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: Removing

Fig 1: Identifying Bore Holes In Transmission Holder

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For mounting rear final drive, transmission support VW 353 must be modified on assembly stand.

Dimensional data in mm.

• Inscribe bore - arrow 1  - corresponding to illustration.
• Bore a 13 mm hole - arrow 1  - into transmission holder.
• Enlarge bore - arrow 2  - to 13 mm diameter.

Fig 2: Identifying Retainer For Electrical Wire For Rear Final Drive

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• Remove retainer - arrow  - for electrical wire for rear final drive.
• Drain gear oil and high performance oil for Haldex clutch

Fig 3: Clamping Rear Final Drive In Assembly Fixture

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• Clamp rear final drive in assembly fixture. To secure, use M12 x 1.5 threaded bolts of appropriate length.

Fig 4: Removing Hex Nut For Driveshaft Flange

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• Unscrew hex nut for driveshaft flange.

A - Hex bolts M10 x 20

Fig 5: Pulling Off Driveshaft Flange Using Three Arm Puller

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• Pull off driveshaft flange.

Fig 6: Identifying Haldex Clutch Pump, Connector, Control Module & Bolts

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• 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: Figure .
• Use key T10066 to loosen and unscrew oil filter - 4  -.

Fig 7: Identifying Cover & Drive Pinion Housing

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• Remove cover - A  - from drive pinion housing - arrows  -.
• Remove bolts for Haldex clutch cover at drive pinion housing.

Fig 8: Removing Cover Of Drive Pinion Housing Using Screwdrivers, VW 313 & VW 309

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• Insert screwdriver - A  - into cut-outs - arrow  - on cover and remove 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.

Fig 9: Removing Axial Needle Bearing With Washer From Drive Pinion Housing Using Hook 3438

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• Remove axial needle bearing with washer from drive pinion housing using hook 3438.
• Remove all securing nuts for drive pinion housing.

Fig 10: Threading In Drive Pinion Housing Bolts

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• Remove drive pinion housing by threading in hex bolts - A  - uniformly so that housing is not canted.
• Remove adjustment shim S ₃ .

Fig 11: Removing Left Flanged Shaft By Threading In Lower Support Of Extractor T10037 Into Left Cover

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• Remove left flanged shaft by threading in lower support of extractor T10037 into left cover - arrow  - (illustration shows final drive installed).

Fig 12: Removing Flanged Shaft By Threading Lower Support Of Puller T10037 Into Housing

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• Remove right flanged shaft by threading lower support of puller T10037 into housing - arrow  -.

Fig 13: Identifying Breather, Bolts & VW 353

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• Pull breather - arrow  - off rear axle housing.
• Remove right cover (next to oil filler plug) by tightening bolts - A  - uniformly so that cover is not canted.
• Remove right cover together with differential.
• Remove left cover.

Fig 14: Identifying Head Bevel Gear With Input Shaft

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• Remove head bevel gear with input shaft.