2004 Volkswagen Caddy Van transmission fastener tightening specifications

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Condition	Value

expand_moreAxle drive


AWD clutch oil control screws	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Oil filler screws.
AWD clutch oil drain plug	28.03 lbf⋅ft28.03 lbf⋅ft38 N⋅m
Replace sealing rings.

expand_moreFront axle drive shaft


M8 screws	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
M10 screws	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
Replace screws.

expand_moreCentral screws

expand_moreHexagon


First stage	147.51 lbf⋅ft147.51 lbf⋅ft200 N⋅m
Use new screw.
Second stage	180°180°180°

expand_moreBi-hexagon

Figure 1. Axle drive, Front axle drive shaft, Central screws, Bi-hexagon.

expand_moreWithout ribbing
See figure 1.


First stage	147.51 lbf⋅ft147.51 lbf⋅ft200 N⋅m
Use new screw.
Second stage	180°180°180°

Figure 2. Axle drive, Front axle drive shaft, Central screws, Bi-hexagon.

expand_moreWith ribbing
See figure 2.


First stage	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
Use new screw.
Second stage	90°90°90°


Propeller shaft intermediate bearing	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_morePropeller shaft


At the gearbox	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m

expand_moreOn rear axle


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace screws.
Second stage	90°90°90°

expand_moreRear axle drive shaft


M8 screws	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
M10 screws	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
Replace screws.

expand_moreCentral screws

expand_moreHexagon


First stage	147.51 lbf⋅ft147.51 lbf⋅ft200 N⋅m
Use new screw.
Second stage	180°180°180°

expand_moreBi-hexagon

Figure 3. Axle drive, Rear axle drive shaft, Central screws, Bi-hexagon.

expand_moreWithout ribbing
See figure 3.


First stage	147.51 lbf⋅ft147.51 lbf⋅ft200 N⋅m
Use new screw.
Second stage	180°180°180°

Figure 4. Axle drive, Rear axle drive shaft, Central screws, Bi-hexagon.

expand_moreWith ribbing
See figure 4.


First stage	51.63 lbf⋅ft51.63 lbf⋅ft70 N⋅m
Use new screw.
Second stage	90°90°90°

expand_moreClutch

expand_moreClutch pressure plate

expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 4000 RPM, 250 N⋅m at 1900 RPM engine (2004.4–2010.8)


M6	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Gradually tighten screws crosswise.
M7	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Gradually tighten screws crosswise.

expand_moreClutch slave cylinder

expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 4000 RPM, 250 N⋅m at 1900 RPM engine (2004.4–2010.8)


0A4 gearbox	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOtherwise


With plastic concentric slave cylinder	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Use new screws.
With metal concentric slave cylinder	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m
Use new screws.


All other modifications	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreRelease bearing guide sleeve


All Volkswagen diesel straight-4 1.9 Liters BJB engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Volkswagen diesel straight-4 1.9 Liters BLS engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreAll other modifications


First stage	3.69 lbf⋅ft3.69 lbf⋅ft5 N⋅m
Use new screws.
Second stage	90°90°90°

expand_moreDifferential


Rear axle differential oil control screws	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Oil filler screws.

expand_moreGear shifting


Back-up lamp switch	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Gearbox shift lever	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m
Replace nuts.
Selector cable linkage	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreGearbox

expand_moreGearbox flange connection at engine


M10	59 lbf⋅ft59 lbf⋅ft80 N⋅m
M12	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreGearbox lubrication


Distributor gearbox oil drain plug	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
Replace screws.
Distributor gearbox oil filler screws	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreGearbox oil drain plug


0A4 gearbox	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_more5-speed 0AH transmission


Hexagon head screws	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
With Torx screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more02Q gearbox


Hexagon head screws	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace sealing rings.
With Torx screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace sealing rings.

expand_moreDSG 02E gearbox


Overflow pipe	2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m
Locking screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace sealing rings.

expand_moreGearbox oil filler plug


0A4 gearbox	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
Fill in gear oil via hole for back-up lamp switch.

expand_more5-speed 0AH transmission


Hexagon head screws	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
With Torx screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_more02Q gearbox


Hexagon head screws	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Replace sealing rings.
With Torx screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace sealing rings.

expand_moreDSG 02E gearbox


Locking screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace sealing rings.

expand_moreGearbox oil filter cover


DSG 02E gearbox	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreOil control plug

expand_moreFront wheel drive


Overflow pipe	2.21 lbf⋅ft2.21 lbf⋅ft3 N⋅m
Locking screws	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Replace sealing rings.

expand_moreGearbox mounting

expand_moreScrews at the gearbox bracket


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Replace screws.
Second stage	90°90°90°

expand_moreOn chassis


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage	90°90°90°

expand_moreGearbox support

expand_more0A4 gearbox


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage	90°90°90°

expand_more02Q gearbox


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Replace screws.
Second stage	90°90°90°

expand_moreDSG 02E gearbox


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Replace screws.
Second stage	90°90°90°

expand_moreTransfer case

expand_moreTransfer box bracket


First stage	Tighten by hand
Second stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreFlange connection

expand_moreTransfer box onto transmission


First stage	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m
Second stage	90°90°90°

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Volkswagen Caddy Van user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Volkswagen warranty policy for your region. In some regions DIY service may invalidate your warranty.

Maintenance Items

Chassis and Body Fastener Tightening Specifications
Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Volkswagen Caddy Van service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2004 Volkswagen Caddy Van you're not only saving money, but also also improving your technical skills and learning something new.

2004 Volkswagen Caddy Van Third generation Transmission Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Volkswagen Caddy Van Third generation model years

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