Cover for Haldex clutch with disc housing, disc pack for drive pinion housing / shaft bevel gear, head bevel gear / input shaft and differential, removing and installing: Installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Pressing Disc Housing Out Of Haldex Clutch Cover Using Special Tools

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Press disc housing out of Haldex clutch cover.

Fig 2: Identifying Head Bevel Gear With Input Shaft

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Insert head bevel gear with input shaft.
Coat new O-ring with gear oil and install left cover.
Tighten hex bolts to specified torque.

Fig 3: Identifying O-Ring

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Coat new O-ring - A - with gear oil and install right cover with differential. Tighten bolts uniformly in diagonal sequence.
Tighten hex bolts to specified torque.
Press vent into rear axle housing.

Fig 4: Pressing Circlip Out Of Flanged Shaft Groove With New Circlip

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Pressing circlip out of flanged shaft groove with new circlip - A -

Drive in right and left flanged shafts using plastic mallet.
Install adjustment shim S ₃ .

Fig 5: Identifying O-Ring

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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 specified torque in diagonal sequence.

Fig 6: Identifying Washer, Axial Needle Bearing, Thrust Washer & Hub

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Insert washer - 1 - for axial needle bearing with shoulder to axial needle bearing - 2 -.
Install axial needle bearing - 2 -.
Insert thrust washer - 3 - with larger smooth surface - arrow B - pointing toward hub - 4 -.
Slide hub - 4 - with 3 holes - arrow C - pointing upward onto shaft bevel gear.

Fig 7: Identifying Drive Pinion Housing, Inner Clutch Plates & Outer Clutch Plates

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Set first inner clutch plate - 2 - into drive pinion housing - 1 -.
Insert first outer clutch plate - 3 - and then remaining 6 inner and 6 outer plates.

Fig 8: Identifying Cam Disc & Broken Teeth

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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 installation.

Fig 9: Identifying Disc Housing, Rollers & Ring

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When inserting, rotate - arrows - disc housing - A - and guide housing on to cam disc/disc pack to stop while doing so.
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.

Install ring - D -.

Fig 10: Identifying Thrust Washers, Axial Needle Bearing, Dished Washer & Gap

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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:

The 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 dished washer - 4 - with large diameter (concave side) pointing toward ring ( Fig 9 ).

Fig 11: Identifying O-Rings, Center Piston & Special Tool 80-200

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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 approx. 5 mm over total circumference.

Fig 12: Identifying Haldex Clutch Cover, Drive Pinion Housing, Gap & Bolts

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Carefully set Haldex clutch cover - 1 - onto drive pinion housing - 2 -.
Screw in 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 specified torque.

Fig 13: Identifying Cover & Drive Pinion Housing

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Secure cover - A - with new seal (note the different versions, Different versions of drive pinion housing cover ) on drive pinion housing - arrows -.

Fig 14: Identifying Haldex Clutch Pump, Connector, Control Module & Bolts

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Install oil filter - 4 - and tighten to specified torque.
Install Haldex clutch pump - 3 - and Haldex clutch control module - 2 -. Tighten bolts - arrows A - and - arrows B - to specified torque.
Connect electrical 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.

Fig 15: Driving In Seal Using T10019

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Drive in new seal flush.
Install driveshaft flange.

Fig 16: Identifying Hex Nut, Counterhold Flange/Drive Shaft Over Tube & Special Tools

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Insert new hex nut with D 000 600 and tighten to specified torque.

A - Hex bolts M 10 x 20

NOTE:

When tightening hex nut, counterhold driveshaft flange over tube - C - using transmission holder V.A.G 2004 (second technician required).

Remove rear final drive from assembly stand.

Fig 17: Identifying Retainer For Electrical Wire For Rear Final Drive

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Install retainer - arrow - for electrical wiring to rear final drive.