How Haldex (AWD) All Wheel Drive Works ~ Teardown and inspection

Today we look at how VW and Audi Haldex All Wheel Drive (AWD) systems work. How VW and Audi get all wheel drive on some cars. We also teardown a 215,000 mile Haldex and rear differential. This video started out as a limited slip differential install. However I exploded part of the original diff. I lucked out and got a second diff with a Haldex unit.
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disclaimer:
The content of this video is available for informational and educational purposes only. It is not intended to be a substitute for the professional advice of a mechanic who has personally inspected your vehicle, nor does it create a relationship of any kind between the Humble Mechanic and you. Every situation may be different, and the Humble Mechanic does not make any warranties, whether express or implied, as to the accuracy, fitness, or applicability of the information or automotive parts portrayed in this video to any project and makes no guarantee of results. The Humble Mechanic and any sponsors of this video will not be liable for any damages related to personal injury, property damage or loss of any kind that may result from the use or reliance on this video and/or any automotive parts represented in this video. You are using the information and automotive parts portrayed in this video solely at your own risk.

[@tomthompson7400]

The man who never made a mistake , never made anything.

[@tt-rs1457]

By all means ! Wer arbeitet, macht Fehler........

[@polo16v191]

@@tt-rs1457 Yes exactly. Il n'y a que ceux qui ne font rien, qui ne font pas d'erreurs :)

[@PatricioGarcia1973]

From mistakes we learn, albeit sometimes the mistakes are on the expensive side...

[@robertwilliams7768]

This ^

[@natelysy3114]

Man made it, man broke it, man can fix it.

[@HumbleMechanic]

Something I am not sure how I forgot to mention. The Haldex and diff fluid are DIFFERENT. If you do the service, be sure to use the proper fluid.

[@blackpete]

Simply RTFM. Different diff, different oil. Just look it up, to be sure. Helps not killing things. 😇

[@tm199100]

Charles, have it dry ice cleaned

[@Xappt]

Please do the diy! I am absolutly enjoing the videos!

[@donbrashsux]

I’m glad you mentioned this fact as no one else points this important fact out to all the DIY legends

[@Xappt]

What LSD is it? Looking forward to do it myself!

[@gplusgplus2286]

DIY detailed install P L E A S E ! ! ! No other video exists of this job ( I have a spare haldex waiting for this). Also, I hear you need to also put an LSD at the front gearbox/transfer case; the front LSD has more pronounced result than the rear LSD (obviously better to do both).

[@TimppTV]

Almost 5 years at a VW/Audi dealer as a tech I could never wrap my head around how a Haldex worked. All I needed was this video! Do newer Haldex units work in a similar way?

[@colinwie9192]

There's actually some more stuff Charles missed. This is a gen 1 haldex which actually works on a mostly mechanical(ish) function. The rollers that fell out when Charles pulled the clutch drum assembly, those are parts of the mechanical pump and piston function. The small rollers act on a Cam plate/Lobed plate which serves as the "pump" plate, the three big rollers act on the piston plate which applies pressure on the clutch pack. The pumping action starts as soon as there's a difference in shaft rotation speed between the input and output. The electric pump really only serves to prime the system and charge the accumulator. System regulation is handled through the regulating valve. Basically, when you're easy cruising/coasting/parking with no wheel slip, the system is always at the ready to lock up for AWD. When you're mobbin' around pedal to the floor, "spirited driving", etc..., the system is already set for AWD, but the mechanical pumping action is what actually engages the lock up for AWD, therby making it a "reactive system". That's how gen 1 & 2 Haldex works. Gen 3 onwards used an entirely electric pump system, meaning through software the system can be, or is, tuned to be "proactive" so AWD could be locked up, or "pre tensioned" before wheel spin. All depends on the software parameters. To this day, as best I know, Audi/VW has only used gen 1 & 4 systems. Mechanical(ish) or electric, which is better? Each have their pro's and con's, but my 03 BEA powered TT's AWD is fantastic, so much so it does it's job seamlessly and I still haven't needed to replace my Haldex pump yet, ....unlike many people with gen 4 Haldex cars. BTW, not trying to rip on Charles. He's great and this was an absolutely great tear down video (speaking as a former long term Audi/VW tech myself). Just typing out a long winded ramble to answer your question.

[@rolandm9750]

Didn't you guys have to do courses all the time? I'm guessing the VAG line on how to repair these was to "replace Haldex coupling" entirely? Either that or you never saw one fail apart from electronics/pump? Anyway yeah the newer ones are very similar, they've changed some of the operation in terms of pumps, etc. but the main principle is the same. It has actually been continually simplified over the years with 4th gen doing away with the mechanical pump, and 5th gen doing away with the accumulator, netting a smaller and lighter package over the years. At the same time the electronics and integration with other systems (ESP/TC/ABS and driver inputs like steering & throttle) have improved quite a bit netting significantly improved real-world vehicle performance.

[@rolandm9750]

@@colinwie9192 VAG used Gen2 in later PQ34 cars with quattro/4motion (e.g. Mk4 .:R32, Mk1 TT, A3) as well as early PQ35 cars (Mk2 A3 & TT 3.2L VR6/Mk5 .:R32); later PQ35 cars got Gen4 Haldex, starting around MY09 (in Can/US) including A3, TT, and Mk6 .:R. B6 Passat/CC being PQ46 follows a similar timeline. MQB cars have Gen5 couplings and much more integrated electronics than previous iterations. Gen4 in the PQ35 cars never integrated ESP & steering functions (it did on other brands and the capability is there, VAG just didn't implement it). There weren't many problems with 4th gen couplings, the problems were more on the early MQB cars with 5th gen Haldex. 5th gen has no accumulator so arguably the electric pump has a higher duty cycle or higher demand on it, which could have led to the failures though this is just speculation on my part. Mk8 Golf R has what I *believe* would be Gen6, though it may just be a highly customised system with a Gen5 coupling at heart, not entirely sure. The one gen they never used was Gen3 because this was specific to Land Rover. Saab also had a customised Saab-only version in their XWD system, which nobody else ever used.

[@thePeterpumpkin68]

​@@colinwie9192and a very informative ramble. Thanks.

[@Paulie_franga]

😂​@@thePeterpumpkin68

[@scottibass]

Amazing how much pressure a snap ring can take!

[@SplicesAndCelluloid]

Past Charles: "I'm nervous about this part" Little does he know...

[@emilianofloridia4445]

Try with dry ice blasting. It's not cheap but the best result, and good content for the channel. Greetings from Argentina!

[@tm199100]

Came here to say that..

[@desertwind16v]

I just saw a video of a Porsche getting this treatment on its undercarriage today! Pretty insane results.

[@thegrimreaper7777]

DIY with Soda Blasting, (Bicarbonate of Soda from a Farm Supply store) in a blasting pot gun, just sleeve down the pickup tube so you don't turn your driveway (DO NOT DO IT INDOORS) into a winter wonderland in a second. Wash soda off with warm water.

[@carlosdorantes9884]

Coc melon

[@RC-fe9py]

Beat me to it lol!😄

[@George-zq2sk]

I loved that description of how the haldex works! That was incredible! You kept it so simple! killer content Charles!

[@andrewgonyou9903]

never been super big on euro stuff, but I have to admit the threaded holes to press the parts apart is pretty genius

[@Wachueu]

Hi there, i just want to say huge THANK YOU for all the materials you have uploaded, it really helps for people like me to understand how these things works.

[@tonylopes8175]

Hello Charles, first of all I want to thank you for all the awesome things you show us. I also like to add that your not an idiot for what you did, its all in a days work, I do that all the time that's how we learn sometimes. I hope I learn from my mistakes, anyway awesome job. Those who do will eventually brake something and learn, those who don't will never learn anything lol.

[@Thaddeus.J.DeWyse]

Awesome video!!! I always appreciate learning from you!! You helped inspire my love for Volkswagen and the VR6 engine in particular!! I own a 2002 VW Jetta with the 2.8l 24V VR6. It only has 82,000 miles but needs a whole lot of work. I don't think the previous owner really did much maintenance at all. My ultimate goal is to take the entire car apart piece by piece, clean it, then put it all back together how it came from the factory. Thanks for all the awesome content!! Cheers!!!!

[@danielmarshall4587]

Always enjoy your honesty "THIS IS WHAT NOT TO DO".... stay on the path you're on loving your vids.

[@herrkulor3771]

I just love those 3 finger pullers. Things come of with such ease when the forces align perfectly. Instead of hammering and random

[@wayneyoung146]

It’s great that the pro stuff up. Enjoy watching your channel

[@YouilAushana]

Man! I drove one of those original R32 Golf cars back in 2004. Definitely a great car that inspires confidence in the driver. Had that short wheel based AWD in the 4 wheel drift like it was riding on rails through the corner!

[@DonryuRaiden]

And again a humble thank you for your informative videos.

[@19maho87]

Nice description and a good video. Greetings from Germany

[@arnoldwienke4758]

Thanx Charles! Did a haldex service on my tiguan today. Had really bad sludge coming out but no metal.😅 It’s funny to see that the generation 5 haldex is using the same filter on the pump. Keep up the good videos!

[@stephenprice7502]

Super cool to see this video. That was a bit of an "oops" moment, but at least you managed to get another. I remember having to press half shafts for a Jaguar XF out so I could replace bearings. No forgotten snap rings, just seized tapers. 40T press failed to shift them. Ended up taking them to an heavy goods service centre who failed to press them out with & 15OT press. They had to take them round to the big boy toy and that registered 265T before the shafts finally broke taper. The bang was super loud.

[@robt8042]

That's insane. I wonder how the Jaguar dealer does that job?

[@cumbob]

@@robt8042 they sell you new assemblies of it's that stuck lol

[@martinkominek6712]

Have you tried hamer it from the side while pressing? Usualy works if its not too stuck.

[@Hawk7886]

@@robt8042 That's an easy conversation: "Hello, Mr. Customer? Your axles are corroded and seized and our shop press is unable to get them separated. We'll have to order new ones." If it's not a personal project and I don't have a bunch of time authorized to dick around with giant shop presses, I'm not gonna waste a bunch of time on that noise.

[@autovmcomposites9997]

Another great video. Also nice that you show us that every mechanic makes mistakes. We learn from mistakes. Best regards from Germany👍🏻

[@oetic5016]

You're always the man to watch. Love to watch these lengthy vids is really informative and relaxing.

[@HumbleMechanic]

Thank you

[@ne2i]

This system is amazing. Its actually smart enough to shut itself off when the unit is low on oil. I had a Audi TT quattro that had a non working rear diff. I just changed the filter and oil and it came back to life.

[@robertwilliams7768]

Really like your videos man, and honestly i appreciate that you show youre mistakes. Anyone who says they dont make mistakes and always know exactly what theyre doing doesnt know how to work on cars. Humility is the best virtue of a good mechanic, because a true master mechanic knows that he doesnt know everything. There always something to learn , and mistakes to make. Mistakes are the greatest teacher.

[@robertwilliams7768]

Also.. i can smell most of this video lol

[@darrelsmith3907]

Would love to see a full assembly video. Always love to see how you explain things and how you show the methodical process you take to restore things

[@HumbleMechanic]

AWESOME! My parts came in today. I have some paint on the way too. HAHA couldn't leave it nasty.

[@doughampton5991]

That explosion was totally rad!

[@jackvr32]

Nice work! Can’t go wrong posting more detailed videos. Powder coating looks awesome

[@TheBSHE]

fantastic video! I will be tearing down the suspension on my S3 8L pretty soon and was wondering whether i should rebuild the diff or not. After you explained how easy it is to tear it down i'm going with yes!

[@meeterhead462]

Yup . DRY ICE is the move .... its gonna look fantastic ..And a BIGG YES to any DYI educational video ..I Love your commitment to the culture ..Thankyou ..🤓

[@mikeburne7581]

I have a haldex issue on my Sharan VR6, so this is really useful, thank you.

[@mijanhussain2241]

Awesome vid! Would love the full assembly video! Especially how the axles go back in and are secured

[@miketeeveedub5779]

Great video Charles! I like how the Haldex is basically an eletronically-controlled dirt bike wet-clutch assembly mated to a differential housing. I also like how the actual differential is separated from the ring/pinion gear drive via an input shaft. MUCH easier to set up then lets say a LSD on a ford 9" or a GM 10/12 bolt, but a bit more difficult to get to those same internals. The one bit of advice I'd like to add is: the secret to long Haldex diff/clutch life is to change the Haldex and diff gear fluid on a regular basis. Every 20 or 30K. The Haldex fluid isn't cheap, but it's cheaper then replacing the ECM, pump and pressure switch. Ask me how I know that! 😢 💸💸💸 Love your content bro! Cheers!

[@conspiracyfifteensixteenth5756]

Love your videos! I own a 2006 passat3.6l Vr6 4motion.. These videos have helped me keep the longevity of this Car also saving me thousands of dollars.👍

[@jayburrell]

Great video love seeing how these work great colour👍

[@jamesmedina2062]

Through your mistakes emerges our own knowledge and some pretty gnarly shop drama! Thanks Charles!

[@HumbleMechanic]

Exactly!! Learn from others mistakes. It what I prefer to do. Haha but mine are much more painful

[@christianarchibald4029]

Failure, the best teacher, I love your videos

[@miamirice6840]

really appreciate your videos. i am happy to say years after owning a great MK5 (the return of the GTI)…..i just picked up a mk7.5

[@MySunroofWorks]

Yes, love the content and would love to see a step-by-step process!

[@vwmechano]

I installed a locker diff to a T5 van today and this vid shows up :)

[@AdamShaiken]

Heated pressure washer with a citrus based solvent for cleaning the case.

[@ChristopherBristol]

yea I was gonna say similar, strong citrus cleaner with a high pressure steamer.

[@thomascanning595]

Nice vid. eager to see what mods you'll do the haldex system!

[@1csearle]

Would enjoy to see the step by step, excited to see the results..

[@adriansmith1410]

great content always luv to watch true pro😄

[@pablofernandez57]

Awesome video as usual! I thought that my rear diff was broken and after changing the haldex oil and a new filter it came back to life! Amazing what a service does!

[@humbertom1184]

did your car experience binding around the corners? I am having an issue when my car binds when cornering. did the oil change fixed the issue?

[@pablofernandez57]

@@humbertom1184 It was like a chattering/clicking noise when cornering hard,specially when parking or coming out of tight spots and some corners. It was similar as if a calliper was seized too and the oil and filter change worked for me,it took a day to start working properly and it’s been good for a couple of years now.

[@jameshewitt4708]

I'm having the same issue, oil and filter change seemed to fix it for an hour or so. Problem goes away then unplugging the haldex.

[@jeremys.4423]

A testament to the strength of snap rings everywhere

[@n.b.5258]

Yes to getting another video / DIY for installing the diff. Also, if you don't want to blast and powdercoat the case, Eastwood makes a spray paint that looks exactly like freshly cast aluminum. You could wire wheel or really just clean and de-grease the case and then use that spray paint. I've used it on alternators and engine mounts, and it holds up pretty well and looks good.

[@HumbleMechanic]

I like that idea!!!!

[@putinisgod6814]

Love the colour and also dry ice

[@bradcarpenter1881]

I know this comment is months after upload and likely to never be seen by anyone lol, but how does this vid only have 90k views?! This is incredible top notch gearhead content and about as professional quality as you can get from being on YT. This channel deserves way more views! Honestly I think the problem these days are that the are so many "car related" or mechanic related channels that makes it difficult for YT algorithms to properly promote the better, underrated channels. For that, I did my part and hit the like button!

[@HumbleMechanic]

I totally agree!

[@Dimm88]

Good job! There is not many instructions how to fix haldex on internet. Its way easier now that I saw this video gotta get rid of pinion noise that my haldex produces

[@moe5046]

AWESOME, you got your engineering degree Keep up the great vids.i love watching you fix vw's ....and dont worry about the c clip,it happens,just a hurdle,lol

[@brmo6232]

2019 4motion Tiguan - was OUTRAGEOUS in the snow and ice up north

[@brmo6232]

@@oijhhytdirhrbru gotta love the simplicity of it, it feels wonderful drives fantastic

[@jhyde2129]

Charles - That sucks about the missed snap ring but it made the video really fun to watch! Yes, a full limited slip DIY install would be awesome! After seeing this I want to do this upgrade in my MK1 TT. PS - your videos rock!

[@tylerm.9408]

Would love to see that case cleaned up and a full install video!

[@32krod]

I know my miata manual trans was pretty coated. I cleaned it using purple power and some brushes over a couple days (covering the openings, and before installing new seals)

[@europerformance]

Sodablasting is a great way to clean it up without damaging anything

[@Honda-te2gq]

If the haldex clutch plates were replaced with solid drive plates, wouldn't that cause the front and rear axle to bind? Your enthusiasm and energy is admirable. Thanks for sharing your knowledge.

[@Legoman585]

Love watching you wrench dude. There is a special tool to do this job but we don't have it so I'm just going to do it this way.

[@HumbleMechanic]

That’s so much

[@oleksandrmenko5276]

Need to do my haldex flush soon helped out a lot

[@dantemagz6672]

Great video! Please do a gen 4 haldex tear down!

[@daviscc65]

Love that purp

[@Just.a.random00]

Ive had awesome results using oven cleaner to clean dirty aluminum and steel parts. Obviously avoiding electrical connectors but everything else comes out great. Finishing off with dishwashing liquid stops the aluminum from getting those white crusties afterwards.

[@labradormcgraw]

LMAO at the cursing! I'm glad it's not just me who does that.

[@HumbleMechanic]

It continued for a while after the camera was off

[@labradormcgraw]

@@HumbleMechanic Yes, I can imagine. lol

[@dErWixxer63]

Please do a detailed video for assembling the diff, i really wanna see it step by step. Thanks man!

[@marcanderson1627]

Try dry ice blasting. From what I've seen it does an amazing job.

[@MIH11MI6]

When I did my 02M gearbox rebuild I used aluminium acid cleaner (wear gloves) to wash over, use general degreaser before. Leave acid on for 15 minutes, then I washed off with water. For an extra step I then hovered a blow torch over the casing to absorb the water and it came up looking near new

[@HumbleMechanic]

The torch idea is awesome

[@MIH11MI6]

@@HumbleMechanic good luck! Can't wait to see this process all the way through

[@Swordie100]

I think I need to watch that haldex explanation more than once.. :")

[@blkcoupequattro]

That ring gear side taper bearing is the boss, like twice the size of 9" Ford big bearing carrier...

[@franciscovasquez4555]

The diy would be a great idea, and doing a deep cleaning and coating video also. Keep up the great content

[@HumbleMechanic]

that video is so cool!!! I can't find anyone locally. Well I Can, but they are all big scale stuff.

[@wille0113]

if you have the time and dedication you can take a fine scotch bright pad and use it as sandpaper all over the diff and do tricky sections with a small wire brush wheel on a dremel. I used this metod on the engine of my motorcycle (also aluminium, was in a similar condition), turned out much cleaner and had that "aluminium" colour again.

[@davej.6290]

I closed all openings on mine and sandblasted it. Afterwards i gave it another blast with glas pearls to give it a smooth finish.

[@davej.6290]

@Charles: i left some picture on your fb post

[@Rainoffire]

Dry Ice blasting gets my vote. Expensive, but very effective at cleaning and making things like factory new.

[@jameswalsh3040]

Dry Ice blast it to get it looking new - wont have to take anything apart!!!

[@300DBenz]

I’ve smelled PLENTY of things worse than old diff fluid: Smokers’ cars that had so much tar build up, the windows looked like they were tinted. Burnt up automatic transmissions. A car that had 2 dead cats in the spare tire well.

[@jamesmedina2062]

OMG!!! 😂😂😂😂😂👌

[@HumbleMechanic]

The smokers thing I’ve seen too. Ugh!!!!

[@brendanconnelly1835]

Worst smell is the trash compactor at a supermarket nothing like rotting meat and vegetables getting baked by the summer sun.

[@aaronhall7740]

Diff oil that's mixed with water, or reduction hub oil the same is pretty foul!

[@pczapp827]

@@brendanconnelly1835 Went to a farm on a 4H trip & they had a huge barn of Turkey's,don't suggest you expose yourself to that unless your a farmer growing them,stay with a Turkey Club at a Diner. The Fish Market in San Fran was too much for me also.

[@stacycarter8641]

Yes step by step for the diff

[@HumbleMechanic]

Awesome. Waiting on parts!

[@ketillundsrensen6167]

So i guess that there are a clutch pack with better friction plate and more of them like there is on Motorcycles. It's a normal upgrade on MX machines. That combined with the LSD diff and front LSD dig should give you a lot more traction to the wheels. And yes a install video would be nice. It's always nice to have youtube to show you how to do stuff. I have saved a ton of money and time by watching KZbin to finde and repare faults.

[@anthonydalessandro6363]

Reassemble video would be awesome!!

[@kennethd7048]

Yeah charles.. except for the KABOOM.. segment. It's pretty interesting watching you take it apart. Since I have 2 Volvo R's I'm sure my AWD is similar. Take care. Oh... while you're in there.. sprinkle baking soda on the housing and then fill a windex bottle with vinegar and spray it on. Might work or I could be totally around the bend... Probably

[@Smoovindecat]

Dry ice cleaning! Great on stuff like gearbox and blocks!

[@jrb1737]

nice vid 👍

[@jp2246]

Nice accent color choice 👍

[@carsncabins1349]

I want that part you spoke of bypassing the haldex altogether. Full time awd. Hell yes lol

[@HumbleMechanic]

I can’t find it

[@turdiousmcfurgeson1570]

I have a 03 Jetta with the 24v VR6... I would LOVE to see a step by step on replacing the front diff so i can add power and be able to put it all down

[@tkinak]

I've used Aluma Bright on several aluminum boats. However they weren't that dirty. Leaves the aluminum "white". Might be a good place to start.

[@motoray69]

Love the purple

[@mazleo4430]

love the purple with the black actually have the same color scheme tho i like your shade better

[@HumbleMechanic]

NICE!!!

[@vr6_lover]

Yes please full DIY would be great if u could include part numbers also thanks Charles

[@HumbleMechanic]

YES to the PN!!!

[@sparkplug1018]

Wonder if you took the electronic parts off if you could throw the entire unit into an ultrasound cleaner? Would think it would do a pretty good job cleaning it up and as long as you got oil back in it as soon as its dry you wouldnt have any rust issues.

[@michaelskinner896]

Laser cleaning. Fast, efficient with minimal impact to the base material. They are now available as handheld units but they might be a little pricey.

[@curvs4me]

That unit looks super stout for an r32 car. I know they can put out 1200hp with some love and tenderness. I'm actually considering the vr36 for mi 944. Infinite cosmic power, itty bitty little living space.

[@Chimera6297]

"we should be careful and make sure we don't damage anything" *SNAP* I know that feel

[@Embermist69]

As usual, when one does not listen to their gut, bad things can and do happen. 😑 That's going to leave a mark in the brain for a bit. Anywho thanks for the video and best of luck on the project Charles. 🙂

[@danielpalmer9079]

Charles if you haven't yet come up with a solution for the diff case I would definitely look into dry ice blasting if there's someone nearby you that has a setup for it. No need to disassemble as there's no true abrasive media, just dry ice that evaporates to atmosphere.

[@bash5552]

Great Vid!! ThanKS!

[@diabloman5666]

Not 3 weeks ago I snapped a bolt putting my haldex pump housing back together so....that was fun

[@HumbleMechanic]

YIKES!

[@diabloman5666]

@@HumbleMechanic yea, I had it towed to a professional out of an abundance of caution. I didn't want to make it worse. I still don't know what the proper torque spec is supposed to be but I am surprised the bolt snapped at 15 nm.

[@mry82]

You're not an idiot, just "testing the snap ring in the interest of science" (it passed!). Art of the spin! :) Best!

[@ABFCUT]

Excellent presentation as always !!! I have a question regarding the permanent engagement insert you mentioned from an Italian guy. As far as I know, the prop shaft spins continuously as long as the engine works since it transfers the power from the gearbox in front, before the clutch. That, in my understanding implies that the rear wheels have to spin too, regardless of any gear engaged or not. Is that so? Would you elaborate please?

[@magnusdanielsson2749]

Nice vid 👍 I got a Bora thats not driving on the back wheels. Ill have to check the haldex later this year when its warmer outside.. I found out the hard way that its difficult to know if the 4motion actually works when buying second hand.. 🙄

[@ocdpvw1]

Awesome video Charles. My vote goes to cleaning it to original state or coating silver. It'd look great with your purple. Does Zealous do anything for the rear diff/haldex?

[@HumbleMechanic]

I don't think he does. But I have a set of beauty washers I may run!

[@petermatteson4619]

The only methods I can think of to clean the case without disassembly are probably cost prohibitive or not easy to locate, laser cleaning being the best choice. You might be able to do a dry ice media blast without worrying about taking things apart.

[@BeeShopcs]

this guy and this but you are the best guy