How to Service Haldex Generation 4 Full Guide

Audi S3 8P Facelift - Fitted with Haldex Generation 4

Servicing Interval for Vehicles Fitted with a GEN 4 Haldex Coupling

The below vehicles from VAG are fitted with the GEN 4 Haldex All-wheel drive coupling:

All-Wheel Drive Coupling Haldex Generation 4 (GEN4)	1st Oil Service	Oil & Filter	Oil Capacity /refill Quantity
VW Golf Mk6 5K 4Motion, 2008 - 2012	20,000 Miles	40,000 Miles	850ml (refill amount 700ml) *1135ml (refill amount 950ml)
VW Golf R Mk6 5K 2008 - 2012
VW Tiguan B6 2008 - 2014
VW Sharan 7N Mk2 2011 - 2015
VW Passat, CC, B7 2010 - 2015
VW Transporter Late Model T5 Facelift 2009 - 2015*
VW Caddy Mk3 2K 2010 Facelift 2010 - 2015
Audi A3 S3 8P Facelift 2009 - 2012
Audi TT / TTS / TTRS, 8J, 2008 Facelift 2008 - 2012
Audi Q3 / RS Q3 2011 - 2013
Seat Altea XL, Freetrack 2010 - 2015
Seat Alhambra 2nd Generation 7N 2011 - 2013
Skoda Yeti Pre 2014 Facelift 2009 - 2014
Skoda Superb B6 Type 3T 2008 - 2014
Skoda Octavia 4×4, Scout, vRS 4×4 1Z Facelift 2009 - 2013

How to perform a GEN 4 Haldex Service

Required Parts for Servicing the Haldex GEN 4:

Haldex Coupling GEN4 Filter x1 Borg Warner Only - 02D598574

Haldex Oil - G060175A2

Drain Bolt - N91082701

Inspection hole Bolt / Fill Plug N90281802

Aftermarket Generation 4 Haldex Service Kit Optional Fill & Drain Plug

Pump Gasket - 0AY598305 (Ordered Seperately if required)

Haldex GEN 4 Servicing Tools

• 4mm Hex or Allen Key – Haldex Filter Housing Bolts
• 8mm Hex or Allen Key - Drain Plug
• 5mm Hex or 5mm Allen Key –Fill Plug
• 3/8 Torque Wrench
• Syringe – to push oil into the fill plug
• Diagnostic Tool – VCDS / VAGCOM / ODIS & VAS TOOL / Other tool Capable of reading the oil temperature in the Haldex Coupling Clutch Chamber

 

 

 

 

 

 

 

1 – fill plug – Haldex Oil

2 – drain plug – Haldex Oil

3 – final drive fill plug – Gear Oil

4 – final drive drain plug – Gear Oil

 

Diagnostic Guide for Checking Oil Temperature for GEN 4 Haldex:

Using your diagnostic machine, you can check the Temperature of the Oil in the Haldex Coupling:

• Connect Vehicle Diagnostic Testing Machine
• Select - Running gear Group 01; 40…49
• Select – All-Wheel Drive with Haldex coupling (4^thgeneration)
• Select - 01 - Self-diagnosis-capable system
• Select - Four-wheel drive Haldex
• Select - Electrical components
• Select - Oil temperature
• The oil temperature must be between 20 and 40 °C before you empty the oil from the Haldex Coupling - Top Tip – the oil will be close to the right temperate if the vehicle has been driven/idling before you start the process  

 

 

 

 

 

 

Procedure for Emptying the Haldex GEN 4 Coupling Oil:

Once you have checked the oil is at the correct temperature with your diagnostic tool, you can now start the process of removing the filter and emptying the oil from the Haldex Coupling.

• Make sure the vehicle is level and safely placed on your ramp
• Loosen the 2 Bolts for Filter Housing and allow a for some space (do not remove fully)
• Lower the vehicle and go the diagnostic tool
• Select - 22 - AWD
• Select - Basic Settings - 04
• Use the drop-down menu and select - MAS02928 - Pump Motor
• Select – Go
• This should have now popped the filter out to the end of the loosened bolts to break the seal
• Fully remove bolts and filter
• Remove fill plug (5mm Hex/Allen)

 

 

 

 

 

 

 

• Check if an excessive amount of oil leaks – sometimes overfilled by other garages
• Place Oil catch under the oil drain plug (8mm Hex/Allen) and remove #2

 

 

 

 

 

 

 

• Remove 2 Bolts for Filter Housing and twist to remove
• Allow the entire contents to empty (Dispose any oil legally and be environmentally friendly)

 

 

 

 

 

 

 

Filling the Haldex GEN 4 Coupling with Oil:

• Replace Filter – Remember to lube the new o-ring with the clean Haldex Oil, ensuring a good seal is made when you replace filter cap
• Replace drain plug and crush washer 30nm
• Use syringe to fill around 650-700ml with High Performance Haldex Oil (PN: G055 175 A2) into the fill hole – make sure the adapted nozzle fits slightly loose so you can see when the fill hole starts to drip
• Once the fill hole starts to drip the coupling is full
• Replace fill plug with new crush washer

About the Haldex GEN 4 All-Wheel Drive Coupling

Unlike the GEN 1&2 Haldex Couplings, the GEN 4 Haldex setup is not reactive and moved to a proactive system. The vehicle will be in 100% FWD unless the Haldex coupling is activated which distributes 50/50 torque.

The ABS control unit and the ECU now control when the multi-plate clutch is activated. The Haldex control unit sends power to the Centrifugal Oil Pump based on the data processed by the ABS sensors and engine control data to access how much torque to deliver to the rear axle.

Common Faults for a Generation 4 Haldex Coupling

Fault Code	Possible Cause	Solution
P 00448 – Haldex Clutch Pump (V181) – 002 – Lower Limit Exceeded – Intermittent
P 00448 – Haldex Clutch Pump (V181) 011 – Open Circuit – Intermittent
P 00448 – Haldex Clutch Pump (V181) 011 – Open Circuit – Defective
P 00448 – Haldex Clutch Pump (V181) – 011 – Open Circuit – Intermittent
P 02248 – Valve for Controlling Clutch Operating Angle (N373) – Defective		Repair or Replace Haldex ECU
P 02248 – Valve for Controlling Clutch Operating Angle (N373) – Intermittent		Replacing filter and oil is advisable
P 02248 – Valve for Controlling Clutch Operating Angle (N373) – 012 – Electrical Fault in Circuit		Often pump is at end of service life too
P 01324 – Control Module for All Wheel Drive (J492) 004 – No Signal/Communication (Transporter T5)	Wiring Fault under the vehicle
P 65535 – Internal Control Module Memory Error 00-10 – Intermittent
P 16347 – Control Module – EEPROM error – 014 – Defective – Intermittent
P 00003 – Control Module 014 – Defective – Intermittent / Control module faulty sporadic

How to test if the Haldex Coupling is working

Once you have scanned the vehicles AWD for any fault codes you are now able to test if the coupling is engaging when when the vehicle senses the front wheels slip.

To test the function of the GEN 4 Haldex Coupling follow the below instructions:

Testing the physical function of the Haldex will require either a rolling road or brake roller tester.

• With the front wheel on the rollers engage 1^stgear / drive
• Rev the engine in gear until you 1500 rpm
• If the rear axle does not engage at this point and try to push the vehicle forwards the Haldex Coupling is defective and further diagnosis will be required

 

Changing the GEN 4 Haldex pump

This procedure is a little less involved than replacing the pump on the earlier generation Gen 1 Haldex Coupling.

• Remove Haldex Controller 4mm HEX/Allen bolts
• Unplug the electrical connectors from the Haldex Controller

 

 

 

 

 

 

 

 

• Remove Haldex pump 4mm HEX/Allen bolts
• Twist pump and remove
• Clean out any debris left in the pump housing.
• Prepare new pump to be fitted and Lubricate rubber O rings before installing
• Fit new pump by twisting the pump into place and making the seal for the o ring
• Plug in and feed the wire to Haldex controller back to original positions
• Use diagnostic machine perform a pump relearn.

How to perform a pump relearn on a GEN 4 Haldex:

Using your diagnostic tool:

• Select - 22 - AWD
• Select - Basic Settings - 04
• Use the drop-down menu and select - MAS02928 - Pump Motor
• Select – Go
• Once selected you should be able to hear the pump cycle itself for around 30 seconds to a minute while it relearns its cycles.
• When the process is completed, you should see a message advising – finished correctly

Watch our Haldex Servicing YouTube video's! (GEN 4 COMING SOON)