Volkswagen Workshop Service and Repair Manuals

Renewing deep groove ball bearing for Haldex coupling

Special tools and workshop equipment required

t	Pressure plate -VW 402-

t	Press tool -VW 412-

t	Thrust piece -VW 431-

t	Thrust piece -VW 454-

t	Tube -3296-

t	Drift sleeve -41 - 501-

Special tools and workshop equipment required

t  Adjustment key -VW 278 B-

t  Assembly tool -T10030/6-

t  Hot air blower -V.A.G 1416-

–  Disconnect exhaust system at clamping sleeve -arrows- and remove rear part of exhaust system → Rep. gr.26.   Note The flexible joint of the exhaust system must not be bent more than 10° - danger of damage. –  Remove rear flexible coupling → Chapter.

–  Remove propshaft flange hexagon nut. A -  Hexagon bolts M 10 x 25 B -  Hexagon socket bolt M8 x 15 (screwed from back side into counterhold -3415-).

–  Pull off propshaft flange. If flange is difficult to move, use a 3-arm puller (e.g. Kukko 12-1).

–  Pull out seal using oil seal extractor lever -VW 681-.

–  Remove Haldex coupling → Chapter. –  Lay Haldex coupling on a clean workbench. –  Pull off housing for Haldex coupling. A-Two arm puller -Kukko 20-20-

–  Remove retaining ring -1-.

–  Press out deep groove ball bearing.

–  Press in new deep groove ball bearing to stop.

–  Install retaining ring -1-. –  Heat deep groove ball bearing -2- to about 80° C using hot air blower -V.A.G 1416-.

–  Centre needle thrust bearings -5...7- on multiplate clutch -1- → Fig. „„Multiplate clutch assembly““. –  Set housing for Haldex clutch by hand onto multiplate clutch -1-.   Note It must be ensured that the axial needle bearings -5 ... 7- do not change their centred position when the housing is mounted.

–  Lightly oil new seal around outer circumference and between sealing lips with high-performance oil for Haldex coupling. –  Drive in new oil seal to stop using thrust piece -T10019-. Do not cant oil seal in the process.

–  Press on propshaft flange.

–  Insert new hexagon nuts with locking fluid -D 000 600- and tighten. Torque setting: → Item. A -  Hexagon bolts M 10 x 20 B -  Hexagon socket bolt M8 x 15 (screwed from back side into counterhold -3415-). –  Install Haldex coupling → Chapter. –  Install rear flexible coupling → Chapter. –  Install exhaust system and align system free of tension → Rep. gr.26. –  Fill with high-performance oil for Haldex coupling and check oil level in Haldex coupling → Chapter.