Final Drive 02D And 0AV, HALDEX Clutch Grooved Ball Bearing

Special tools and workshop equipment required

Thrust Plate VW 402
Thrust Disc VW 412
Thrust Pad 16.5/28 mm Dia. VW 431
Thrust Tube VW 454
Tube 3296
Mounting Universal Joint 41 - 501
Wrench VW 278 B
Subframe Support Assembling Device T10030/6
Hot Air Blower V.A.G 1416
Extractor Lever VW 681
Two Arm Puller Kukko 20-20
Thrust Piece T10019
Counter Support 3415

CAUTION:

Risk of damaging decoupling elements.

Do not bend decoupling elements in front exhaust pipe more than 10°.

-- Separate the exhaust system at the clamping sleeve -arrows-.

Fig 1: Clamping Sleeve -Arrows-

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-- Tie the front exhaust pipe to the underbody.

-- Remove the exhaust system rear section. Refer to [For engine(s) CBRA] Description and Operation or to [For engine(s) BPY] Description and Operation or to [For engine(s) CCTA, CBFA] Description and Operation or to Description and Operation .

-- Remove the rear flexible disc. Refer to REAR FLEXIBLE DISC .

-- Remove the flange/driveshaft hex nut.

Fig 2: Identifying Removal Of Nut From Flange/Drive Shaft

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A - Hex head bolts M10 x 25

B - Socket hex head bolt M8 x 15 (installed from rear in bracket 3415)

-- Remove the driveshaft flange. Use a three arm puller (for example, Kukko 12-1) if difficult to access.

Fig 3: Flange/Drive Shaft And Hammer Kukko 12/1

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-- Remove the seal using a VW 681.

Fig 4: Identifying Removal Of Seal Using Extractor Lever VW 681

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-- Remove the Haldex clutch. Refer to HALDEX CLUTCH, FINAL DRIVE INSTALLED .

Fig 5: Identifying Two Arm Puller Kukko 20-20

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-- Place the Haldex clutch on a clean workbench.

-- Remove the Haldex clutch housing.

A - Kukko 20-20

-- Remove the circlip -1-.

Fig 6: Circlip

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-- Remove the grooved ball bearing.

Fig 7: Grooved Ball Bearing (1 Of 2)

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-- Install the new grooved ball bearing all the way in.

Fig 8: Grooved Ball Bearing (2 Of 2)

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-- Install the locking ring -1-.

Fig 9: Circlip

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-- Warm the grooved ball bearing -2- to approximately 80 °C (176 °F) using the V.A.G 1416.

-- Center the axial needle bearing -5 through 7- on the multidisc clutch -1-. Refer to Figure.

Fig 10: Clutch Plate Assembly

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-- Position the Haldex clutch housing by hand on the multidisc clutch -1-.

NOTE:

The axial needle bearings -5 through 7- must not change their centered position when installing the housing.

-- Before installation, lightly coat the new sealing ring with the Haldex clutch high performance oil on the outside circumference and between the sealing lips.

Fig 11: Driving In New Seal To Stop Using Thrust Piece T10019

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-- Install the new sealing ring using T10019. Do not tilt the seal.

-- Install the flange/driveshaft.

Fig 12: Flange/Driveshaft

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-- Insert new hex nut with locking compound D 000 600 and tighten. Tightening specification List Item:Nut.

Fig 13: Identifying New Hex Nut

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A - Hex head bolts M10 x 20

B - Socket hex head bolt M8 x 15 (installed from rear in bracket 3415)

-- Haldex clutch, installing Haldex Clutch, Installing .

-- Install the rear flexible disc. Refer to REAR FLEXIBLE DISC .

-- Install the exhaust system and align it. Refer to [For engine(s) CBRA] Description and Operation or to [For engine(s) BPY] Description and Operation or to [For engine(s) CCTA, CBFA] Description and Operation or to Description and Operation .

-- Reconnect exhaust system making sure it is not under stress. Refer to [For engine(s) CBRA] Description and Operation or to [For engine(s) BPY] Description and Operation or to [For engine(s) CCTA, CBFA] Description and Operation or to Description and Operation .

-- Add high performance Haldex clutch oil and check the oil level in the Haldex clutch. Refer to OIL LEVEL IN THE HALDEX CLUTCH, CHECKING .