All Wheel Drive Control Module -J492-, Rear Final Drive 02D/0AV (HALDEX-Clutch Generation II)

Special tools and workshop equipment required

Torque Wrench 5-50 Nm V.A.G 1331
Drip Tray for VAS 6100 VAS 6208

Removing

Fig 1: Control Module Remove/Install Components

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NOTE:

When removing control module -1-, cover -2- and plate spring -5- are removed together. Pressure sensor -4- and valve -3- are removed separately.

-- Turn off the ignition.

-- Disconnect the harness connectors -1 and 2- at the upper control module.

Fig 2: Disconnecting Connector To Upper Control Module

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-- Place drip tray under final drive.

-- Remove the bolts -arrows-.

Fig 3: All-Wheel Drive Control Module J492

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Make sure no parts fall down when removing the control module.

-- Carefully remove the control module -A-.

-- Carefully grasp the Haldex clutch control valve -N373- - A- with pliers on the metal housing -arrow- and remove.

Fig 4: Identifying Haldex Clutch Control Valve N373, Metal Housing & Pressure Sensor

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-- Remove the pressure sensor -B-.

-- Remove Haldex clutch control valve seal -arrow- from housing.

Fig 5: Identifying Haldex Clutch Control Valve N373 Seal From Housing

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Installing

Fig 6: Identifying Valve Seal Internal Diameters

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Install in reverse order of removal.

NOTE:

Install the seal coated with high performance oil for the Haldex clutch.

The valve sealing rings have different internal diameters.

-1- internal - diameter 11 mm
-2- internal - diameter 12 mm
-3- sealing ring on the valve body

-- First, place the seal -1- onto the Haldex clutch control valve.

Fig 7: Identifying Valve Seal Internal Diameters

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-- Then sealing ring -2 and 3-.

-- Press the centering lips (quantity 4) of the sealing ring -3- into the groove.

-- Replace the O-ring -arrow A- on pressure sensor.

Fig 8: Identifying O-Ring, Marking, Plate Spring & Pressure Sensor

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NOTE:

Marking -arrow B- on convex side of plate spring -2- faces upward and toward pressure sensor -1- in installation location.

-- Place plate spring -2- with convex side on pressure sensor -1-.

-- Place the new cover -2- on the control module -1-.

Fig 9: Control Module, Cover, Seals & Oil Pressure/Temperature Sensor

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NOTE:

The cover fits in one position only.

-- Insert the Haldex clutch control valve -3- into the control module -1-.

NOTE:

The valve only fits in one position.

-- Insert the oil pressure/temperature sensor -G437- -4- and plate spring into the control module -1-.

NOTE:

The sensor fits in one position only.

-- Carefully position the control module -A- and tighten the bolts -arrows- to the tightening specification List Item:Bolt.

Fig 10: All-Wheel Drive Control Module J492

Courtesy of AUDI OF AMERICA, LLC

-- Check oil level in Haldex clutch. Refer to OIL LEVEL IN THE HALDEX CLUTCH, CHECKING .