All Wheel Drive Clutch, Changing Oil

NOTE:

On vehicles equipped with a all wheel drive clutch and final drive, the drain and sealing screws of both systems get interchanged due to the integrated housing. This results in avoidable mistakes in maintenance and servicing, which can result in the all wheel drive clutch or the axle drive failing.

The all wheel drive clutch and axle drive are a single unit with separate oil housings.

Fig 1: Identifying Drain Plug -1-, Filler Plug -2-, Axle Oil Filler Plug -3- And Axle Oil Drain Plug -4-

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-1- Oil filler hole plug for the all wheel drive clutch oils

-2- Drain plug for the all wheel drive clutch oil

-3- Gear oil filler hole plug

-4- Gear oil drain plug

Special tools and workshop equipment required

Digital Thermometer:VAS6519

Fig 2: Identifying Digital Thermometer VAS 6519
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Torque Wrench 1331 5-50Nm:VAG1331

Fig 3: Identifying Torque Wrench
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Used Oil Collection and Extraction Unit:SMN372500

Fig 4: Identifying Used Oil Collection And Extraction Unit
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Charging Device For BorgWarner Coupling 2 :VAS6291 A

Fig 5: Identifying Charging Device For Haldex Coupling 2 VAS6291A
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Shop Crane - Drip Tray:VAS6208

Fig 6: Identifying Drip Tray
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Oil, draining

-- Raise vehicle using the hoist and position the Used Oil Collection and Extraction Unit:SMN372500 under the all wheel drive clutch.

-- Remove the oil drain plug -2- and drain the high performance oil completely.

Fig 7: Identifying Drain -1- And Filler -2- Plugs

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-- Install a new oil drain plug with a new gasket and tighten to the tightening specification. The oil drain plug has a permanent gasket.

Tightening specification	Nm
Oil drain plug	30

Filling with Oil

-- Remove the oil filler plug -1-.

Fig 8: Identifying Drain -1- And Filler -2- Plugs

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-- Disconnect the elbow -B- from adapter -A- and completely install adapter in oil filler opening.

Fig 9: Identifying Adapter -A- And Haldex Coupling 2 VAS 6291

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-- Position the elbow again and route the hose over drive axle to prevent it from hanging down.

-- Place the :VAS6208 under the final drive.

-- After the hose is routed above left rear wheel and away from vehicle, the vehicle can be drained.

NOTE:

The oil temperature when checking the oil level is 20 °C to 40 °C (68 °F to 104 °F).

Pay attention to the temperature of the oil container when filling.

The oil temperature can be measured using the :VAS6519 .

Oil Capacity and Oil Specification. Refer to Oil Capacities and Oil Specifications .

-- Screw the oil container -A- with the valve closed -arrow- onto :VAS6291 A .

Fig 10: Identifying Oil Container -A- With Valve Closed Onto Charging Device F/Held 2 Coup. VAS 6291 A

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-- Open the valve -arrow- and hold the oil container as shown in illustration.

-- Using the :VAS6291 A fill with oil until flows out between the adapter and the transmission housing.

-- Remove the :VAS6291 A .

-- Remove the adapter -A-.

-- If necessary let the excess oil flow out until it only drips.

Fig 11: Identifying Adapter -A- And Haldex Coupling 2 VAS 6291

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The oil level is correct when the oil drips out of the oil filler hole.

-- Install a new oil filter plug -arrow- with a permanent seal and tighten to the tightening specification.

Fig 12: Identifying Oil Drain Plug -Arrow-

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Tightening specification	Nm
Oil filler plug	15

Check the specified temperature range while checking the oil level, if while filling an oil temperature between 20 °C to 40 °C (68 °F to 104 °F) cannot be guaranteed.

The oil temperature can be measured using the :VAS6519 .

If the oil temperature is not between 20 to 40 °C (68 °F to 104 °F), either drive the vehicle to warm it up or let the oil temperature cool down.

Oil Capacities and Oil Specifications
Oil specification	Refer to the Maintenance, Diagnosis