Service: Crafter 2006

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Crafter 2006 ➤
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Power take-off (PTO)
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Edition 05.2014
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Service Department. Technical Information

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List of Workshop Manual Repair Groups
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Repair Group
00 - Technical data
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34 - Controls, housing
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E80448B1A

Crafter 2006 ➤
Power take-off (PTO) - Edition 05.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General notes on power take-off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Selector operation and management AG. Volkswa. g.e.n .A.G.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2 Technical data . .by.V. . . . . . . . . . . . . . . . . . . . . . . o.t .gu. a. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Technical dataoris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.ee. . . . . . . . . . . . . . . . . . . . . . . . . .
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Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . . . . . . . . . . . 5
ss
3.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.2 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.3 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.4 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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spec
1 Power take-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.1 Assembly overview - power take-off housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Assembly overview - power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Assembly overview - intermediate gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
rrectne
1.4 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
s
1.5 Assembly overview - selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.6 Removing and installing power take-off housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.7 Removing and installing input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
mer
1.8 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.9 Removing and installing intermediate gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n 19

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1.10 Removing and installing selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.11 Dismantling and assembling selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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1.12 Removing and installing power take-off flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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2 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.1 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.2 Removing and installing selector cylinder for power take-off . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.3 Bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
AG.
Contents i
Crafter 2006 ➤
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ii Contents
Crafter 2006 ➤
00 – Technical data
1 General notes
(VRL006820; Edition 05.2014)
⇒ “1.1 General notes on power take-off (PTO)”, page 1
⇒ “1.2 Functional check”, page 1
⇒ “1.3 Operation”, page 2
⇒ “1.4 Selector operation and management”, page 2
1.1 General notes on power take-off (PTO)

The optional power take-off is offered for the 6-speed manual
gearboxes.
Retrofitting the power take-off on vehicles without power take-off
is not planned.
The selectable, mechanically driven power take-off allows for
driving auxiliaries via vehicle's gearbox. Depending on the ver‐
sion, the gearbox may have a flange or an ancillary bolted on
directly.
Versions of power take-off:
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♦ with or without
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♦ with flange
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♦ WSG with variable or fixed engine speed

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1.2 Functional check

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The power take-off is driven by the layshaft of the manual gearbox

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The synchromeshed gear -4- drives the output shaft -3- or the
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gear wheel of the ancillary (not shown) via an intermediate gear

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-2-. The power take-off is engaged or disengaged via the selector

cylinder -5-, the selector fork -6- and the locking collar -7-.
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Note
Explanation of the selector mechanism function and control of the

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power take-off ⇒ page 2 .

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1. General notes 1
Crafter 2006 ➤
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Function of the gearbox shift lock
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To engage the power take-off,
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selector fork -5- via the selector rod. This causes the shoulder of
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the selector fork -arrow- to press the selector rod -4- upwards.
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Selector lever -3- moves into a striker -2- on selector lever -1-.
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The gear selector is now blocked.
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Function of the gearbox shift lock in the 0CB gearbox
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To engage the power take-off, the selector cylinder -6- presses
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the selector fork -4- via the selector rod -5-. This causes the
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shoulder of the selector fork -arrow- to press the selector rod -3-
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1.3 Operation
For vehicles with a gearbox lock, the manual gearbox is locked
when the power take-off is switched on.
On vehicles without gearbox lock, the power take-off can be used
when the vehicle is stationary or moving in 1st or 2nd gear.
For further information and safety instructions for operating the
power take-off, refer to ⇒ Crafter operation .
1.4 Selector operation and management

The power take-off is switched on and off with the working speed
governor switch - E261- . The gearbox selector cylinder is actu‐
ated by the control unit for programmable special functions -
J820- (vehicles with WSG) as well as by the power take-off valve
- N254- and the hydraulic pressure unit.
When the power take-off is switched on, the warning light in the
working speed governor switch - F247- is activated via the power
take-off warning switch - E261- .
The working speed of vehicles with WSG (Working Speed Gov‐
ernor) is controlled via the control unit for programmable special
functions - J820- . For variable working speed regulation, the
working speed can be set using working speed governor switch
2 - E604- .
2 Rep. gr.00 - Technical data

Crafter 2006 ➤
1 - Working speed governor

switch - E261-
2 - Working speed governor
switch 2 - E604-
❑ For vehicles with WSG
3 - Brake servo
4 - Vacuum reservoir
❑ Location: behind front
left wheel housing liner
5 - Hydraulic pressure unit
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❑ Generates hydraulic olksw not
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pressure and transfers it ise d b ara
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6 - Power take-off warning

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switch - F247-
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❑ For warning light in
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working speed governor
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switch - E261- and dash
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❑ For warning light for
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working speed governor
(WSG) in dash panel in‐
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7 - Selector cylinder
❑ On gearbox
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8 - Power take-off valve -
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❑ Actuated by the control

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unit for programmable special functions - J820- ⇒ Item 9 (page 3)

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❑ Directs vacuum to the hydraulic pressure unit ⇒ Item 5 (page 3)

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9 - Control unit for programmable special functions - J820- t. Cop py
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❑ Location: under left front seat
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❑ Controls the power take-off and regulates the working speed via the engine control unit - J623-
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1. General notes 3
Crafter 2006 ➤
2 Technical data
⇒ “2.1 Technical data”, page 4
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Depending on type of application, the operating time or the
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Gearbox 0B7 with power take-off
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Manual gearbox with pow‐ 6-speed 0B7
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Allocation Engine 2.5 l - 65 kW is n
2.5 l - 120 kW
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2.5 l - 80 kW
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2.5 l - 100 kW
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max. continuous output 28 kW 28 kW
max. torque 141 Nm 141 Nm
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min. engine speed (power 1200 rpm 1200 rpm
take-off with WSG)
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max. engine speed (power 2750 rpm 2750 rpm
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take-off with WSG)
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Power take-off speed 0.687 x engine 0.704 x engine
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speed speed
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Manual gearbox 0CB with power take-off
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Manual gearbox with pow‐ 6-speed 0CB

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Allocation Engine 2.5 litre - 65 kW 2.0 litre - 80 kW Cop py
2.5 litre - 80 kW 2.0 litre - 100 kW ht. rig
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2.5 litre - 100 kW 2.0 litre - 105 kW copy Vo
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max. continuous output 28 kW 28 kW
max. torque 141 Nm 140 Nm
min. engine speed (power 1200 rpm 1200 rpm
take-off with WSG)
max. engine speed (power 2750 rpm 2526 rpm
take-off with WSG)
Power take-off speed 0.757 x engine 0.756 x engine
speed speed
4 Rep. gr.00 - Technical data

Crafter 2006 ➤
3 Repair instructions
⇒ “3.1 Gearbox”, page 5
⇒ “3.2 Seals and sealing rings”, page 5
⇒ “3.3 Locking devices”, page 6
⇒ “3.4 Nuts and bolts”, page 6 AG. Volkswagen AG d
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To ensure flawless
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care and cleanliness
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are essential. Of course, the basic rules for safety also apply dur‐
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This chapter summarises a number of generally valid instructions
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applicable for the various repair procedures, formerly repeated in
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numerous sections in the workshop manual. They apply to this
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♦ During installation, ensure that the dowel sleeves between the
t to the co
engine and gearbox are correctly located.
♦ When installing mounting brackets or waxed components, the
rrectness of i
contact surfaces must be cleaned. Contact surfaces must be
free of wax and grease.
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♦ When renewing gearbox, gear oil must be refilled ⇒ 6-speed

manual gearbox; Rep. gr. 34 .
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♦ Gearbox capacity ⇒ 6-speed manual gearbox; Rep. gr. 34 .

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♦ Gear oil ⇒ Maintenance ; Booklet 10.2 .
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3.2 Seals and sealing rings

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♦ Before installing oil seal, half-fill space between sealing lips

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with sealing grease - G 052 128 A1- -arrow-.
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♦ The open side of the oil seal faces the side with fluid filling. rig ht
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♦ Following installation, check gear oil ⇒ 6-speed manual gear‐ cted agen
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box; Rep. gr. 34 .
♦ Lightly oil O-ring before installing; this prevents the rings being
crushed when inserted.
♦ Thoroughly clean parting surfaces and apply sealant - AMV
188 200 03- .
♦ Apply sealant uniformly but not too thick.
♦ Check oil level and top up if necessary ⇒ 6-speed manual
gearbox; Rep. gr. 34 .
3. Repair instructions 5
Crafter 2006 ➤
3.3 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot must be in line
with direction of force.
3.4 Nuts and bolts

♦ Loosen and tighten bolts and nuts for covers and housings
diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ 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.
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Rep. gr.00 - Technical data Prote
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Crafter 2006 ➤
34 – Controls, housing
1 Power take-off system
⇒ “1.1 Assembly overview - power take-off housing”, page 7
⇒ “1.2 Assembly overview - power take-off”, page 9
⇒ “1.3 Assembly overview - intermediate gear wheel”,
page 10
⇒ “1.4 Assembly overview - input shaft”, page 11
⇒ “1.5 Assembly overview - selector shaft”, page 12
⇒ “1.6 Removing and installing power n Atake-off
G. Volkswhousing
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page 12 wage does
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⇒ “1.7 Removing and installing
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⇒ “1.8 Dismantlingssand
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⇒ “1.9 Removing and installing intermediate gear wheel”,

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page 19
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⇒ “1.10 Removing and installing selector shaft”, page 19
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⇒ “1.11 Dismantling and assembling selector shaft”, page 19
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⇒ “1.12 Removing and installing power take-off flange”,
spec
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page 22
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1.1 Assembly overview - power take-off housing
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1. Power take-off system 7

Crafter 2006 ➤
1 - Input gear
2 - Compression spring
3 - Pin
❑ 8 × 14.5
4 - Seal
5 - Housing cover
❑ Only on vehicles with
separate hydraulic
pump.
❑ Hydraulic pump is bol‐
ted directly to cover.
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6 - Bolt olksw not
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❑ 46 Nm orise nte
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7 - Washer ss a c
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8 - Hexagon nut
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❑ M12
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❑ 46 Nm
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9 - Bolt
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❑ M12 x 1.5 x 45
spec
10 - Washer
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❑ 13.2
11 - Flange
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❑ Only on vehicles with
separate ancillary.
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❑ Vehicles with alterna‐

f in
tors, pumps and com‐ form
mer
pressors are equipped

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with this variant.

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12 - Oil seal
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13 - Front part of power take-off housing cover

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❑ Only vehicles with flange ⇒ Item 11 (page 8)

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14 - Bolt
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❑ 28 Nm Prote AG.
15 - Bolt
❑ M8
❑ 28 Nm
16 - Power take-off warning switch - F247-
17 - Selector cylinder
18 - Seal
❑ Always renew before installing.
19 - Washer
8 Rep. gr.34 - Controls, housing

Crafter 2006 ➤
1.2 Assembly overview - power take-off

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1 - Selector fork Volksw not
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2- Selector rod rise nte
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3- Synchromeshedssgear c
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❑ Removing and installing

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⇒ page 19
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❑ Dismantling and assem‐
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4 - Intermediate gear wheel
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⇒ page 19
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5 - Axle
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6 - Input gear
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⇒ page 16
nform
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bling ⇒ page 17
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Crafter 2006 ➤
1.3 Assembly overview - intermediate gear wheel

lkswage es n
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1 - Washer byV ua
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2 - Needle bearing auth or
ac
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3 - Intermediate shaft
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Cop py
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Prote AG.

Crafter 2006 ➤
1.4 Assembly overview - input shaft
1 - Thrust washer
2 - Tapered roller bearing
3 - Input shaft agen
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❑ Removing and installing by Vo gu
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⇒ page 16 rise
d
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❑ Dismantling and assem‐ s aut ra
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4 - Tapered roller bearing
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Crafter 2006 ➤
1.5 Assembly overview - selector shaft
1 - Selector shaft
⇒ page 19
bling ⇒ page 19
2 - Needle bearing
3 - Needle bearing lkswage es n
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4 - Synchromeshed oris gear tee
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❑ Removing
ss
au
and installing ac
⇒ page 19
ce
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nl
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erm
ab
ility
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5 - Thrust washer
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❑ Shoulder must face to‐
h re
hole
wards bush.
spec
es, in part or in w
6 - Bush
t to the co
❑ Collar must face to‐
wards synchromeshed
gear.
rrectness of i
l purpos
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Prote AG.
1.6 Removing and installing power take-off

housing cover
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Crafter 2006 ➤
AG. Volkswagen AG d
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olksw s no
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♦ Torque wrench - V.A.Gho1332-
ris nte
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spec
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t to the co
rrectness of i
♦ Engine and gearbox jack - V.A.G 1383 A-
l purpos
nf
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Prote AG.
♦ Sealant ⇒ ETKA (Electronic Parts Catalogue)
Removing
– Catch oil which runs out.
– Remove selector cylinder ⇒ page 24 .
– Mark position of propshaft in relation to propshaft flange.
– Unscrew propshaft from propshaft flange -A- and attach prop‐
shaft to bodywork, e.g. using “wire”.
– Remove propshaft flange ⇒ Power transmission; Rep. gr. 34 .
Vehicles without power take-off flange:
– Unscrew bolts and nut -arrows- to remove cover -1-.

Vehicles with flange:

Crafter 2006 ➤
– Remove power take-off flange -1- ⇒ page 22 .
– Unscrew bolt -2- and nuts -arrows- from upper part of housing
cover -1-.
AG. Volkswagen AG d
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– Remove front part -1- of housing cover
s aut -2- in ra
c
-direction of arrow-. s
ce
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nl
pt
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Continuation for all vehicles:
an
itte
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erm
ab
– Place engine and gearbox jack - V.A.G 1383 A- under gearbox
ility
ot p
with a wooden block.
wit
, is n
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hole
Note spec
es, in part or in w
t to the co
Disregard bolts -2-.
rrectness of i
l purpos
– Remove securing bolt for gearbox mounting -1-.

nform
ercia
Note
m
at
om
io
Different housing covers might be installed.

n
c
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or
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ate
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rig ht
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by lksw
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Prote AG.

Crafter 2006 ➤
– Unscrew bolts -arrows- of housing cover -1-.

Or
– Unscrew bolts -arrows- of housing cover -1-.
AG. Volkswagen AG d
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spec
t to the co
rrectness o
cial p
f inform
mer
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c
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Cop py
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Prote AG.

Crafter 2006 ➤
– Unscrew bolts -arrows- of power take-off housing cover -1-.
Note AG. Volkswagen AG d

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Do not use sharp-edged tools like screwdrivers to releaseorhous‐
ise nte
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ce
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un
– Carefully remove housing from power take-off.
pt
an
d
itte
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Installing
rm
ab
pe
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Install in reverse order of removal, observing the following:
ot
wit
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hole
spec
Note
es, in part or in w
t to the co
♦ Renew bolts that are tightened with specified tightening angle.
♦ Renew self-locking nuts and bolts.
rrectness of i
♦ All cable ties which have been undone or cut open during re‐
l purpos
moval must be fitted in the same position when installing.

♦ Sealing surfaces must be grease-free.
nform
mercia
a
com
– Clean sealing surfaces.
tion in
r
te o
– Install selector cylinder ⇒ page 24 .
thi
s
iva
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– Install power take-off flange ⇒ page 22 .
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– Install propshaft flange ⇒ Power transmission; Rep. gr. 34 ;

n
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Controls, housing . Cop py
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– Refill gear oil ⇒ Power transmission; Rep. gr. 34 ; Controls, p by
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agen
– Secure gearbox mountings ⇒ Power transmission; Rep. gr.

34 ; Controls, housing .
– Secure propshaft ⇒ Power transmission; Rep. gr. 39 ; Final
drive, differential .
Specified torques
♦ ⇒ “1.1 Assembly overview - power take-off housing”, page 7
1.7 Removing and installing input shaft

Removing
– If fitted, remove flange for power take-off ⇒ page 22 .
– Unscrew bolt -2- and nuts -arrows- from cover -1-.

agen
AG. Volkswagen AG d
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ksw Power gu take-off (PTO) - Edition 05.2014
ol not
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– Remove front part -1-auof
th housing cover -2- in
o eo
ra
-direction of arrow-.ss c
ce
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un
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an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
– Carefully remove input shaft -1- from housing in
s
-direction of arrow-.
s o
cial p
f in
Installing
form
mer
atio
om
n
c
– If present, install flange for power take-off ⇒ page 22 .
i
or
n thi
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sd
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Specified torques
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Cop py
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rig ht
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by lksw
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Prote AG.
1.8 Dismantling and assembling input shaft
♦ Separating tool Kukko 17-2
♦ Counter support Kukko 18-2

Crafter 2006 ➤
♦ Tube - VW 416 B- lkswage es n
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byV ua
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a ac
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ab
ility
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spec
es, in part or in w
t to the co
Dismantling
rrectness of i
– Remove input shaft ⇒ page 16 .
l purpos
– Clamp input shaft -1- with roller bearing -arrow- in Separating

tool Kukko 17-2 .
nform
ercia
– Remove input shaft thrust washer.

m
at
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io
– Screw counter support Kukko 18-2 into separating tool Kukko
n
c
in t
or
17-2 .
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ate
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Cop py
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Prote AG.
– Insert spindle of counter support Kukko 18-2 centrally into in‐

put shaft -arrow- and turn spindle until shaft is pushed out of
tapered roller bearing.
Note
♦ The procedure of pressing on and off is the same for both ta‐
pered roller bearings.
♦ Coat all shafts and bearings with gear oil before fitting.
♦ Heat tapered roller bearings to approx. 80 °C before installing.
Assembling
– Press tapered roller bearing -arrow- with tube - VW 416 B- onto

input shaft -1-.
– Push thrust washer onto shaft.
– Install input shaft ⇒ page 16 .

Crafter 2006 ➤
1.9 Removing and installing intermediate

gear wheel
Removing
– Remove housing cover for power take-off ⇒ page 12 .
– Carefully remove intermediate shaft -1- from axle in
Installing
– Install housing cover for power take-off ⇒ page 12 .
Specified torques
1.10 Removing and installing selector shaft

Removing
– Remove housing cover for power take-off ⇒ page 12 .
– Remove selector rod -1- from selector fork -2- in AG. Volkswagen AG d
-direction of arrow-. olksw
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spec
es, in part or in w
t to the co
– Remove selector shaft -1- and selector fork from shaft in
rrectness of i
Installing
l purpos

nf
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or
Note
m
m
atio
om
n in
Ensure proper seating of compression spring in tension fork.

or c
thi
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sd
iva
– Install housing cover for power take-off ⇒ page 12 .

r
rp
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Specified torques
t.
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1.11 Dismantling and assembling selector
agen
Prote AG.
shaft

Crafter 2006 ➤
♦ Separating tool Kukko 17-2
AG. Volkswagen AG d
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♦ Counter support Kukko 18-2
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
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thi
s
iva
do
♦ Tube - VW 416 B-
r
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Dismantling
– Remove selector shaft ⇒ page 19 .
– Remove locking collar from synchromeshed gear.
Note
Place bush or tube between selector shaft and spindle if spindle

cannot be screwed in far enough.

Crafter 2006 ➤
– Install synchromeshed gear -1- into separating tool Kukko

17-2 . Install counter support Kukko 18-2 , position spindle
centrally in selector shaft and turn spindle until shaft is pushed
out of synchromeshed gear.
– Remove selector shaft with needle bearing. Remove roller
bearing from shaft.
– Remove thrust washer and bush. Remove synchromeshed
gear from counter support Kukko 18-2 .
Note
♦ Coat all shafts and bearings with gear oil before fitting.
♦ Heat needle bearing to approx. 80 °C before installing.
Assembling
– Fit needle bearing -arrows- onto selector shaft -1-

-in direction of arrow-.
Note
♦ Shoulder of thrust washer must face towards bush.

♦ Bush collar must face towards synchromeshed gear.
AG. Volkswagen AG d
agen oes
olksw not
– Fit synchromeshed gear -arrow- onto selector y V -1-
shaft
b gu
ara
ed
-in direction of arrow-. Then push thrust washer
horis
-2- onto shaft nte
eo
and fit bush -3- onto shaft. aut ra
ss c
ce
e
nl
pt
du
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itte
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Press bush -arrow- with tube - VW 416 B- onto selector shaft

-1-.
l purpos
– Push locking collar onto shaft.

nform
ercia
– Install selector shaft ⇒ page 19 .

m
at
om
ion
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ate
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for
en
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

Crafter 2006 ➤
1.12 Removing and installing power take-off

flange
♦ Two-arm puller Kukko 20-2
Removing
Note
♦ On vehicles with a separate hydraulic pump: the hydraulic

pump is bolted directly to power take-off housing. Those ve‐
hicles are not equipped with flanges.
♦ The flange is required to drive separate ancillaries such as an
alternator or compressor. AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Unscrew bolt -arrows- from flange -1- riseby approx. 5 turns.
d b ara
nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– If necessary, pull out flange -2- to stop on bolt head, using two-
arm puller Kukko 20-2 -1-.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Carefully remove flange -1- from housing in

Installing
Note
♦ Renew bolts that are tightened with specified tightening angle.

♦ Renew self-locking nuts
wage
n AGand
. Volkbolts.
swagen AG
doe
ks s no
Vol t
♦ All cable eties
d b which have been undone or cut open
y gu
ara during re‐
movalthomust
ris be fitted in the same position when installing.
nte
e or
au ac
ss
Specified torques
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
2 Selector mechanism
⇒ “2.1 Assembly overview - selector mechanism”, page 24
⇒ “2.2 Removing and installing selector cylinder for power take-
off”, page 24
⇒ “2.3 Bleeding hydraulic system”, page 25
2.1 Assembly overview - selector mechanism
1 - Vacuum reservoir
2 - Rivet
3 - Retainer
4 - Hose
❑ To brake fluid reservoir
5 - Filter
6 - Hose
7 - Hydraulic pressure unit
❑ Bleeding hydraulic sys‐
tem ⇒ page 25 AG. Volkswagen AG d
agen oes
olksw not
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8 - Nut ed b ara
nte
ris
❑ 9 Nm aut
ho eo
ra
ss c
9 - Bolt
ce
le
un
pt
❑ 25 Nm
an
d
itte
y li
erm
ab
10 - Retainer
ility
ot p
❑ On longitudinal member
wit
is n
h re
ole,
11 - Nut
spec
❑ 9 Nm
t to the co
12 - Power take-off valve -
N254-
rrectne
13 - Non-return valve
❑ Blue side facing power
ss
take-off valve - N254-

o
cial p
⇒ Item 12 (page 24)

inform
mer
14 - Connecting piece
atio
m
15 - Hose
o
n
c
i
or
n thi
❑ To brake servo
te
sd
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16 - Cable
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fo
en
ng
17 - Cable
t.
yi Co
Cop py
❑ To selector cylinder ⇒ Item 7 (page 3) ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.2 Removing and installing selector cylin‐

der for power take-off

Crafter 2006 ➤
Removing
– Unlock and disconnect connector from power take-off warning
switch - F247- .
– Unscrew bolts -arrows- from selector cylinder -1- and remove
. Volkswagen AG
selector cylinder. swa
gen AG does
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Installing edb ara
nte
ris
ho e
– Install in reverse
aut order of removal. Observe the following: or ac
ss
– If hydraulic system has been opened, it needs to be bled
ce
le
un
pt
⇒ page 25 .
an
d
itte
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rm
ab
pe
Note ility
ot
wit
, is n
h re
hole
♦ Note different bolt lengths.

spec
es, in part or in w
♦ Always renew seal.

t to the co
♦ When renewing selector cylinder, remove the power take-off

warning switch - F247- from old selector cylinder and install to
rrectness of i
new one.
l purpos
– Specified torque for bolts: 28 Nm.

nform
ercia
2.3 Bleeding hydraulic system

m
a
com
tion in

r
te o
thi
♦ Brake filling and bleeding equipment - VAS 5234-

s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Brake fluid specifications ⇒ Rep. gr. 47 .
2. Selector mechanism 25
Crafter 2006 ➤
Procedure:
– Connect brake filling and bleeding equipment - VAS 5234- to
brake fluid reservoir.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
– Connect bleeder hose to bleeder of selector cylinder -arrow-.
AG. Volkswagen n AG do
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– Pressurise system ytoVo2lksbar. ot g
ua
b
ed ran
– Open bleeder
tho
valve
ris by approx. 1/4 turn. tee
or
au ac
– Leave bleeder
ss valve open until brake fluid flowing out is free
ce
e
of bubbles.
nl
pt
du
an
itte
– Close bleeder valve.
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E80448B1A

3.4 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 Power take-off system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.6 Removing and installing power take-off housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.8 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.9 Removing and installing intermediate gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n 19

1.10 Removing and installing selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.11 Dismantling and assembling selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.12 Removing and installing power take-off flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.1 General notes on power take-off (PTO)

♦ WSG with variable or fixed engine speed

1.2 Functional check

The power take-off is driven by the layshaft of the manual gearbox

gear wheel of the ancillary (not shown) via an intermediate gear

-2-. The power take-off is engaged or disengaged via the selector

Explanation of the selector mechanism function and control of the

power take-off ⇒ page 2 .

Function of the gearbox shift lock in the 0CB gearbox

To engage the power take-off, the selector cylinder -6- presses

1.4 Selector operation and management

2 Rep. gr.00 - Technical data

1 - Working speed governor

6 - Power take-off warning

working speed governor

switch - E261- and dash

❑ For warning light for

8 - Power take-off valve -

❑ Location: behind front

left wheel housing liner

❑ Actuated by the control

unit for programmable special functions - J820- ⇒ Item 9 (page 3)

❑ Directs vacuum to the hydraulic pressure unit ⇒ Item 5 (page 3)

Manual gearbox with pow‐ 6-speed 0CB

4 Rep. gr.00 - Technical data

applicable for the various repair procedures, formerly repeated in

numerous sections in the workshop manual. They apply to this

♦ During installation, ensure that the dowel sleeves between the

♦ When renewing gearbox, gear oil must be refilled ⇒ 6-speed

♦ Gearbox capacity ⇒ 6-speed manual gearbox; Rep. gr. 34 .

3.2 Seals and sealing rings

♦ Before installing oil seal, half-fill space between sealing lips

3.3 Locking devices

3.4 Nuts and bolts

⇒ “1.9 Removing and installing intermediate gear wheel”,

⇒ “1.11 Dismantling and assembling selector shaft”, page 19

⇒ “1.12 Removing and installing power take-off flange”,

1. Power take-off system 7

❑ Vehicles with alterna‐

pressors are equipped

with this variant.

13 - Front part of power take-off housing cover

❑ Only vehicles with flange ⇒ Item 11 (page 8)

8 Rep. gr.34 - Controls, housing

1.2 Assembly overview - power take-off

❑ Removing and installing

1. Power take-off system 9