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HALDEX rear clutch & repair kit catalog- 2013







Audi A3, Audi S3, Audi TT Coupe, Audi TT Roadster, Bugatti Veyron, Buick La Crosse,Buick Regal GS, Cadillac SRX, Ford 500, Ford Freestyle, Ford Kuga, LandRover Freelander, Mercury Montego, Opel Insigna OPC, Open Insigna, SAAB 9-3 Turbo, SAAB 9-3 X, SAAB 9-5, Seat Alhambra, Seat Altea Freetrack, Seat Leon, Skoda Octavia Scout, Skoda Super B, Skoda Yeti, Volvo S40, Volvo S60, Volvo S60R, Volvo S80, Volvo S80L, Volvo V40, Volvo V50, Volvo V70 , Volvo V70R, Volvo XC60 , Volvo XC 70,Volvo XC 90, VW Beetle RSI, VW Bora, VW Caddy, VW Golf R, VW Golf R32,VW Golf Variant, VW Golf, VW Multivan, VW Passat CC, VW Passat, VW Sharan, VW Tiguan, VW Transporter.





All numbers of producers presented in the catalog are submitted only for the general viewing.

What is the Haldex





For a start we will understand the general principle of operation of the connected full drive (designated as AWD). The main difference of the connected full drive from constant full is lack of the central differential.

It means that under standard conditions the most part of a torque is transferred to one axis (in case of Haldex — on a lobby), and if necessary the back axis is connected. The cardinal error consists in the wrong understanding of the distributed moment. Most often confuse extent of distribution of a torque and percent of blocking of the coupling. So, in a case with the connected full drive the coupling can be blocked ranging from 0 to 100%, but in all generations of the Haldex coupling there is small pressure at a hydraulic system which provides 5-10% of preliminary blocking of the coupling. It is made to clean gaps between coupling disks the coupling and to accelerate process of blocking of the coupling.

This it is necessary to understand that the proportion of distribution of draft between a lobby and a back axis can change ranging from 100:0 (only the forward axis) rotates till 50:50 (both axes rotate with an identical speed). It means that back wheels can't quicker rotate, than lobbies, unlike cars with the constant full drive

in differential. But if to speak about a torque, in a case when forward wheels completely lose coupling with the road, the torque on a forward axis comes nearer to zero and therefore 100% of a torque are transferred to a back axis.


Haldex 1 generation (since 1998)



The mechanism which defines a difference in the speed of rotation of the shaft going to a lobby and a back axis of the car is the cornerstone of operation of the coupling. It means that the coupling is blocked depending on extent of pro-slipping of wheels

on the leading (forward) axis. This feature of operation of the coupling generated a set of the negative

the responses connected that the behavior of the car on the how many road was ambiguous and it was expressed in sudden connection of a back axis of the car that is especially noticeable at turns when the insufficient

the turning sharply turned into the superfluous. The differential hydraulic pump is responsible for extent of blocking of the coupling: cam washers being rolled on the wavy worker

surfaces push pistons of pumps which pump up oil in the executive cylinder which in turn squeezes a package of disks of coupling.

Besides at system there are two electric components. The first — the electric pump creating together with the hydroaccumulator preliminary pressure in system (cleans gaps disks of the coupling and reduces a delay prior to blocking of the haldex). The second — the electromagnetic valve which task is pressure decrease in a hydraulic system and disconnection of multidisk coupling of the coupling, for example on a signal from ABS and ESP control units (not to prevent to work to these systems, the coupling will completely be unblocked).

Despite very difficult electro-hydraulic scheme of work, the Haldex coupling of the first generation was far from perfect.


Haldex 2 generation (since 2002)

In the second generation of the coupling there were better technical improvements, thus structurally the scheme of work remained former.


The coupling became integrated into one block together with back differential,

this is the electro-hydraulic module became a separate component with

possibility of easy replacement.


The electromagnetic valve was replaced on electrohydraulic that

allowed to increase the speed of work of system.


The electric pump of the coupling was replaced with more productive


The oil filter became completely unattended


The working volume of oil in the coupling was increased for extension interservice

interval.


The coupling began to work at practice quicker, now to start operation of system was enough that the difference in rotation of wheels made only 10 degrees. And full blocking of the coupling could be reached at a mismatch of rotation of wheels on 20 degrees.

The main problem of Haldex couplings of the first two generations was that the main pump of the coupling was hydraulic and actually intervention of electronics in process of blocking of the coupling was reduced to its unblocking (by opening of the valve and pressure decrease in a hydraulic system) on command from ABS and/or ESP blocks.


Haldex 3 generation (since 2004)





The Haldex coupling of the third generation wasn't installed on Volkswagen cars. For the first time the coupling was developed for the LandRover Freelander 2 car, and subsequently began to be used on all-wheel drive Volvo cars.

Introduction of even more productive electric pump and backpressure valve by means of which became possible preliminary blocking of the coupling at the command of electronics became the main constructive change. Full blocking of the coupling was reached during 150 milliseconds. PreX abbreviation was appropriated to this system.

Haldex pumps of 2 and 3 generation are changeable


Haldex 4 generation (since 2007)




Since the fourth generation in a design of the coupling there were very serious changes which cardinally changed algorithm of its work. The principle of action remained the same — a torque transmission with

help of a package of frictional disks. That now there is no differential hydraulic pump and pressure in a hydraulic system of the coupling is new is created by the powerful electric pump. The transferred torque is corrected by the control unit of the full drive by means of giving of a signal on the valve of management of short circuit of the coupling.

The difference of speeds of rotation of wheels of forward and back axes isn't a condition of turning on of the coupling of the full drive any more.

Now the coupling completely copes electronics in not dependence on traffic conditions. Thanks to increased almost by 10 times (to 30 atm) to preliminary pressure (in comparison with Haldex of 2 generations) accumulated in the hydroaccumulator time necessary for full blocking of the coupling was reduced. One more important advantage is constantly included reverse main gear.


The control unit of the full drive receives information on the CAN tire from sensors: cross acceleration, longitudinal acceleration, roving of the car, turns of the engine, provision of a pedal of an accelerator, frequency of rotation of wheels, switch of a stoplight and angle of rotation of a steering wheel. Actually, the main signal on blocking of the coupling arrives from a gas pedal.

For example, at accelerations the coupling is preventivno blocked without waiting for pro-slipping of wheels. Operation of the coupling well considerably when passing turns under draft — it is absolutely obviously felt as draft on a back axis dovorachivat the car in turn. Thus the coupling works always, irrespective of your style of driving. One more important remark — if earlier, in case of intervention of ABS and / or ESP the coupling was always completely disconnected, now during the work the ABS coupling is disconnected, and at intervention the ESP coupling can be closed. The important point — the Haldex coupling of 4 generations can be established only on cars with ESP system.

I want to note one more nuance concerning system of electronic imitation of blocking of differential (EDL) on the Scout which contrary to wrong opinion works not only at a lobby, but also a back axis of the car. As an example it is possible to watch this video where the car comes around three wheels on rollers and without problems from them leaves.





One more important remark — if earlier, in case of intervention of ABS and / or ESP the coupling was always completely disconnected, now during the work the ABS coupling is disconnected, and at intervention the ESP coupling can be closed. The important point — the Haldex coupling of 4 generations can be established only on cars with ESP system.

I want to note one more nuance concerning system of electronic imitation of blocking of differential (EDL) on the Scout which contrary to wrong opinion works not only at a lobby, but also a back axis of the car. As an example it is possible to watch this video where the car comes around three wheels on rollers and without problems from them leaves.


One more remark concerning oil in the Haldex coupling. New oil (G 055 175 A2) in the volume of 1 liter is now used, G 052 175 A1 oil was used earlier. It is necessary to pay attention that this oil only for the coupling, and has no relation to a reducer of the back bridge. In a reducer other oil 500mg 75w90 (G052145A1) and don't take in head to pour it into the coupling at all, you will kill friction clutches and the pump, this oil for a reducer but not for the coupling, the coupling and a reducer - different units, different liquid volumes different types of oils and different viscosity.


The oil filter is calculated on all service life of the car, and the interval of replacement of oil in the coupling makes 60 thousand kilometers. Besides often there is a question concerning what maximum torque can sustain multidisk coupling in the Haldex coupling. The quantity of disks in a package of the frictional coupling depends on car model (from the transferred torque). In particular for all-wheel drive Octavia the limit torque makes 2000 Nanometers, and for the VW Tiguan model it is 2400 Nanometers. It should be noted that conic transfer of a transfer case transfers rotation to a shaft of the drive of a back axis with the raising coefficient 1,6. It allows to use a shaft of smaller diameter. Respectively in reverse main gear the rotation frequency transferred by shaft of the drive decreases by 1,6 times.


We will sum up the results


The Haldex coupling of 4 generations is one of the most perfect systems of the connected full drive presented in the world at the moment (by the way, on the most powerful Bugatti Veyron the Haldex coupling too is used). Its design is very simple and reliable, and, above all advantage in comparison with other systems of the connected full drive is thatразность скоростей вращения колес на передней и задней оси не is a condition of turning on of the coupling.. Electronics blocks the coupling according to a road situation. It is possible to refer the actual lack of the central differential and therefore that fact that structurally back wheels can't have a high speed of rotation, than lobbies to shortcomings of system.



Company HALDEX already released the hydrocoupling of the 5th generation\ V generation. In this regard we appealed to the producer to provide us with catalogs of the production, but the answer surprised us even more. Company HALDEX doesn't plan to issue any catalogs in the next some years.



New photos of HALDEX



As well HALDEX conducts further development of hydrocouplings, for example eAWD:



HALDEX (Catalog numbers of VOLVO) ( 2002)





1. Clutch, exch 36050271

2. Control unit 8675233

3. Oil pump 8675234

4. Oil filter 8675235

5. Companion flange 8675236

6. Flange lock nut 31259267

7. Sealing kit 8675238

8. Flange lock nut 31259267

9. Bracket 8675240

10. Connector 8675241

11. Connector 8675537

12. Gasket 6900287

13. Flange screw 985188

14. Flange screw M8x45 982799

16. Repair kit 8689436

17. Wiring harness 8672429

18. Cable tie (948211) \ 983750




HALDEX (catalog numbers of VOLVO) (2003)

1. Clutch, exch CH -524028 36000964

1. Clutch, exch CH -133999 Complete AOC only supplied with flange. Transfer the old vibration damper or order a new one. 8602807

1. Clutch, exch Complete AOC only supplied with flange. Transfer the old vibration damper or order a new one. CH -524230 36000569

1. Clutch, exch Complete AOC only supplied with flange. Transfer the old vibration damper or order a new one. CH 134000-223999 2005 8603277

2. Control unit -2004 kit (8689667) REPL 1 PCS 8689667 \ 30783132

2. Control unit kit 2005 REPL 1 PCS 30713310 \ 30787954

2. Control unit kit S60 CH 522547- REPL 1 PCS 30783061 \ 30759702

2. Control unit, exch kit (30787954) 2005 36001750

2. Control unit, exch. Control module, exch CH 495001- 36002520

2. Control unit, exch. Control module, exch, kit (30783132) CH -424999 36001749

2. Control unit, exch. w/o coil (30783061) 36001751

2. Control unit. no longer available, Replaced with part number 36001751 -2008 kit (30759702) 2006 (30713163)(30759702) 30783061

3. Pressure sensor kit 40 BAR XC70 CH -220976, INCL CH 221037-221041 30651694

3. Pressure sensor S60 CH 522547- XC70 CH 220977- EXC CH 221037-221041 30759668

4. Oil pump kit (8689664) 30783079

4. Oil pump kit CH 495001- 31256757

5. Repair kit (8689668) 30783288

5. Repair kit CH 495001- 31259351

6. O-ring This O-ring differs from the one installed from the factory. The factory installed O-ring is square, the spare part is round. 925263

7. Flange lock nut 31259267

7. Sealing kit 8675238

8. Companion flange 31259350

8. Companion flange (8689665) MAN.TRANS 30783163

8. Flange lock nut 31259267

9. Companion flange kit CH 524028- 31259419

9. Companion flange (8689665) MAN.TRANS 30783163

9. Flange lock nut 31259267

9. Oscillation damper kit CH 524028- AUTO.TRANS 31259424

9. Oscillation damper kit AUTO.TRANS 31302014

9. Oscillation damper kit MAN.TRANS D5244T 30684478

10. Flange screw M8x45 (948217) 982799

12. Cable tie 983678

12. Grommet 30656280

12. Housing yellow 54/74 4-POLE For connection to the AOC coupling wiring harness. 30682145

12. Insulator 54/74 orange 2-POLE For connection to the AOC coupling wiring harness. 30669157

12. Insulator gray 54/74 black 4-POLE For connection to the AOC coupling wiring harness. 30669161

12. Wiring harness CH -133999 8637710

12. Wiring harness CH -253999 CH -616999 8697901

12. Wiring harness CH -327999 CH 134000-223999 8697902

12. Wiring harness CH -424999 CH -172999 30639302

12. Wiring harness CH 254000- CH 617000- 30773380

12. Wiring harness CH 328000- 30773381

13. Flange screw M8x65 (965217) 982803

14. Cable tie 983750

15. DEM reload Differential Electronic Module (DEM). 8688770

15. DEM reload Differential Electronic Module (DEM). 8688769

15. DEM reload Differential Electronic Module (DEM). 8691359

15. DEM reload Differential Electronic Module (DEM). 8688783

16. Grommet 30656280

17. Clip 9470602

18. Filter CH -495000 30787687

18. Filter CH 495001- 31325173




HALDEX (catalog numbers of VOLVO) ( 2008)





1. Clutch, exch CH 353698- (36000175) (8603862) 36000565

2. Control unit (30759758) 30783060

2. Control unit, exch. Control module, exch (30759758) (30783060) 36001160

2. Control unit, exch. w/o coil w/o coil (30783061) 36001751

2. Control unit. no longer available, Replaced with part number 36001751 (30759702) 30783061

3. Oil pump kit CH -495000 (8689664) 30783079

3. Oil pump kit CH 495001- 31256757

4. Repair kit CH -495000 (8689668) 30783288

4. Repair kit CH 495001- 31259351

5. O-ring

This O-ring differs from the one installed from the factory. The factory installed O-ring is square, the spare part is round. 925263

6. Flange lock nut M16x1.5x10 31259267

6. Sealing kit 8675238

7. Companion flange kit CH 495001- 31259350

7. Companion flange kit CH -495000 31256140

7. Flange lock nut M16x1.5x10 31259267

8. Pressure sensor CH -256826 40 BAR 30651694

8. Pressure sensor CH 256827- 80 BAR 30759668

9. Flange screw M8x45 (948217) 982799

11. Cable tie 983678

11. Grommet 30656280

11. Housing yellow 54/74 4-POLE For connection to the AOC coupling wiring harness. 30682145

11. Insulator 54/74 gray 4-POLE For connection to the AOC coupling wiring harness. 30669161

11. Insulator 54/74 orange 2-POLE For connection to the AOC coupling wiring harness. 30669157

11. Wiring harness 30773381

11. Wiring harness 8697902

12. Flange screw M8x65 (965217) 982803

13. Cable tie 983750

14. DEM reload Differential Electronic Module (DEM). 8691359

14. DEM reload Differential Electronic Module (DEM). 8688783

15. Grommet 30656280

16. Clip 9470602

17. Companion flange kit CH 495001- 31259350

17. Companion flange kit CH -495000 31256140

17. Flange lock nut M16x1.5x10 31259267

17.Oscillation damper kit TF-80SC AWD 30759074

18. Filter CH -495000 30787687








HALDEX (catalog numbers of VOLVO) (2009)




1. Clutch, exch CH 135000-. CH 134001-.

Complete AOC only supplied with flange. Transfer the old vibration damper or order a new one. 36001365

1. Clutch, exch

Complete AOC only supplied with flange. Transfer the old vibration damper or order a new one. CH -134999. S80 CH -134000 36002513

2. Filter kit S80 CH -134000 CH -134999. 31325173

3. Control unit, exch. Control module, exch (36002591) kit 36001157

4. Oil pump kit 31256757

5. Companion flange kit 31259350

5. Flange lock nut M16x1.5x10 31259267

6. Flange lock nut M16x1.5x10 31259267

6. Sealing kit 8675238

7. Repair kit 31259351

8. Flange screw M8x45 982799

9. Flange screw M8x65 982803

12. DEM reload Differential Electronic Module (DEM). 30788982

12. DEM reload Differential Electronic Module (DEM). 30783153

13. Protecting plate. (Sorry, we an no longer get this item.inc. screw) 30783129

15. Companion flange kit 31259350

15. Flange lock nut M16x1.5x10 31259267

15. Oscillation damper kit 31259423

16. O-ring 119,5x3

This O-ring differs from the one installed from the factory. The factory installed O-ring is square, the spare part is round. 925263







HALDEX (catalog numbers of VOLVO) (V generation)





1. Clutch, exch Complete AOC only supplied with flange. Transfer the old vibration damper or order a new one.

EXCH FOR 31325006 36013553

2. Control unit, exch EXCH FOR 31325246 36002055

3. Oil pump kit 31367426

4. Companion flange kit EXC 5CYL AUTO.TRANS 31259419

5. Flange lock nut M16x1.5 31259267

6. Oscillation damper 5 CYL kit 31259424

7. Flange lock nut M16x1.5 31259267

8. O-ring 119.5x3 925263

9. Flange screw M8x35 982797

10. Sealing kit 8675238

11. Repair kit For oil pump kit. 31325413



REMARK


*Set of oil seals included 3 seal under the filter , pump and control unit code LR003142 (Number LandRover)


*If you're shooting sleeve is desirable to change the seal between the sleeve and the gear code LR002888 (Number LandRover)


*There is a set of two seals is between the flange and coupling code LR003148 (Number LandRover)


*Pumps from the clutches Haldex 2 and 3 generation interchangeable.


*On the lower part , closer to the front of the vehicle is stamped number:

0AV — Haldex 2

0BR, 0BS, 0AY, 0BY — Haldex 4


*Official information says that Haldex 4 began to put in 2007 , the massive introduction of cars V Volkswagen-Audi Group began in 2008.


*3rd generation none of the producers of the VAG group did not use ... After the second was immediately 4 generation.


*Another note about the oil in the clutch Haldex. Now use new oil (G 055 175 A2) in a 1 liter , previously used oil G 052 175 A1. It should be noted that this oil only for the coupling , and has no relation to the rear axle . The gearbox is filled with other oil 500mg 75w90 (G052145A1) and in any case do not try to pour it into the box , kill friction and pump this oil to the gearbox and not to the clutch , clutch and Gear- different units , different liquid volumes of different types of oils.


*Pump Haldex 4го пок th generation differs from its predecessors , consumables (repair kit) it is quite different, break less often , you can visually the back cover ( back cover looks like a shortened bottle neck ) (Figure below) .


* also apologize for repictured photos from the internet, we collected them for a long time for this writing .






Look of the HALDEX installed on the VOLVO XC 90



Look of the HALDEX installed on VOLVO V50






























Pump of HALDEX II & III Generation




Pump Haldex IV Generation details of pump II & III Generation















filter Haldex II Generation