Assembly Sequence - Haldex Clutch Cover , Drive Pinion Housing/Shaft Bevel Gear Pack, Head Bevel Gear/Differential, Removing
Assembly sequence - Haldex clutch cover with disc housing, drive pinion housing/shaft bevel gear disc pack, head bevel gear/input shaft and differential, removing
Special tools, testers and auxiliary items required
^ Holding plate VW 309
^ Holding fixture VW 313
^ transmission support VW 353 (modifying)
^ Pressure plate VW 402
^ Punch VW 412
^ Pry lever V.A.G 80-200
Special tools, testers and auxiliary items required
^ Slide hammer VW 771
^ Pulling hook 771/37
^ Transmission holder V.A.G 2004
^ Alignment fixture VAS 3253
^ Hook VAS 3438
^ Thrust piece T10019
^ Puller T10037
^ 2 hex bolts M 10 x 20
Special tools, testers and auxiliary items required
^ Wrench T10066
^ Kukko 45-2 Three arm puller
- Remove retainer - arrow - for electrical wire for rear final drive.
- Drain gear oil and high performance oil for Haldex clutch
- Clamp rear final drive in assembly fixture.
- To secure, use bolts M 12 with 1.5 mm incline.
- Remove hex nut for flange / drive shaft.
A - Hex head bolt M10 x 20
Note: When loosening hex nut, counter hold flange / drive shaft over tube - C - using transmission holder V.A. G 2004 (2nd technician).
- Remove drive shaft flange. If difficult, use three arm puller - A - (three arm puller, e.g. Kukko 45-2).
- Disconnect connector - 1 - to Haldex clutch pump.
- Remove securing bolts - arrow A -.
- Remove control module - 2 - for Haldex clutch.
- Remove bolts - arrows B- for pump - 3 -.
- Afterward, rotate pump slightly toward right (clockwise).
- Pull out pump e.g. using slide hammer VW 771 and pulling hook VW 771/37, Fig. NO1-0424.
- Use key T10066 to loosen and remove oil filter - 4 -.
- Remove cover - A - from drive pinion housing - arrows -.
- Remove bolts for cover / Haldex clutch at drive pinion housing.
- Insert screwdriver - A - into cut-outs - arrow - on cover and pry out cover.
- Remove cover together with disc housing out of drive pinion housing.
- Remove 6 track rollers and 3 rollers out of drive pinion housing.
- Remove cam disc, disc pack, hub and thrust washer.
- Remove axial needle bearing with washer from drive pinion housing using hook 3438.
- Remove all securing nuts for drive pinion housing.
- Remove drive pinion housing, install hex bolts - A - uniformly while doing so, so that housing is not canted.
- Remove adjustment shim S3.
- Remove left flanged shaft, install lower support of extractor T10037 into left cover - arrow - (illustration shows final drive installed).
- Remove right flanged shaft, to do so thread lower support of puller T10037 into housing - arrow -.
- Pull breather - arrow - off rear axle housing.
- Remove right cover (next to oil filler plug), tighten bolts - A - uniformly while doing so, so cover is not canted.
- Remove right cover together with differential.
- Remove left cover
Note: Removal is identical to removal of right cover.
- Remove head bevel gear with input shaft.
Installing
- First press disc housing out of Haldex clutch cover.
- Insert head bevel gear with input shaft.
- Install left cover with new O-ring.
- Coat O-ring with gear oil.
- Tighten hex bolts to tightening torque.
- Insert right cover with differential and new O-ring - A - (coat with gear oil), tighten bolts uniformly in diagonal sequence.
- Tighten hex bolts to tightening torque.
- Press vent into rear axle housing.
- Drive in right and left flanged shaft using plastic mallet. Install new circlip first.
- Install adjustment shim S3.
- Insert new O-ring - A - into surrounding groove of drive pinion housing and coat with gear oil.
- Install drive pinion housing with shaft bevel gear.
Installation position:
Oil filter frame is located above oil filler plug.
- Thread on hex nuts with locking compound D 197 300 A1 and tighten in stages to tightening torque in diagonal sequence.
- Insert washer - 1 - for axial needle bearing with offset to axial needle bearing - 2 - pointing - arrow A - into drive pinion housing.
- Then install axial needle bearing - 2 -.
- Insert so that thrust washer - 3 - with larger smooth surface - arrow B - points toward hub - 4 -.
- Slide hub - 4 - with 3 holes - arrow C - pointing upward onto shaft bevel gear.
- Set first inner clutch disc - 2 - into drive pinion housing - 1 -.
- Then insert first outer clutch disc - 3 - and then the remaining 6 inner and 6 outer clutch discs.
- Make sure that cam disc - A - remains visible in cam track during installation.
Installation position:
The 3 broken teeth - arrows - must engage into hub counter-teeth during this.
- When inserting, rotate - arrows - disc housing - A - and guide housing on to cam disc/disc pack to stop.
- Place 3 rollers - B - into recesses of disc housing.
- Place 6 track rollers - C - also into disc housing.
Note: Rollers and track rollers can be inserted only in one position due to the molding in disc housing.
- Then install ring - D -.
- Place thicker thrust washers - A - on track rollers and rollers in disc housing.
- Then insert axial needle bearing - B - and thin thrust washers -C- for axial needle bearing.
Note:
^ These individual axial needle bearing assemblies 1 to 3 are allocated to diameters of pistons in Haldex clutch cover.
^ Make sure that the gap - arrow - between axial needle bearing assemblies 2 and 3 is the same size all around.
- Insert plate spring - 4 - with large diameter (concave side) pointing toward ring (Fig. N39-1043).
- Coat O-rings - arrows A and arrow B - with high performance oil for Haldex clutch and insert into Haldex clutch cover.
- Pull center piston - arrow C - out uniformly over total circumference approx. 5 mm.
- Carefully set Haldex clutch cover - 1 - onto drive pinion housing - 2 -.
- Install securing bolts - arrows - each 1 / 2 rotation in stages and in diagonal sequence.
- Gap - arrow A - must decrease uniformly.
Note: For the current gap, the bolts must not be tight. Axial needle bearing assemblies must be able to be slipped to piston. Then remove cover again and re-align axial needle bearings.
- Tighten hex bolts to tightening torque.
- Secure cover - A - with new seal (note the different versions,) on drive pinion housing - arrows -.
- Install oil filter - 4 - and tighten to tightening torque.
- Install Haldex clutch pump - 3 - and Haldex clutch control module - 2 -. Tighten bolts - arrows A - - and - arrows B - to tightening torque.
- Connect connector - 1 - for pump.
- Before installing, lightly coat new seal on outside circumference and between sealing lips for Haldex clutch with high performance oil G 052 175 A1.
- Drive in new seal flush.
- Install drive shaft flange.
- Insert new hex nut with D 000 600 and tighten to tightening torque.
A - Hex head bolts M10 x 20
Note: When tightening hex nut, counter hold flange / drive shaft over tube - C - using transmission holder V.A.G 2004 (2nd technician).
- Remove rear final drive from assembly stand.
- Install retainer - arrow - for electrical wire to rear final drive.