SSP 333 - 4MOTION With Haldex Coupling Model Year 2004
Service TrainingSelf-study Programme 3334MOTION with Haldex CouplingModel Year 2004Design and Function
4MOTION Drive with Haldex Coupling Modelyear 2004 will initially be used in the Golf 2004 andin the Transporter 2004.Repair and servicing have been made easiercompared with the previous version of the Haldexcoupling.The new Haldex coupling is fitted onto the rear axlegearbox so that no adjustments are necessary. Theelectrical control of the regulating valve has beenreconfigured. The oil filter for the Haldex coupling isnow a fleece filter.S333 091For information on the first generation of the Haldex coupling, please refer toself-study programme 206 “Four-Wheel Drive with Haldex Coupling”.For the previous four-wheel-drive system, please see self-study programme 78 “Golf syncro”.The general function of Visco and Haldex coupling is also explained in the multimedia training course“Power Transmission 2 – Automatic Variable Gearbox – Mechanics”.NEWThe self-study programme shows the design andfunction of new developments.The contents will not be updated.2For current testing, adjustment and repairinstructions, refer to the relevantservice literature.ImportantNote
ContentsBrief Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44MOTION Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Haldex Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
Brief OverviewFour-wheel DriveThere is a long tradition of four-wheel drive vehicles at Volkswagen – even without taking the four-wheel drivesystems on the Iltis and vehicles with air-cooled engines into consideration.The drivetrain from the Syncro four-wheel drive system with Visco clutch has developed into the 4MOTION drivewith Haldex coupling. The Visco coupling was last used in the predecessor to the Transporter 2004.Since 2004, the Transporter 2004 and the Golf 2004 have been available with 4MOTION drives and a secondgeneration Haldex coupling.Syncro four-wheel drive with Visco couplingThe arrangement of the components in the drivetrain has only changed slightly over the years. The Visco couplingwas not electronically controllable. A freewheel had to be added to achieve the ABS functions.Manual gearboxDirection of travelCV jointCV jointThree-piece propshaftVisco couplingCentre supportFlexible couplingBevel gear systemAxle drive withfreewheelFront axleInner plateOuter plateHousing(drive)S333 027Rear axleHub(output)S333 0424
First generation 4MOTION drive with Haldex couplingThe advantage of the Haldex coupling compared with the Visco coupling is that torque transfer can be controlleddepending on the driving situation. A freewheel to make the system ABS compatible is no longer required.S333 002S333 003Haldex coupling model year 2004The Haldex coupling works in exactly the same way in both generations. There have been several improvementsto the design. The configuration of the electrical and hydraulic components has also been changed.Four-wheel drivecontrol unit J492Pressure valvesAccumulatorWet plate clutchHub (output)Input shaft (drive)Oil filterLifting plateHaldexcoupling pump V181S333 0475
4MOTION DrivetrainOverviewThe front wheels are driven via the front axle differential as in a conventional system. The rear axle isdriven via a flanged bevel gear system connected to the front differential cage.The power is transmitted via the propshaft and the Haldex coupling to the rear-axle drive.4MOTION drivetrain in Golf 2004EngineGearboxFront axledifferentialBevel gear systemPropshaftHaldex couplingS333 089Rear axledifferential6
4MOTION drivetrain in Transporter 2004EngineGearboxFront axledifferentialPropshaftBevel gear systemwith intermediate shaftDifferential lockHaldex couplingS333 090Rear axledifferential7
4MOTION DrivetrainBevel gear system in the Golf 2004The bevel gear system in the Golf 2004 transfers the power to the propshaft with a transmission ratio of 1.6.This allows a shaft with a smaller diameter to be used because it has to transfer less torque.In the rear axle differential, the engine speed is then reduced again by the same factor.Right-handwheel outputDrive fromgearbox andoutput onleft-hand wheelS333 080Propshaft output8
Bevel gear system with intermediate shaft in Transporter 2004Due to the higher torques being transferred, the transmission factor for the Transporter is 2.5.Therefore an intermediate shaft is used. In the rear axle differential, the ratio is stepped up againto the front axle speed.Bevel gearsystemIntermediateshaftGearboxOutput onpropshaftS333 030Hollow shaftIntermediateshaftS333 031Differential cage9
4MOTION DrivetrainPower transmission in the Golf 2004The power is transferred from the crown wheel via the differential cage, the hollow shaft and the drive pinionto the propshaft.Crown wheelFrom gearboxDifferential cageHollow shaftOutput onleft-hand wheelOutput onright-hand wheelS333 072Drive pinionOutput onpropshaftPower transmission in Transporter 2004The power is transferred to the hollow shaft from the crown wheel via the differential cage. The differential cageand hollow shaft then form a positive connection. From the hollow shaft, the output power is transferred to theintermediate shaft and then to the propshaft via the drive pinion.Crown wheelFrom gearboxDifferential cageHollow shaftOutput onleft-hand wheelOutput onright-hand wheelIntermediate shaftS333 041Drive pinion10Output onpropshaft
PropshaftGolf 2004The propshaft for the Golf 2004 has two Hardy disks and a CV-joint.Hardy diskCV jointHardy diskDirection of travelS333 070Transporter 2004The propshaft for the Transporter 2004 is split into three sections by four CV-joints. Due to the length of thepropshaft, it has to be mounted on bearings along the body. The working angles on the propshaft are thereforegreater. This means CV-joints that can run at greater working angles are required.CV-jointsDirection of travelS333 07111
4MOTION DrivetrainHaldex CouplingThe Haldex coupling is located on the propshaft in front of the rear axle differential. It engages at an enginespeed of 400 rpm. The transferred torque is regulated by the control unit so that there is no slip in the couplingwhen the vehicle is travelling in a straight line. This occurs via the clamping load of the clutch plate set inside theHaldex coupling. The Haldex coupling has a similar design for the Golf 2004 and the Transporter 2004. Thenumber of plates used in the Haldex coupling and the connection to the different propshafts are differentin the two vehicles.Hub for the shaft to therear-axle differentialPropshaftconnectionS333 08812
New features on Haldex coupling model year 2004Changes to the Haldex coupling model year 2004 compared with the previous model:- The Haldex coupling can be replaced as a unit. There is no need for complicated adjustments after replacementas the drive pinion in the rear-axle differential is no longer replaced, instead it remains in the housing.- A proportional hydraulic valve takes care of hydraulic control instead of the electrical controlvalve previously used.- In addition to the temperature, the oil pressure is also measured with a double sensor.- The paper filter has been replaced with a maintenance-free fleece filter.- The Haldex coupling is integrated in the rear-axle drive.- The oil volume has been increased. This has extended the oil change intervals.Overview of components for Haldex coupling model year 2004Four-wheel drivecontrol unit J492Current supply andCAN communicationPressurevalvesPlate housingAccumulatorWet plate clutchDrive shaftHubOil filterWorkingpistonS333 047Pressurelimiting valveHaldex coupling pumpV181The suction valves are located under the oil filter.13
4MOTION DrivetrainRear Axle DriveGolf 2004A differential lock is not used in the Golf 2004 4MOTION. The transmission ratio is 1.6.DifferentialOil reservoirFour-wheel drive control unit J492Crown wheelClutch plateset for HaldexcouplingDrive shaftS333 079Drive pinion14Seal
Transporter 2004The 4MOTION rear-axle drive for the Transporter 2004 consists of the Haldex coupling, the rear-axle differentialand the optional differential lock. The transmission ratio is 2.5.There are the following differences in the design of the rear-axle drives for the Golf 2004 andthe Transporter 2004:-No optional differential lock for the Golf 2004The rear-axle differentials have different transmission ratiosDifferent oil reservoirsDifferent connection to the axleDifferent number of plates in the Haldex couplingReed contact switches 1-3for differential lock F360-F362Differential lock pressure cellDifferential lockDrive pinionSealCrown wheelClutch plate set forHaldex couplingDifferentialS333 055Drive(propshaft)Four-wheel drive control unitJ492Oil reservoir15
4MOTION DrivetrainDriving situationsThe powerful system of the 4MOTION drivetrain stabilises the vehicle together with the ESP in almost all drivingsituations. The following paragraphs explain how a vehicle with Haldex coupling works without the use of otherelectronic systems (e.g. EDL).Normal accelerationEven during normal acceleration, there are speeddifferences between the front and the rear axle(approx. 1-2 rpm), which are sufficient to close theHaldex coupling and therefore cause the power tobe transferred to all four wheels.S333 067S333 006100% slip on one front wheelIf there is 100% slip on one of the front wheels, thewhole driving power is transferred to the rear axle.The differential balances out torque differencesbetween the two front wheels. That means thatmomentum cannot be transmitted to the road by theother wheel when there is 100% slip on one wheel.S333 066S333 00716
100% slip on one rear wheelIn this case too, there are different speeds on the frontand rear axles. The positive connection to drive allfour wheels is formed. The rear axle is driven,however, due to the slip on the rear wheels, no drivingpower can be transferred to the road. The front axletherefore takes over driving.S333 065S333 008100% slip on one wheel at the front and one at the rearIn theory, propulsion is not possible in this situation:There is no driving power at any of the wheels due tothe power distribution of the axle differentials.On the Golf and the Transporter, however, the fourwheel EDL intervenes here and ensures propulsionwith the other wheels.The wheels that are slipping are braked and thetractive force is transmitted to the wheels via thedifferential with a greater positive engagementpotential.S333 068S333 00917
Haldex CouplingHaldex coupling designThe 4MOTION system features a second-generation Haldex coupling in both the Golf 2004 and theTransporter 2004. Here is a schematic diagram.Working pistonWet plate clutchLifting pistonPressure valveSuction valveControl valveOutput shaftInput shaftS333 034Response of Haldex coupling model year 2004The clutch plate set for the Haldex coupling cantransfer torque once there is approx. 10 wheelturning angle difference between the axles. The totaltorque can be transferred once the wheel turningangle reaches 20 .20 Totaltorque18S333 033
General functioning of Haldex couplingAs soon as there are different wheel speeds, the inputshaft turns with the actuating roller of the lifting pistonaround the lifting plate connected to the output shaftthat is rotating at a lower speed.S333 035The roller transfers these up and down movementsto the lifting piston. The lifting piston is made to moveupwards and builds up a flow.S333 036The flow is diverted to the working piston via an oilchannel. The working piston is pushed to the rightagainst the actuating rollers of the working piston andthe thrust washer on the clutch plate set.S333 038The clutch plate set is pushed together. The couplinginput shaft and output shaft are connected and allfour wheels are thus driven. The torque can nowbe transferred.S333 03919
Haldex CouplingMain Components of Haldex Coupling Model Year 2004The Haldex coupling consists of three differentcomponent systems:Mechanics- mechanical components,- hydraulic components and- electronic (and electrical) components.HydraulicsElectronicsS333 004Four-wheel drive control unitJ492Pressure valvesAccumulatorWet plate clutchInput shaft(drive)Hub (output)Oil filterWorking pistonS333 054Haldex coupling pumpV18120
Mechanical componentsThe mechanical parts include the Haldex coupling drive with the coupling cage and the outer plates that meshinside it as well as the lifting plate on the output hub with the inner plates that mesh inside it. The working pistonsstill belong to the mechanical components.You will find an overview of all mechanical components on the following double page.Outer actuatingrollers forlifting pistonTeeth forouter platesActuating rollersfor workingpiston120 30 S333 076The pump effect is transferred to the lifting pistons bythe actuating rollers. We distinguish between theouter lifting piston with the three outer actuatingrollers and the inner lifting piston with the three inneractuating rollers. The actuating rollers for the liftingpistons are arranged offset at an angle of 120 . Thisoffset allows three lifting motions per revolution. Thelifting pistons work at an angle of approx. 30 toprovide a higher pressure over a longer period. Thisimproves the response.The three actuating rollers for the working piston,which press the clutch plate set together when theworking pressure is reached, are also arranged atan angle of 120 .Inner actuatingrollers for lifting pistonInner plateThe outer plates (friction plates) are connected tothe coupling housing via their outer teeth.The inner plates are fitted inside on the outputhub and have teeth on the inside. They are madefrom steel.Outer plateS333 075Lifting plate(undulated surface)The lifting plate on the output hub has an undulatedsurface over which the lifting pistons run to producethe pumping effect.Teeth for innerplatesS333 07721
Haldex CouplingOverviewPropshaft flangeSealHousingBearingThis exploded view will help explain the functionsand connections.Axial needlebearingWorking pistonOuterlifting pistonInnerlifting pistonThrust washerThe working piston and the two lifting pistons are allannular pistons.If there is a difference in speed, the lifting plate withits undulated surface runs over the lifting pistonrollers. The lifting pistons are thus moved andgenerate pressure. This pressure acts on the workingpiston. The working piston transfers the pressure to theactuating roller for the working piston. This acts on thethrust washer for the clutch plate set so that the platesare pressed together.For information on separately availablegenuine parts, please see theETKA electronic parts catalogue.22
Coupling cageActuating rollers forworking pistonLifting plateClutch plate setThrust washerS333 074Lifting pistonactuating rollersSpacerBellevillewasherLocking ringTo maintain minimum friction while the clutch is open,the clutch plate set is spread as long as no pressure isgenerated by the pump effect of the lifting piston.23
Haldex CouplingHydraulic componentsThe hydraulic components include the valves and the accumulator. The hydraulic system of theHaldex coupling has 5 valves that open or close due to the spring force:- two suction valves,- two pressure valves and- the pressure limiting valve.The coupling opening control solenoid valve N373 is one of the electrical components.Oil systemYou will find all hydraulic components in the following picture. The diagram has been simplified to make it easierto understand: Instead of two as shown below, three actuating roller pairs for the listing pistons are operated by thelifting plate. The two rollers in a pair are arranged at an angle of 120 .Pressure limiting valveLifting pistonactuating rollersPressure valvesCoupling openingcontrol valve N373Lifting plateSuction valvesFleecefilterClutch plate setWorking pistonLifting pistonHaldex couplingpump V181AccumulatorStrainerOil reservoirS333 01024
AccumulatorThe accumulator sets the supply pressure using thespring force and keeps the pressure constant.The supply pressure set by the accumulator is 3.2barin the Golf 2004 and 3.8bar in the Transporter 2004.S333 044System pressure-free: The accumulator spring isrelaxed no oil flows through.S333 011System with supply pressure: If the supply pressure istoo high, it will be reduced by the accumulatortowards the oil reservoir. If the pressure is too low,the spring will reduce or stop the flow.S333 01225
Haldex CouplingPressure limiting valveThe pressure limiting valve is used to protect thecomponents and limits the working pressure toapprox. 100bar. It works using a spring set to aspecific force. If the pressure in the system rises to100bar, the pressure limiting valve will open andallow the oil to flow via the accumulator into oilreservoir. The overpressure is reduced in this way.S333 045under100barS333 015over100barS333 056Suction valvesThe suction valves are on the supply pressure side ofthe Haldex coupling and the lifting piston. They arespring-loaded and open when the supply pressure isapplied in the direction of the lifting piston.If a working pressure is built up by the lifting piston,the suction valves will close so that the pressure on thelifting piston or working piston is maintained.S333 043Suction valvesopen(supply pressure)S333 016Suction valvesclosed(working pressure)S333 01726
Pressure valvesThe pressure valves are located between the liftingpiston, the working piston and the control circuit withthe pressure limiting valve and the coupling openingcontrol valve N373. They are spring-loaded and openwhen the supply pressure is exceeded.They then transfer the pressure from the lifting pistonto the working piston. At the same time, they open thecontrol circuit with the coupling opening control valveN373.They prevent pressure reduction towards the liftingpiston by closing when the working piston reaches alow point on the lifting plate.S333 040Pressure valvesclosed(no pressure orsupply pressure)S333 018Pressure valvesopen(working pressure)S333 01927
Haldex CouplingSystem overviewSensorsG28Engine speed senderG79Accelerator pedal positionsenderCAN data busG44 - G47Engine control unitJ .Speed sensorFBrake light switchG165Acceleration senderJ104ABS control unitJ533Data bus diagnostic interfaceF9Handbrake warning switchG8528Steering angle sender
Control elementsG437Oil pressure and oil temperature senderN373Coupling openingcontrol valveJ492Four-wheel drivecontrol unitV181Haldex coupling pumpS333 051FBrake light switch(only on vehicleswithout ESP)J419Brake lightadditional relay(only on vehicleswith ESP)Components inside theHaldex coupling29
Haldex CouplingElectrical and electronic componentsThe electrical and electronic components include the oil pressure and oil temperature sender G437 plus theHaldex coupling pump V181 and coupling opening control valve N373 as control elements.Furthermore the Haldex coupling has its own control unit, the four-wheel drive control unit J492.Four-wheel drive control unit J492In the Haldex II, the four-wheel drive control unit J492 is incorporated in the drive CAN data bus. This allows it toregulate the system precisely with a few individual sensors (oil pressure and oil temperature sender).The control unit uses the data from the oil pressure and oil temperature sender G437 and the data on the drivingsituation fro
Four-wheel Drive There is a long tradition of four-wheel drive vehicles at Volkswagen – even without taking the four-wheel drive systems on the Iltis and vehicles with air-cooled engines into consideration. The drivetrain from the Syncro four-wheel drive system with Visco clutch has developed into the 4MOTION drive with Haldex coupling.
Tiguan 4Motion Yes Remove the Haldex oil pump fuse Passat 4Motion Yes Remove the Haldex oil pump fuse Passat CC 4Motion Yes Remove the Haldex oil pump fuse . is an all-wheel drive model from the higher rolling friction of the differential and switch the dynamometer automatically to all-wheel drive mode.
SSP allows you to manage your access to USPS web applications that offer convenient, confidential, . 18. Why do you need my email id? SSP allows USPS employees to receive updates to their Self Service Profile using either their USPS email or a personal email. If you choose not to supply an email in SSP, all communications from SSP will be sent to your address of record by USPS First Class .
A. Orders for all Haldex Brake Products Aftermarket (referred to throughout this document as Haldex) productsare to be directed to Haldex Brake Products Corporation, Attention: Customer Service Department: MAIL ORDERS 10930 North Pomona Avenue Kansas City, Missouri 64153 PHONE ORDERS (816) 891-2470 (800) 643-2374 FAX ORDERS (800) 533-1941 .
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