Volkswagen Workshop Service and Repair Manuals

Installing

–  First press plate housing out of Haldex coupling cover.

–  Insert bevel gear with stub shaft. –  Install left cover with new O-ring. –  Moisten O-ring with gear oil. –  Tighten hexagon bolts to specified torque → Item.

–  Insert right cover with differential and new O-ring -A- (moistened with gear oil) and tighten bolts evenly and diagonally. –  Tighten hexagon bolts to specified torque → Item. –  Press breather into rear final drive housing.

Use new retaining ring -A- to press old retaining out of groove in flange shaft. –  Drive in left and right flange shafts with plastic hammer. –  Install shim S3.

–  Insert new O-ring -A- in circumferential groove of pinion housing and moisten with gear oil. –  Install pinion housing with shaft bevel gear. Installation position: Oil filter mounting is located above oil filler plug. –  Screw in hexagon nuts with locking fluid -D 197 300 A1- and tighten in stages diagonally to specified torque → Item.

–  Lay washer -1- for needle thrust bearing in pinion housing with shoulder facing needle thrust bearing -2--arrow A-. –  Then set needle thrust bearing -2- in place. –  Then insert thrust washer -3- with larger smooth surface -arrow B- facing hub -4-. –  Now push hub -4- onto shaft bevel gear with the 3 holes -arrow C- facing upwards.

–  Lay first inner plate -2- in pinion housing -1-. –  Then insert first outer plate -3- and then the remaining 6 inner and 6 outer plates.

–  Ensure that cam track remains visible when cam disc -A- is installed. Installation position: The 3 shortened teeth -arrows- must engage in the mating teeth of the hub.

–  Turn plate housing -A- while inserting it -arrows-, guiding housing onto cam disc and set of plates. –  Lay the 3 rollers -B- in recesses of plate housing. –  Also set the 6 wheel rollers -C- in plate housing.   Note The plate housing is shaped so that rollers and wheel rollers can only be fit in one position. –  Then install ring -D-.

–  Lay thicker thrust washer -A- on wheel rollers and rollers in plate housing. –  On top of that, lay needle thrust bearing -B- and thin thrust washer -C- for needle thrust bearing.   Note t  The individual needle thrust bearing packets 1 through 3 are allocated to the diameters of the pistons in Haldex coupling cover. t  Ensure that gap -arrow- between needle thrust bearing packets 2 and 3 is of uniform size all around the circumference. –  Insert dished spring -4- with greater diameter (concave side) facing ring ( → Anchor, fig. N39-1043).

–  Moisten O-rings -arrows A- and -arrow B- with high-performance oil for Haldex coupling and insert in Haldex coupling cover. –  Pull out middle piston -arrow C- about 5 mm uniformly around the entire circumference.

–  Carefully set Haldex clutch coupling -1- on pinion housing -2-. –  Screw in securing bolts -arrows- diagonally in stages of 1/2 turn each. –  Gap -arrow A- must close uniformly.   Note Bolts must not become tight as long as there is a gap. It is possible that a needle thrust bearing packet has slipped to the piston. Then remove cover and reposition needle thrust bearing. –  Tighten hexagon bolts to specified torque → Item.

–  Secure cover -A- with new seal (observe different versions → Fig.) to pinion housing -arrows-.

–  Install oil filter -4- and tighten to specified torque → Item. –  Install pump -3- for Haldex coupling and control unit for Haldex coupling -2-. Tighten bolts -arrows A- and -arrows B- to specified torque → Item. –  Push on connector -1- for pump. –  Lightly oil new seal around outer circumference and between sealing lips with high performance oil -G 052 175 A1- for Haldex couplings.

–  Drive new oil seal in flush. –  Install propshaft flange.

–  Insert new hexagon nuts with locking fluid -D 000 600- and tighten to specified torque → Item. A -  Hexagon bolts M 10 x 20   Note When tightening hexagon nuts for propshaft flange, counterhold using pipe -C- with gearbox bracket -V.A.G 2004- (2nd mechanic). –  Remove rear final drive from assembly bracket.

–  Install retainer -arrow- for electrical wiring on rear final drive.