

I have the same problem on a 2004 Porsche 955 Cayenne Turbo with 183000 miles. Would you recommend finding a used transfer case or getting a remanufactured one. Also can you give me some options on where to find the transfer case as well as Wolf Auto.Thanks love the video and your channel.

[@Antonyg2100]

"Grinder" the one tool that is always the right size haha

[@tomaunofilms534]

You did it MAN!! A lot of work!!

[@ben7020]

I've had a 4wd front wheel hub skipping and sounding terrible like your video. I took it apart and no damage was visible, just wasn't engaging 100%. I'd suggest the stepper engagement was playing up

[@rkan2]

Yeah, I think something to do with the stepper motor too.

[@JCHerrera007]

Thanks guys. I’m fixing a TReg as well. Can’t wait for your next update with it. Questions, one my lower control arms on my ‘04 Treg is busted. Should I go ahead and do both lower control arms? Entire upper and lower arms on both sides? What parts brand do you recommend? Just wondering. This car is a keeper so looking for expert opinion.

[@n9wox]

Makes FWD only look beautiful.

[@ramtinhv2400]

i think i found the problem 😁 if you pause the video at 2:55 or 2:56 you can see transfer case splines that mates output shaft of gearbox are damaged. and when locating the 10 transfer case bolts in the video you can see the splines inside the stock transfer shaft are in good condition. kia and hyundai suv's have the same problem but mostly both the transfer case and the diff housing get damaged together. when the transfer case spline tooth start skipping it makes sounds like sounds in video; if you don't repair it soon both splines get damaged and the power not transferred to rear wheels any more.

[@geirkleven3936]

You must put the chain on to the wheel and see if its stretched, you cant see that just by looking at it.

[@fidoexpeditions9366]

Some pretty heavy duty stuff!

[@richardanita]

The problem was caused by the chain. I have heard the same noise from New Process transfer cases in GM products many times.

[@frederiquekruger4818]

That's correct.

[@jonathanbrand1270]

Really awesome video

[@queenwolf16875]

I take back what I said this a very good and interesting video

[@jmcdetail]

Great video guys! Keep the Touareg videos coming! Thanks!

[@shermgohn]

I've thought about buying a Touareg W/ a diesel 3.0L , A good move or not? I've been second thinking because I'm not sure about reliability and I'm not a mechanic but I can do quite a few repairs myself. Should I or should I not?

[@douglasfeeley5502]

I see you're using some of your suspension install tips on the transfer case!! :-)

[@dlessard2369]

Might it be the front split drive shaft that has a housing under the cross support with 1/2 inch thick ? I don't know what it is called but it could make that type of sound that will travel.

[@einfelder8262]

One thing we have learned from this - the transfer case is massively strong for the weight of the car. Overbuilt for sure.

[@MrTheHillfolk]

1:19 Airgun makes the same sound as the transfer case did. I know the problem , someone left their airgun inside the transfer case. 😁

[@simondunstall3520]

Hey guys you should do a video on how to change the front head light trays both my bolts to move the light assembly are now broken, i hear its a 3 hour job?

[@chriskelvin248]

Wait, wut? So there was no physical damage to the innards of the t-case? I guess you just had a clack-a-dack-a-dack stuck in there. Probably oozed out when you drained the gear oil. Shame. All you had to do was refill the case to spec and there you go!

[@Rachmaninoff85]

Is the syncro westfalia going to be a future video?

[@sfseals]

What is the part you removed at 1:18? Looks like a bearing connecting to the front drive shaft. My transfer case is making a high pitched whining noise (not clicking like yours). Wondering if i can try swapping out that bearing. Suggestions?

[@joshbridges6299]

they are just trolling guys. its was chain stretch/wear. i will post a video tomorrow of mine. same exact thing

[@Deutscheautoparts]

Not trolling there was no evidence of a jumping chain upon disassembly. Replacing the transfer case took care of our issue. I’m pretty confident that the chain was stretched but there’s no replacement option so no way to know for sure

[@joshbridges6299]

k

[@rbfokc3470]

@@joshbridges6299 so did changing the chain fix it? any evidence? not being mean just asking because mine is doing same thing lol

[@alexanderfields4172]

it is the chain.

[@shimon2476]

Hey I followed your disassembly tutorial meticulously everything went fine I'm having a little issues in reassembly any chance you guys make a video on that? thanks.

[@aronbennett4760]

You guys rock... I hope to one day have my T1 Touareg back on the road.

[@mihao21]

You didnt upload the video on KZbin how you repaired the engine.

[@FairladyS130]

Take your transferred AWD to these guys to fix, the fix will be putting a used transfer of unknown condition in it. Brilliant.

[@slocavky]

I wonder if since that transfer case shifter rod was stuck.... wonder if it was stuck between high and low?

[@fishmonger6879]

I bought a 2009 Touareg 2 TDI new, still driving it today with 185,000 miles. I can't find me service records. Should I drain and flush the trans at this point? One dealer suggested against it.

[@audiwankenobi361]

Im looking for a RNS-510 radio for my Passat.....gonna give Wolf Auto a try.

[@ajnanyc]

My 05 T1 just started to have this issue. Any idea if the chain can be replaced with a new one? I see them for sale and it seems like the most logical route to follow for this issue.

[@MrLakerboy824]

You should make a video about the common mk5 sunroof leak and how to replace the tube coming from the rear pillar.😔😐

[@christhebeau]

Everything about that car transfers into the Porsche Cayenne as well.

[@pehrjansson9606]

I'm not a mechanic, but it sure seems you'd suspect chain stretch to be the culprit. Just curious what would have been the result of checking the chain for stretch and replacing the chain if it were faulty instead of destroying the transfer case.

[@dreamitbuildit1380]

Was it maybe the chain being loose and hitting the case? 🤔

[@likhwadube5937]

Dream it, build it! There would be wear on the chain, a few metal bits all over the place & wear on the case itself? 🤔

[@dave-osmodernlife6885]

Always a good sign when initial pull out is smooth....now did you remember the magnetic tray stuck to the gastank strap before lowering it?

[@Deutscheautoparts]

Yup, almost forgot it ; )

[@V10PDTDI]

@@Deutscheautoparts was the the new to you transfer case filled with oil ? because most of the recycling yard drain the fluid before shipping it to customers.

[@ralphrousseau6986]

hello i have a touareg 2010 TDI 3.0 i would have to change the the front light for LED is it possible or not . If it possible can you tell me what type of LED should i buy

[@dejanmeki]

what oil grade should go to transfer case ?? how about Royal Purple® Synchromax for manual transmission ? is it good enough ?

[@VelleyIndustrial]

Was this a Haldex t-case?

[@Zionfarm]

Congrats guys.

[@yankeedoodle6293]

My 2016 Touareg TDI has some slight hesitation/jerking when I accelerate at lower speeds (25-30mph. Do I need to change fluids in the transfer case ? Dealer couldn’t figure out the problem

[@Bingzor1337]

Wrong/old oil, causing por friction on discs. Engages enough to build tension to chain, but when discs slip the tension slaps back causing «metallic noise». That could have been repaired with oilflush and new oil and a few km’s arohnd the block.

[@Free76Thinker]

Thanks for the tip,think I'll try this first as mine '08 Treg is making almost this same noise. kzbin.info/www/bejne/mZmYqZxunpempsU

[@crysmc5272]

Hey DAP, I placed an order one week ago and cannot seem to get in contact with you regarding status. What do I need to do to get my items or refund, please??

[@davidraezer5937]

The chain stretched guys!

[@Deutscheautoparts]

Google transfer case chain stretch. It looks to be pretty common on Jeeps

[@benndjokic9797]

Why you didn’t try a new steper motor before removing the old transfer case. I see thet you remove the stepper motor but you should try a new one.

[@lukasschmid1623]

VW mechanics are happy with the VW,s

[@jjmarz1001]

Looks like it needed fresh oil.

[@andrewdoig9937]

My Touareg made a similar noise from the transfer box - but not as bad. I drained the oil and didn't see any metal in the oil so I simply changed the t.box oil and the noise disappeared! I think you could have done the same!

[@Free76Thinker]

I hope you are right. Mine just started making this same noise this week. I will try new fluid first. Here is mine making the noise. kzbin.info/www/bejne/mZmYqZxunpempsU

[@abdulnasserlawi7619]

What fluid you have used?

[@MetalRay88]

Bad stepper motor ?

[@gabrielleal4366]

Good video!!!

[@arborharbor7408]

Can this be done without a lift? (replacement)

[@mjbalice]

Gotta admit the size of transfer case for the Touareg is big. I’ve seen full size trucks with transfer cases that big or smaller

[@JDLNYC]

Stretched chain had same issue simple fix no need for new case they are built like tanks

[@Confused_engr]

My touareg makes a "dhak dhak" noise when I got the accelerator when moving forward after a stop.

[@bryonfaust5243]

Like a BOSS

[@index6738]

That chain was stretched badly, and would have slapped around and likely jumping teeth. You made no observation or bothered to measured chain stretch.

[@chrisr5364]

My transfer case broke twice on my t reg..

[@audiwankenobi361]

Even tho I drive VW im officially terrified of Touaregs.....if i should ever need a tow vehicle or another SUV ima get a Tahoe.

[@Michaeltje89]

Gears?

[@kenwang4139]

Does anyone have way to unstuck from low reduction? Can't find anymore info than replacing the step motor (which did not work) or removing and dismantling the entire unit.

[@patricekonrad4972]

Top top top !!!