All Wheel Drive Clutch, Changing Oil

NOTE:

On vehicles equipped with an 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:VAS 6519 
  Fig 2: Identifying Digital Thermometer VAS 6519

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

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• Charging Device For BorgWarner Coupling 2 :VAS 6291 A 
  Fig 4: Identifying Charging Device For Haldex Coupling 2 VAS6291A

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• Shop Crane - Drip Tray:VAS 6208 
  Fig 5: Identifying Drip Tray

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Oil, Draining

Fig 6: Identifying Drain -1- And Filler -2- Plugs

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-- Lift the vehicle using the hoist and place the Used Oil Collection and Extraction Unit:VAS 6622A  under the all-wheel drive clutch.

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

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

Oil, Filling

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

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-- Remove the oil filler plug -1-.

Fig 8: Identifying Adapter -A- And Haldex Coupling 2 VAS 6291

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-- Disconnect the elbow -B- from the adapter -A- and install the adapter completely in the oil fill hole.

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

-- Place the Shop Crane - Drip Tray:VAS 6208  under the final drive.

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

Oil Capacity and Oil Specification. Refer to ALL WHEEL DRIVE CLUTCH, CHANGING OIL Oil Capacities and Oil Specifications .

Fig 9: Identifying Oil Container -A- With Valve Closed Onto Charging Device F/Held 2 Coup. VAS 6291 A

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-- Screw the oil container -A- with the valve closed -arrow- onto Charging Device For BorgWarner Coupling 2 :VAS 6291 A  .

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

-- Using the Charging Device for AWD Clutch Coupling 2 :VAS 6291A  , fill with oil until it flows out between the adapter and the transmission housing.

-- Remove the Charging Device For BorgWarner Coupling 2 :VAS 6291 A  .

-- Remove the adapter -A-.

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

Fig 10: 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 11: Identifying Oil Drain Plug -Arrow-

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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) could not be guaranteed.

The oil temperature can be measured using the Digital Thermometer:VAS 6519  .

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