Components

Components

Rear final drive
^ When assembling mounting brackets as well as other waxed components the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.
^ Allocate bolts and other components.
^ When replacing rear final drive, fill gear oil and Haldex clutch oil up to the lower edge of the filler hole.
^ Filling quantity and specification.

O-rings, seals, right and left flange shaft radial shaft seals
^ Thoroughly clean separation surfaces and apply sealant AMV 188 200 03.
^ Apply sealant uniformly, but not too thick.
^ Replace O-rings.
^ Radial shaft seals.

Before installing:





Lightly lubricate outer edge and fill space between sealing lips - arrow - halfway with grease G 052 128 A1.

After installation:
^ Check gear oil level in rear final drive.

Radial shaft seals for flange/drive shaft and shaft bevel gear on rear final drive
^ Before installing, lightly coat outer diameter and space between sealing lips with Haldex clutch High Performance Oil G 052 175 A1.
^ After installation, check oil level in Haldex clutch.

Locking elements
^ Do not over-stretch circlips.
^ Always replace circlips which have been damaged or over-tensioned.
^ Circlips must be properly seated in base of groove.





^ Replace spring pins. Installation position: Slit - A - should be in line with line of force - arrow -.

Bolts and nuts
^ Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
^ Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
^ The tightening torques stated apply to un-oiled bolts and nuts.
^ Replace self-locking bolts and nuts.
^ Ensure with installed connections that the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly, if necessary.
^ Use thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be installed. Otherwise there is a risk that the bolts will shear the next time they are removed.

Bearings
^ Install new tapered roller bearing as supplied and do not use additional oil.
^ Install needle bearings with lettering on the bearing (the side with thicker metal) facing towards drift.
^ Taper roller bearings installed to one shaft must be replaced as a set. Use same make of bearings.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
^ Heat inner races to approx. 100° C before installing.
^ Temperature can be check using temperature tester V.A.G 1558, ignition tester V.A.G 1767 or diesel tester V.A.G 1743.

Adjustment shims
^ Measure shims at several points using a micrometer. Varying tolerances make it possible to measure the required shim thickness exactly.
^ Inspect for burrs and signs of damage.
^ Install only shims that are in perfect condition.

Guided Fault Finding, On Board Diagnostic (OBD) and measuring technology





^ Before servicing Haldex clutch, malfunction cause must be determined as closely as possible via Vehicle Diagnostic, Testing and Information System VAS 5051B in operating modes "Guided Fault Finding", "Vehicle Self-Diagnosis" and "Test Instruments".
^ The Vehicle Diagnostic, Testing and Information System VAS 5051 / VAS 5051A, Vehicle Diagnostic and Service Information System VAS 5052 or Diagnostic System VAS 5053 can also be used.