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Removing and installing four-wheel drive pumpV415 > < Removing and installing hydraulic control unit

A4 Mk3

Dismantling and assembling hydraulic control unit
   
Dismantling and assembling hydraulic control unit
1 - Bolt
q   5 Nm
2 - Four-wheel drive pump -V415-
q   Removing and installing → Chapter
3 - O-ring
q   Always renew
4 - Adapter
  Note
t  Adapter can fall out during removal of four-wheel drive pump -V415-
t  Before installing four-wheel drive pump -V415-, insert adapter in recesses in hydraulic pump
5 - Hydraulic pump
q   Consists of guide ring, housing and 6 pistons
q   Assembling → Fig.
6 - Ball bearing
q   Can be removed and installed by hand
7 - Pipe (left-side)
q   Tighten nuts to 30 Nm
q   Installed between hydraulic control unit and superposition gear (left-side)
q   When installing, first screw in both nuts hand-tight
8 - O-ring
q   Always renew
9 - Oil pressure and oil temperature sender -G437-
q   10 Nm
q   Brown connection
q   Removing and installing → Chapter
10 - Oil pressure and oil temperature sender 2 -G640-
q   10 Nm
q   Black connection
q   Removing and installing → Chapter
11 - Clutch valve 2 for four-wheel drive -N446-
q   Colour: brown
q   Removing and installing → Chapter
q   Installation position: connector must face upwards towards oil pressure and oil temperature sender
  Caution
Do not interchange with clutch valve for four-wheel drive -N445-.
12 - Clutch valve for four-wheel drive -N445-
q   Colour: black
q   Removing and installing → Chapter
q   Installation position: connector must face upwards towards oil pressure and oil temperature sender
  Caution
Do not interchange with clutch valve 2 for four-wheel drive -N446-.
13 - Bolt
q   2.5 Nm
14 - O-ring
q   Always renew
q   Fit on clutch valve
15 - Spring
q   Insert in guide → Item
16 - Guide
q   Installation position: large diameter must face ball → Item
17 - Ball
q   Before installing, insert in guide → Item
18 - Housing for hydraulic control unit
q   With centring pins -arrows-
q   Centring pins lock hydraulic control unit with gasket on final drive housing
19 - Ball
q   Before installing, insert in hole in shuttle valve → Item
20 - O-ring
q   Always renew
21 - Shuttle valve
q   8 Nm
q   Removing and installing → Fig.
22 - Gasket
q   With strainer
q   Position on centring pins of housing for hydraulic control unit
23 - Pipe (right-side)
q   Tighten nuts to 30 Nm
q   Installed between hydraulic control unit and superposition gear (right-side)
q   When installing, first screw in both nuts hand-tight

   
Assembling hydraulic pump
–  Insert the 6 pistons -A- into housing -B-.
–  Then position guide ring -C- so that pistons make contact with shoulder -arrow-.
  A39-10404
–  Fit hydraulic pump -1- with guide ring -2- in housing for hydraulic control unit.
Function test:
–  Rotate hydraulic pump -1- several times. Check the following:
t  The hydraulic pump must turn smoothly without sticking or catching.
t  All pistons must move in and out.
  A39-10447
Removing and installing shuttle valves
  Note
First remove four-wheel drive pump -V415-, hydraulic pump and ball bearing → Item.
–  Unscrew shuttle valves -A- (it is important to also remove ball -C-).
–  To install, insert ball in hole in shuttle valve.
–  Then carefully screw in shuttle valve with new O-ring -B- as far as stop.
l  The shuttle valve must be below the surface of the housing -arrow-. If this is not the case, remove the valve and position the ball correctly.
–  Tighten shuttle valve to specified torque → Item.
  A39-10403

Removing and installing four-wheel drive pumpV415 > < Removing and installing hydraulic control unit