Service

Workshop Manual
Altea XL 2009 ➤
Altea XL Freetrack 2008 ➤
Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR
Edition 04.2010

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
39 - Final drive - rear differential

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Seat S.A S01B0AV8U20

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of the rear final group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Codes, allocation behind the 0AV final drive, filling amounts . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Codes, allocation behind the 0BR final drive, filling amounts . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 propeller shaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Propeller shaft: Installation summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Separation and connection of front section of propeller shaft . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Separation and connection of rear section of propeller shaft . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Removal and installation of complete propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Rear final group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 Removal and installation of rear axle drive, 0AV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Removal and installation of rear axle drive, 0BR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Rubber/metal bearing for rear axle drive: assembly summary . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Installing rubber/metal bearing for rear axle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5 Installing sealing rings for left and right propeller shafts (with rear axle drive installed) . . . . 40
2.6 Replacing sealing ring on propeller shaft connection to rear axle drive (with axle drive
installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Haldex clutch: rear axle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Haldex clutch: assembly summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Removal and installation of Haldex clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Haldex clutch II: function check, rear axle drive “0AV” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 Check the operation of the Haldex clutch II closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2 Check the operation of the Haldex clutch II open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 Haldex clutch IV: function check, rear axle drive “0BR” . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1 Checking oil level in rear axle drive “0AV”; replenishing if required . . . . . . . . . . . . . . . . . . 54
6.2 Checking oil level in rear axle drive “0BR”; replenishing if required . . . . . . . . . . . . . . . . . . 54
6.3 Checking oil level in Haldex clutch II and IV; replenishing oil, if required . . . . . . . . . . . . . . 56
7 Electrical and electronic components, rear final drive “0AV” . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 Electrical and electronic components and their location . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.2 Control unit for all-wheel drive: J492 assembly summary . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.3 Removal and installation of four-wheel drive control unit J492 . . . . . . . . . . . . . . . . . . . . . . 63
7.4 Removing and installing pump for Haldex clutch V181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8 Electrical and electronic components and fitting locations, rear final drive “0BR” . . . . . . . . 71
9 Conversion table by relevance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.1 Graphical information on the use and VW units, Seat equivalents . . . . . . . . . . . . . . . . . . 72

Contents i
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

ii Contents
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

00 – Technical data
1 Identification of the rear final group
With the rear final drive 0AV, one designates this as the 6-speed
manual gearbox 02Q, four-wheel drive.
With the rear final drive 0BR , one designates this as the 6-speed
manual gearbox 02Q, four-wheel drive and the gearbox DSG 02E
for four-wheel drive.

Note

♦ The “Haldex coupling” is incorporated in the final drive.

♦ The final drive and the “Haldex coupling” have separate oil
circuits.
♦ The final drives “0AV” are equipped with the “Haldex clutch II”.
Identification and ⇒ page 1 .
♦ The “0BR” final drive is integrated in the “Haldex coupling IV”.
Identification ⇒ page 1 .

Example of identification markings on rear final drive “0AV”

-Arrow A- Part number of final drive
-Arrow B- Code letters of final drive
♦ If the code letters are not shown, the unit can be identified via
the Part No. ⇒ Electronic parts catalogue .
-Arrow C- Production date of final drive
Example:
HHJ 09 08 05
I I I I
I I I I
Identification Day Month Year of manufacture
letters -2005-
Any additional data is related to the manufacturing process.

Rear final drive “0BR”

Note

♦ The identification -arrow- on the “underside” of the final drive

unit indicates which final drive version is installed.
♦ For further explanation of the identification markings on the
“underside” of the final drive ⇒ page 1 .

1. Identification of the rear final group 1

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

1.1 Codes, allocation behind the 0AV final drive, filling amounts
Rear final group 0AV1)
Identification letters JJN JYP, KJT JYP, HVZ KJT
Correspond‐ Model Altea XL Free‐ Altea XL Free‐ Altea XL Free‐ Altea XL Free‐ Altea XL 2009▸
ence track 2008▸ track 2008▸ track 2008▸ track 2009▸
Engine 2.0L 147 KW 2.0 103 kW 2V 2.0 L 125 kW 2,0l 125 kW CR 1.9L 77KW TDI
TFSI 16V TDI TDI 16V DPF
Transmis‐ Rear final 27 : 17 = 1,588
sion Z2 : Z1 group
Filling capacity for the fi‐ 0.95 litres
nal group
Filling capacity for the 0.85 litres
Haldex clutch
Filling capacity for the 0.65 litres
Haldex clutch (if re‐
placement is necessary)
• Intervals for chang‐
ing filter ⇒ Mainte‐
nance ; Booklet 101
1) Rear final drive “0AV” in conjunction with the “Haldex clutch II”
Drive shaft flange ∅ 100 mm
The following information is found in the ⇒ Spare parts catalogue :
♦ Gear oil for the rear final group
♦ High performance oil for Haldex clutches
♦ Gearbox assignation

1.2 Codes, allocation behind the 0BR final drive, filling amounts
Rear final group 0BR1)
Identification letters KMC KMC, MMK KMC, MMK
Correspond‐ Model Altea XL Freetrack Altea XL Freetrack Altea XL Freetrack Altea XL 2009▸
ence 2008▸ 2008▸ 2009▸
Engine 2.0l 147 kW TFSI 2.0 103 kW 2V TDI 2.0l 155 kW TFSI / 1.9L 77KW TDI
16V / 2.0l 125 kW 2.0l 125 kW CR / DPF
TDI 16V 2.0l 103 kW DPF
Transmission Rear final 27 : 17 = 1,588
Z2 : Z1 group
Filling capacity for the final 0.95 litres
group
Filling capacity for the Hal‐ 0.85 litres
dex clutch
Filling capacity for the Hal‐ 0.70 litres
dex clutch (if replacement is
necessary)
• Intervals for changing fil‐
ter ⇒ Maintenance ;
Booklet 101
1) Rear final drive “0BR” in conjunction with the “Haldex clutch IV”
Drive shaft flange ∅ 100 mm
The following information is found in the ⇒ Spare parts catalogue :

2 Rep. Gr.00 - Technical data

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

♦ Gear oil for the rear final group

♦ High performance oil for Haldex clutches
♦ Gearbox assignation

1. Identification of the rear final group 3

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

2 General repair instructions

Repair work on the final group must be carried out with greatest
care and cleanliness possible, using tools that are in perfect con‐
dition. Naturally, the customary basic safety rules must be ob‐
served during repair work.
A series of instructions applicable to all repair processes is given
below:
Rear final group
♦ If the rear final group is replaced, check the oil level of the
Haldex clutch and the final group, and top off ⇒ page 54 .
♦ Filling amounts ⇒ page 2 .
♦ Types of oil ⇒ Parts catalogue .
♦ Clean contact surfaces on fitting blocks, supports or waxed
components. The surfaces must be completely free from wax
or grease.
Fault finding
♦ Before carrying out repairs on the Haldex clutch, determine
the cause of the fault by using the “Guided fault finding”, the
“Vehicle self-diagnosis” or the “Measurement module”of the
central diagnosis -VAS 5051B- or the central diagnosis -VAS
5052- .
O-rings, seals, gaskets
♦ O-rings, seals and gaskets must always be replaced.
♦ Thoroughly clean contact surfaces.
Before assembly:

♦ Lightly lubricate the outside diameter of the shaft radial seals

before installing them. Refill the space between the sealing
lips -arrow- with grease ⇒ Parts catalogue .
♦ Before installing the radial seals for the Cardan shaft flange,
lightly lubricate the outside diameter and the space between
the sealing lips with high performance oil for Haldex clutches
⇒ Parts catalogue .
♦ The open side of the seals should face the liquid to be retained.
After assembly:
♦ Check the rear final group oil level ⇒ page 54 .
♦ Check the Haldex clutch oil level ⇒ page 57 .
Safety locks

4 Rep. Gr.00 - Technical data

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

♦ Do not over-expand safety rings.

♦ Always replace damaged or over-expanded safety rings.
♦ The securing rings must be perfectly seated in their groove.
♦ Replace the support sleeves. Installation position: The
groove-A- must remain parallel to the direction of the flow of
pressure -arrow-.
Bolts, nuts
♦ Nuts and bolts for securing covers and housings must be
slackened and tightened in diagonal sequence.
♦ Do not bend the parts, especially fragile parts; loosen and
tighten them in stages in diagonal sequence.
♦ The torque settings refer to non-oiled nuts and bolts.
♦ Always renew self-locking bolts and nuts.
♦ Contact surfaces, bolts and nuts for all threaded joints must
be waxed when fitted if necessary.
Bush
♦ The needle bearings must be inserted with the engraved part
(thicker side of the plate) facing towards the installation tool.
♦ All bearings of the gearbox must be fitted lubricated with
sprocket oil.
♦ Conical roller bearings fitted into one same shaft must be re‐
placed together. If possible, use parts from the same manu‐
facturer.
♦ Heat inner rings up to approx. 100 °C before installing.
♦ Do not confuse the outside and inside rings of the bearing with
the rings from other bearings of the same size. The bearings
come in matched pairs.
Shims
♦ Check shim settings at various points, using a micrometer.
The existence of different thickness shims will enable the se‐
lection of the correct thickness required.
♦ Check that it is not burred or damaged.
♦ Only fit shims in perfect state.

2. General repair instructions 5

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

3 Safety precautions
Observe the following precautions if tests have to be performed
with the engine running.

WARNING

Vehicles with direct shift gearbox: accidents can be caused if

a gear is inadvertently engaged while the engine is running.
♦ Before working on the vehicle while the engine is running,
shift the selector lever into position “P” and apply the
handbrake.
Danger from toxic fumes!
♦ When the engine is running, the exhaust system must al‐
ways be connected to the exhaust gas extractor.

If in the test drives it is necessary to use the tester units, take note
of the following:

WARNING

Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not se‐
cured.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
Always secure testing equipment to the rear seat with a strap
and have them operated from there by a second person.
♦ Move the passenger's seat to the rearmost position.
♦ Use only Vehicle Diagnosis and Service Information Sys‐
tem -VAS 5052- .
♦ Test equipment may only be operated by the passenger;
the tester -1- must be placed flat on the passenger's lap
as illustrated.

Observe the following precautions to avoid possible injury and/or

damage to electrical and electronic components:
♦ Disconnect and connect test and measurement equipment
only when the ignition is switched off.

Caution

When disconnecting the battery there is a risk of serious dam‐

age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery.
♦ Always switch off the ignition before disconnecting the
battery.

6 Rep. Gr.00 - Technical data

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

39 – Final drive - rear differential

1 propeller shaft:

Note

♦ Work related to the propeller shaft must be carried out with the
vehicle on a two post lift.
♦ During the production process the complete propeller shaft is
always balanced to obtain the smoothest operation possible.
With the equipment available in the workshop, it is not possible
to balance either the complete propeller shaft or parts thereof.
For this reason it is always necessary to replace the entire
propeller shaft when any part is damaged.
♦ Do not bend the propeller shaft, store and transport extended
only.
♦ Before removing, mark the position of each part with respect
to the other parts. The parts must be reassembled in the same
position. If not, the system will be excessively unbalanced.
This can damage the assignments and cause noise.

1.1 Propeller shaft: Installation summary

1. propeller shaft: 7
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

1 - Gearbox with bevelled gear

2 - Collared securing bolt with
double hexagon head bolt with
notching
❑ For the front flexible disc
on the propeller shaft
❑ M 10 x 30
3 - Front flexible disc
4 - Collared securing bolt with
double hexagon head bolt with
notching
❑ For the flexible disc on
the bevelled gear
❑ M 10 x 30
❑ 60 Nm
5 - propeller shaft:
❑ Should not be separa‐
ted on the joint -arrow-
❑ Separation and connec‐
tion of front section
⇒ page 8
❑ Separation and connec‐
tion of rear section
⇒ page 13
❑ Removal and installa‐
tion of complete propel‐
ler shaft ⇒ page 18
6 - Plug
❑ M 8 x 38
❑ 25 Nm
7 - Central bearing
❑ Align free of tension
8 - Plug
❑ For the rear flexible disc on the propeller shaft
❑ M 10 x 52
9 - Plug
❑ Secures the flexible disc to final drive
❑ M 10 x 45
❑ 60 Nm
10 - Rear flexible disc with vibration damper
11 - Rear final group

1.2 Separation and connection of front sec‐

tion of propeller shaft
Detaching ⇒ page 9
Connecting ⇒ page 11
Tightening torques ⇒ page 13
Consult the equivalence table for tools and equipment according
to applicability among Seat / VW / Audi / Skoda ⇒ page 72 .

8 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Special tools and workshop

equipment required
♦ Counterhold -T20111- , see
equivalent ⇒ page 72
♦ Counterhold -T20185- , see
equivalent ⇒ page 72
♦ Torque wrench -V.A.G
1331- , see equivalent
⇒ page 72
♦ Torque wrench -V.A.G
1332- , see equivalent
⇒ page 72
♦ Engine/gearbox crane -
V.A.G 1383 A- , see equiv‐
alent ⇒ page 72

Detaching
With diesel engine:
– Remove central soundproofing -Anchorage points 1 ... 3-.
With petrol engines:

1. propeller shaft: 9
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Remove central soundproofing

-Anchorage elements 1 and 2-.
All vehicles (continued)

– Remove right soundproofing -Anchorage points 1 ... 3-.

Note

♦ The securing bolts of the heat protection plate and the centre
bearing of the propeller shaft retain these two elements at the
same time.
♦ It is necessary to fasten the propeller shaft before completely
unscrewing the two locating screws from the heat shield and
the resilient centre bracket. Otherwise it can buckle in the mid‐
dle and damage the intermediate bearing.

– Loosen the mounting screw -1- of the centre bearing of the

propeller shaft.

– Unscrew bolts -2 and 3 and screw out the pendulum arm sup‐
port on the gearbox.

10 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Push the subframe to the front and secure in this position using
the support tool -T20111- and support tool -T20185- .
– Check to see if a marking (coloured point) is located on the
front flexible disk and on the flange on the front bevelled gear.
If there are no marks, the position of the flexible disc with regard
to the flange on the front tapered unit should be marked.

Caution

Mark the position of the bolts, as some of these may have bal‐
ance washers to prevent vibration.

– Release the flector on the propeller shaft from the bevel gear
-arrows-, supporting it with a lever held against the triangular
flange.

Note

♦ Do not allow the propeller shaft to fall to one side when re‐
moving; Keep it horizontal when separating from the centring
pivot. Take care not to damage the O-ring in the dowel sleeve
-arrow-.
♦ Disc coupling and oscillation damper cannot be separated
from each other.

– Support the propeller shaft using the engine and gearbox jack
-V.A.G 1383 A- and a wooden block inserted -A-.
Connecting
Install in reverse order of removal; note the following.
– Reinstall the propeller shaft so that its marks are aligned.

1. propeller shaft: 11
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Note

♦ Do not damage the flange seals -arrow- for the propeller shaft
while fitting. Replace the propeller shaft if the seals are dam‐
aged.
♦ Install the propeller shaft on the centring pivot while keeping it
horizontal.

Installation position:
♦ The flanges for the bevelled gear that are joined to the pro‐
peller shaft have three bushings that protrude and encase the
holes corresponding to the flexible discs.

– Push the subframe to the front and feed the pinion of the bev‐
elled gear into the flange for the propeller shaft with great care
at the same time.
– Screw in the bolts -arrows- of the front flexible discs into the
flange of the front bevelled gear and tighten with the specified
tightening torque ⇒ page 13 .

– Mount the pendulum support, screw in -bolts 2 and 3- and

tighten with the specified tightening torque ⇒ page 13 . Al‐
ways use new bolts.

– Align the centre elastic support inside the oblong orifices. Do

not force the orifice or the propeller shaft into position.
– When installing heat shield-2- on the middle bracket it is nec‐
essary to ensure that bolt -1- is located in the centring plate.
Fasten bolts-1- and tighten to proper torque ⇒ page 13 .
– First fix the centre bearing after tightening the front and rear
section of the propeller shaft and the pendulum support.
With diesel engine:

12 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Fit the central soundproofing -Anchorage elements 1 ... 3-.

With petrol engines:

– Fit the central soundproofing -Anchorage elements 1 and 2-.

All vehicles (continued)

– Fit the right soundproofing -Anchorage elements 1 ... 3-.

Note

♦ If noises are heard while it is running, proceed as follows:

♦ If necessary, the front section of the propeller shaft with the
the flexible disc must be unscrewed from the flange of the front
drive and screwed tight again after turning by one position.
♦ If the noise continues, readjust the position of the propeller
shaft.

Tightening torques
Component Nm
Centre support to bodywork 25
• The bolts must be positioned within the four
centring tabs of the thermal protection plate
for the centre support.

Pendulum support to gearbox 40 + 90° 2) 1)

Pendulum support to subframe 100 + 90° 2) 1)
Flexible disc to the con‐ 60
ical gear pair
1) Replace bolts
2) 90º is equivalent to a quarter turn

1.3 Separation and connection of rear sec‐

tion of propeller shaft
Detaching ⇒ page 15
Connecting ⇒ page 16

1. propeller shaft: 13
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Tightening torques ⇒ page 18

Consult the equivalence table for tools and equipment according
to applicability among Seat / VW / Audi / Skoda ⇒ page 72 .

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331- , see equivalent
⇒ page 72
♦ Key for the tension-free as‐
sembly of the centre bear‐
ing -V.A.G 1332- , see
equivalent ⇒ page 72 .
♦ Engine/gearbox crane -
V.A.G 1383 A- , see equiv‐
alent ⇒ page 72
♦ Belt tensioner -T10038-

14 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Detaching
With diesel engine:
– Remove central soundproofing -Anchorage points 1 ... 3-.
With petrol engines:

– Remove central soundproofing

-Anchorage elements 1 and 2-.
All vehicles (continued)
– Remove the rear section of the exhaust system ⇒ Rep. Gr.
26 ; Exhaust system; Front and rear silencers: remove

Note

♦ The securing bolts of the heat protection plate and the centre
bearing of the propeller shaft retain these two elements at the
same time.
♦ It is necessary to fasten the propeller shaft before completely
unscrewing the two locating screws from the heat shield and
the resilient centre bracket. Otherwise it can buckle in the mid‐
dle and damage the intermediate bearing.

– Loosen the mounting screw -1- of the centre bearing of the

propeller shaft.

– Check for a mark (a coloured point) on the rear flexible disc

and on the Haldex clutch flange -arrows-.
If there are no marks, mark the position of the flexible disc with
respect to the Haldex clutch flange -arrows-.

Caution

Mark the position of the bolts, as some of these may have bal‐
ance washers to prevent vibration.

1. propeller shaft: 15
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Remove the bolts -arrows- from the final group flange.

– Carefully pull the propeller shaft to uncouple it from the final
group flange centring pivot.

Note

♦ Do not allow the propeller shaft to fall to one side when re‐
moving; Keep it horizontal when separating from the centring
pivot. Do not damage the O-ring on the centring bush-arrow-.
♦ Disc coupling and oscillation damper cannot be separated
from each other.

– Support the propeller shaft using the engine and gearbox jack
-V.A.G 1383 A- and a wooden block inserted -A-.
– Fasten propeller shaft with retaining strap -T10038- to prevent
it from falling down.
Connecting
Install in reverse order of removal; note the following.

Note

♦ Do not damage the flange seals -arrow- for the propeller shaft
while fitting. Replace the propeller shaft if the seals are dam‐
aged.
♦ Install the propeller shaft on the centring pivot while keeping it
horizontal.

Installation position:
♦ The flange for the rear bevelled gear that are joined to the
propeller shaft have three bushings that protrude and encase
the holes corresponding to the flexible discs.

16 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Join the propeller shaft to the rear final group flange so that
the marks -arrows- are aligned.

Note

♦ When fitting and removing the final drive, make sure the seal
on the propeller shaft flange is not damaged. When damaged,
the propeller shaft must be replaced.
♦ Push propeller shaft horizontally onto guide pin.

– Screw in the bolts -arrows- of the final drive flange and tighten
with the specified tightening torque ⇒ page 18 .

1. propeller shaft: 17
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Align the centre elastic support inside the oblong orifices. Do

not force the orifice or the propeller shaft into position.
– When installing heat shield-2- on the middle bracket it is nec‐
essary to ensure that bolt -1- is located in the centring plate.
Fasten bolts-1- and tighten to proper torque ⇒ page 18 .
– First fix the centre bearing after tightening the front and rear
section of the propeller shaft and the pendulum support.
– Install exhaust system and align so it is not under tension⇒
Rep. Gr. 26 ; Exhaust system; Exhaust system: align tension-
free .

Note

♦ If noises are heard while it is running, proceed as follows:

♦ If necessary, the rear section of the propeller shaft with the the
flexible disc must be unscrewed from the flange of the front
drive and screwed tight again after turning by one position.
♦ If the noise continues, readjust the position of the propeller
shaft.

Tightening torques
Component Nm
Centre support to bodywork 25
• The bolts must be positioned within the four
centring tabs of the thermal protection plate
for the centre support.

Flexible disc to the rear 60

final group
Pendulum support to gearbox 40 + 90° 3) 4)
Pendulum support to subframe 100 + 90° 3) 4)
3) Replace bolts
4) 90º is equivalent to a quarter turn

1.4 Removal and installation of complete

propeller shaft
Removing ⇒ page 19 .
Install ⇒ page 22 .
Tightening torques ⇒ page 24 ⇒ page 33
Consult the equivalence table for tools and equipment according
to applicability among Seat / VW / Audi / Skoda ⇒ page 72 .

18 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Special tools and workshop

equipment required
♦ Counterhold -T20111- , see
equivalent ⇒ page 72
♦ Counterhold -T20185- , see
equivalent ⇒ page 72
♦ Torque wrench -V.A.G
1331- , see equivalent
⇒ page 72
♦ Torque wrench -V.A.G
1332- , see equivalent
⇒ page 72
♦ Engine/gearbox crane -
V.A.G 1383 A- , see equiv‐
alent ⇒ page 72

Removing
– Remove central soundproofing, only diesel engines
-Anchorage points 1 ... 3-.
– Remove the rear section of the exhaust system, when neces‐
sary, also remove the front section of the exhaust system ⇒
Rep. Gr. 26 ; Exhaust system; Front and rear silencers: re‐
move .

1. propeller shaft: 19
 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Unscrew bolts -2 ... 3- of the pendulum arm support.

– Push the subframe to the front and secure in this position using
the support tool -T20111- and support tool -T20185- .

Note

♦ The securing bolts of the heat protection plate and the centre
bearing of the propeller shaft retain these two elements at the
same time.
♦ It is necessary to fasten the propeller shaft before completely
unscrewing the two locating screws from the heat shield and
the resilient centre bracket. Otherwise it can buckle in the mid‐
dle and damage the intermediate bearing.

– Support the propeller shaft using the engine and gearbox jack
-V.A.G 1383 A- and a wooden block inserted -A-.
– Unscrew the bolts -arrow- of the heat protection plate and
screw-out the intermediate bearing of the propeller shaft. Re‐
move the heat plate.

Screw the bolts -arrows- back into the intermediate bearing of the
propeller shaft.

20 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

– Check if there is a mark (a coloured point) -arrows- on the

flexible disc, flange coupling, rear final group and the front dif‐
ferential that coincides with the propeller shaft.
If there are no marks, mark the position of the flexible disc with
respect to the rear final group flange and the front differential
-arrows-.

Caution

Mark the position of the bolts, as some of these may have bal‐
ance washers to prevent vibration.

– Unscrew the bolts -arrows- of the flector on the propeller shaft

on the bevel gear, supporting it with a lever held against the
triangular flange in doing so.

Note

♦ Do not allow the propeller shaft to fall to one side when re‐
moving; Keep it horizontal when separating from the centring
pivot. Take care not to damage the O-ring in the dowel sleeve
-arrow-.
♦ Disc coupling and oscillation damper cannot be separated
from each other.

– Remove front crosspiece from vehicle underbody -arrows-.

Note

Do not observe -item 1-.

1. propeller shaft: 21
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Final drive 0AV and 0BR - Edition 04.2010

– Remove the bolts -arrows- from the final group flange.

– Carefully loosen the rear section from the centring pin.

Note

♦ Do not allow the propeller shaft to fall to one side when re‐
moving; Keep it horizontal when separating from the centring
pivot. Take care not to damage the O-ring in the dowel sleeve
-arrow-.
♦ Disc coupling and oscillation damper cannot be separated
from each other.

– Unscrew the bolts -arrows- of the intermediate bearing of the

propeller shaft.
– Remove the propeller shaft from the final group and lower it
with help from a second mechanic.
– Do not bend the propeller shaft, store and transport extended
only.
Installing .
Installation is carried out in reverse sequence; note the following:

Note

♦ Reinstall the propeller shaft so that its marks are aligned.

♦ Do not damage the flange seals -arrow- for the propeller shaft
while fitting. Replace the propeller shaft if the seals are dam‐
aged.
♦ Do not bend the propeller shaft, transport and fit extended on‐
ly.
♦ Install the propeller shaft on the centring pivot while keeping it
horizontal.

Installation position:
♦ The flanges for the conical gear pair and the rear final group
that are joined to the propeller shaft have three bushings that
protrude and encase the holes corresponding to the flexible
discs.

22 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

– Join the propeller shaft to the flanges for the rear final group
and the front bevelled gear so that the marks -arrows- are
aligned.

Fitting position of the different collar bolts. Tighten to the specified

tightening torque ⇒ page 24 .
Bolt with Location
small collar -arrow A- propeller shaft to front final group
-A-
large collar -arrow B- propeller shaft to rear final group
-B-

– Mount the pendulum support, screw in -bolts 2 and 3- and

tighten with the specified tightening torque ⇒ page 24 . Al‐
ways use new bolts.

1. propeller shaft: 23
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Final drive 0AV and 0BR - Edition 04.2010

– Align the centre elastic support inside the oblong orifices. Do

not force the orifice or the propeller shaft into position.
– When installing heat shield-2- on the middle bracket it is nec‐
essary to ensure that bolt -1- is located in the centring plate.
Fasten bolts-1- and tighten to proper torque ⇒ page 24 .
– First fix the centre bearing after tightening the front and rear
section of the propeller shaft and the pendulum support.
– Install exhaust system and align so it is not under tension⇒
Rep. Gr. 26 ; Exhaust system; Exhaust system: align tension-
free .

Note

♦ If noises are heard while it is running, proceed as follows:

♦ If necessary, the propeller shaft with the the flexible disc must
be unscrewed from the rear final group and the flange of the
front drive and, after turning by one position, screwed tight
again.
♦ If the noise continues, readjust the position of the propeller
shaft.

Tightening torques
Component Nm
Centre support to bodywork 25
• The bolts must be positioned within the four
centring tabs of the thermal protection plate
for the centre support.

Flexible disc to the rear 60

final group
Flexible disc on the 60
front bevelled gear
Pendulum support to gearbox 40 + 90° 6) 5)
Pendulum support to subframe 100 + 90° 6) 5)
5) Replace bolts
6) 90º is equivalent to a quarter turn

24 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

2 Rear final group

2.1 Removal and installation of rear axle

drive, 0AV
Removing ⇒ page 26 .
Install ⇒ page 27 .
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331- , see equivalent
⇒ page 72
♦ Torque wrench -V.A.G
1332- , see equivalent
⇒ page 72
♦ Engine assembly crane -
V.A.G 1383 A- , see equiv‐
alent ⇒ page 72 , with
universal gearbox support -
V.A.G 1359/2- .

2. Rear final group 25

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Removing
– Disconnect the connector -1- from the height sensor and un‐
screw the bolts -2- and -3-.

– Disconnect the connector -2- on top of the control unit.

– Remove the rear subframe with final drive ⇒ Running gear,
shafts, steering; Rep. Gr. 42 ; Rear subframe removing and
fitting .
– Remove the drive shafts from the final group flanges.

– Loosen the two flexible hoses from the final group to deaerate
-1- and unscrew the bolts -2- from the subframe.

– Loosen the front bolt with a few turns -arrow-.

– Move the final group toward the right and separate the left
drive shaft.
– Move the final group toward the left and separate the right
drive shaft.

26 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

– Unscrew the attachment bolt -arrow- for the final group front
support block.
– Carefully extract the front final group.
Installing .
Installation is carried out in reverse sequence; note the following:
– Tighten the bolts that fasten the final group to the subframe
with a torque of 60 Nm + 90 º (1/4 turns).
– Install rear assembly support ⇒ Chassis, Axles, Steering;
Rep. Gr. 42 ; Removal and installation of rear assembly sup‐
port .
– Install the exhaust system and align without tensioning ⇒ Rep.
Gr. 26 ; Components of the exhaust system; removal and fit‐
ting .

Note

If the rear final group is being replaced, check the oil level of the
rear final group and the Haldex clutch. Top off if necessary
⇒ page 54 and ⇒ page 57 .

2.2 Removal and installation of rear axle

drive, 0BR
Brief description
– Print out diagnostic report when staring repair. After removing
the axle drive return it through the usual channels together with
this report.
Before hoisting the vehicle, it is necessary to remove a cap and
make a cut in the luggage compartment insulation with a cutting
tool. Unscrew the basic locating screws between the axle drive
and the assembly support and pull upward and out.
Unscrew the pendulum support from the gearbox in the front area.
Remove stabiliser; detach propeller shafts from axle drive. Dis‐
connect electrical connectors and vent lines from axle drive.
Remove “end section ” of exhaust system. Unscrew axle drive
propeller shaft and put down on carrier support.
Remove the final drive “downwards” and in the driving direction
together with a second mechanic.
Check the tool and equipment equivalence table according to the
applicability between SEAT / VW / Audi / Skoda ⇒ page 72 .

2. Rear final group 27

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Special tools and workshop

equipment required
♦ Counterhold -T20111- , see
equivalent ⇒ page 72
♦ Counterhold -T20185- , see
equivalent ⇒ page 72
♦ Torque wrench -V.A.G
1331- , see equivalent
⇒ page 72
♦ Torque wrench -V.A.G
1332- , see equivalent
⇒ page 72
♦ Engine assembly crane -
V.A.G 1383 A- , see equiv‐
alent ⇒ page 72 .

Special tools and workshop equipment required

♦ Support equipment -T10172-

2.2.1 removing
– Remove the cover from the luggage compartment floor.
Depending on the vehicle equipment:
– Remove the spare wheel or the toolbox for the tyre repair set.

28 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

– Remove the rubber cap -2-, cut out the sound insulation on the
floor of the luggage compartment according to the shape of
the sheet plate opening -1-.

Note

When fitting, refit the cap that is the same as the cap removed
from the other opening ⇒ Spare parts catalogue

– Loosen and unscrew the both bolts.

These bolts must be replaced later.
– Raise the vehicle.
– Separate exhaust system from clamping sleeve -Arrows-.
– Remove the rear exhaust system ⇒ Rep. Gr. 26 ; Exhaust
system; Components of the exhaust system; removal and fit‐
ting .

– If necessary, remove the front exhaust system as well ⇒ Rep.

Gr. 26 ; Exhaust system; Components of the exhaust system;
removal and fitting .
– Fit the front exhaust pipe to the bracket of the support.
– Unscrew the left and right propeller shaft from flange shafts on
the rear final drive.
– Remove the stabiliser ⇒ Running gear, shafts, steering; Rep.
Gr. 42 .
So that the rear left vehicle level sender -G76- cannot be dam‐
aged.

– Disconnect the connector, unscrew the sensor and place on

the swinging arm -A-.

– Unscrew the bolts -1- and -2- of the pendulum support.

2. Rear final group 29

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Final drive 0AV and 0BR - Edition 04.2010

– Unscrew the bolts one or two turns -1- from the central elastic
mount for the propeller shaft.
Future noises caused by imbalance are therefore avoided:

– Check to see if a marking (coloured mark) is located on the

flexible disk and on the flange of the rear final drive that should
be connected with the propeller shaft -arrows-. If there are no
marks, the position of the flexible disc with regard to the flange
on the rear final drive should be marked -arrows-.
– Support the final drive on the lift.

– Unscrew the bolt -arrow- from the front support block.

These bolts must be replaced later.

– Remove the washer -C- from the support block.

30 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

– Move the engine assembly toward front and arrest in this po‐
sition with retaining device -T20111- and retaining device -
T20185- .

– Unscrew the propeller shaft from the rear final drive -arrows-.

– The fixed section at the rear final drive must be counter held
for loosening and tightening the propeller shaft.
– Move the final drive as far back as possible.
– Separate the propeller shaft from the final drive and rest on
the tunnel support; place a cloth on the support to protect the
shaft.

– Separate the left propeller shaft -B- from the flange and care‐
fully guide downwards.

2. Rear final group 31

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Separate the right propeller shaft -B- from the flange and care‐
fully guide downwards.

– Disconnect the connector -A- on the four-wheel drive control

unit -J492- .
– Separate the venting lines -arrows- from the final drive.
Remove the final drive.

Note

Remove the final drive by hand with help from a second mechan‐
ic.

The “first mechanic” holds the final drive (in the area of the pro‐
peller shaft flange) and the “second mechanic” adjusts the gear‐
box jack to the rear and removes it completely from underneath
the vehicle.
Then remove together with the final drive.

2.2.2 Fitting .
Installation is carried out in reverse sequence; note the following:

Note

Fit the final drive by hand with help from a second mechanic.

Fit the final drive.

• The gearbox jack is located “within range” under the subas‐
sembly / luggage compartment floor.
– Carefully fit the final drive. Take care that both end washers
-B- have not displaced or do not fall down from the bottom
bearings.
– Support the final drive on the lift.

32 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Connect the connector -A- of the four-wheel drive control unit

-J492- .
– Connect the venting line -arrows- to the respective lines of the
final group.
– Lift the final drive using the gearbox jack until the fitting position
is reached.
– Fit both propeller shafts to the final drive but do not screw to‐
gether.
– Begin with the right propeller shaft.
– Fit the propeller shaft and fix to the final group. Tightening tor‐
que
.

– The fixed section at the rear final drive must be counter held
for loosening and tightening the propeller shaft.

– Fit the washers -C- to the front support block.

– Screw on the final drive from “underneath” -B-.However, do

not tighten the bolts.

2. Rear final group 33

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Remove the gearbox jack from underneath the vehicle.

– Insert and tighten two “new” bolts -1 and 2- through holes in
luggage compartment floor. Tightening torques ⇒ Running
gear, axles, steering; Rep. Gr. 42 .

Note

When fitting, refit the cap that is the same as the cap removed
from the other opening ⇒ Spare parts catalogue

– Fit the cover caps.

– Fit the trim and the floor covering -A- ⇒ Rep. Gr. 70 ; Trims,
cargo and luggage compartment .
– Raise the vehicle.

– Tighten the final drive from “underneath” -B-. Tightening tor‐

ques ⇒ Running gear, axles, steering; Rep. Gr. 42 .

– Fix the pendulum support using two “new” screws. Tightening

torques ⇒ Running gear, axles, steering; Rep. Gr. 40 .
– Align the centre elastic support inside the oblong orifices. Do
not force the orifice or the propeller shaft into position.

34 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

When screwing on the heat protection plate -2- to the centre

bearing, you have to check that the bolts -1- are positioned within
the four centring tabs.
– Install stabiliser ⇒ Chassis, Axles, Steering; Rep. Gr. 42 ;
Assembly summary: Assembly support bridge, axle drive (all-
wheel drive)
– Tighten the propeller shaft. Tightening torques ⇒ Running
gear, axles, steering; Rep. Gr. 42 .
– Mount the soundproofing element ⇒ Bodywork, exterior in‐
stallation work; Rep. Gr. 50 ; Soundproofing
– Install the rear left vehicle level sender -G76- . ⇒ Chassis,
Axles, Steering; Rep. Gr. 42 ; Assembly summary: Assembly
support bridge, axle drive (all-wheel drive)
– Remove the exhaust system ⇒ Rep. Gr. 26 ; Exhaust system;
Components of the exhaust system; removal and fitting .
When replacing the final drive:
– Check the oil level of the Haldex clutch, top up with oil
⇒ page 56 .
– Check the oil level of the final drive, top up with oil
⇒ page 54 .
Perform basic setting of headlights, see ⇒ Vehicle diagnosis,
testing and information system VAS 5051.

2.3 Rubber/metal bearing for rear axle drive: assembly summary

2. Rear final group 35

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

1 - Attack washer
❑ Remove before remov‐
ing the bonded rubber
bush
⇒ Item 2 (page 36)
❑ Install on the bonded
rubber bush
⇒ Item 2 (page 36)
⇒ page 40
2 - “Top rear” bonded rubber
bush
❑ Removing ⇒ page 38
❑ Difference between the
“top rear” and “lower
front” ⇒ page 39 bush‐
es
❑ Installation position
⇒ page 40
❑ Installing ⇒ page 38 .
3 - “Lower rear”bonded rubber
bush
❑ Removing ⇒ page 38
❑ Installing ⇒ page 38 .
4 - Attack washer
❑ Remove before remov‐
ing the bonded rubber
bush
⇒ Item 5 (page 36)
❑ Fit on the bonded rubber
bush
⇒ Item 5 (page 36)
⇒ page 40
5 - “Lower front”bonded rubber
bush
❑ Removing ⇒ page 39
❑ Difference between the “top rear” and “lower front” ⇒ page 39 bushes
❑ Installation position ⇒ page 40
❑ Installing ⇒ page 39 .
6 - “Top front” bonded rubber bush
❑ Removing ⇒ page 39
❑ Installing ⇒ page 39 .
7 - Rear final group
❑ Removing and fitting ⇒ page 25

2.4 Installing rubber/metal bearing for rear

axle drive
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72

36 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Special tools and workshop

equipment required
♦ Die mandrel -30 - 505-
♦ Locking pin -VW 554-
♦ Inlay device -3128-
♦ Locking pin -T40033/1-
♦ Cross beam -T10030/5-
♦ Spindle -3346/2-
♦ Bolt -3346/3-

2. Rear final group 37

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

♦ -1- Interior extractor -

Kukko 21/1-

♦ -4- Support bracket -

Kukko 22/1-
Remove the “top rear”
bonded rubber bush
A - Support bracket , ex.
-Kukko 22/1-
B - Internal remover 12...
16 mm , e.g. -Kukko
21/1-
– To install the support
bracket brake a piece
from the collar of the
bonded rubber bush
-arrow-.
– Install the inside ex‐
tractor on the separa‐
tion joint of the top
and bottom bush, and
pre-tension it.

Remove the “lower rear” bonded rubber bush

Note

If the bush is going to be replaced separately, use the bracket

support to extract it, ex. -Kukko 22/1- and the inside extractor 12…
16 mm , ex. -Kukko 21/1- . ⇒ page 38

Install the “top rear” -A- and the “lower rear” -B- bonded rubber
brushes
– Before fitting the spindle -3346/2- place a washer on it with an
“inside diameter of 15 mm” and an “outside diameter of 27 mm
or greater”.

38 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Remove the “lower front” bonded rubber bush

– Close the two deaeration hoses so that oil cannot run out from
the final group during the following procedure.
– Next place the final group on the vice, with the top facing down,
and extract the bonded rubber bush:
A - Support bracket , ex. -Kukko 22/1-
B - Internal remover 12... 16 mm , e.g. -Kukko 21/1-
– To install the support bracket brake a piece from the collar of
the bonded rubber bush -arrow-.
– Install the inside extractor on the separation joint of the top and
bottom bush, and pre-tension it.

Remove the “top front” bonded rubber bush

Note

If the bush is going to be replaced separately, use the bracket

support to extract it, ex. -Kukko 22/1- and the inside extractor 12…
16 mm , ex. -Kukko 21/1- . ⇒ page 39

Install the “lower front” -A- and “top front” -B- bonded rubber
brushes
– Before fitting the spindle -3346/2- place a washer on it with an
“inside diameter of 15 mm” and an “outside diameter of 27 mm
or greater”.

Difference between the “top rear” and the “lower front” bonded
rubber bushes
The “top rear” and the “lower front” bushes have different heights
Value “a” mm Bonded rubber bush
22 “top rear”
17 “lower front”

2. Rear final group 39

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Position the “top rear” and the “lower front” bonded rubber bush‐
es. Installation of the stop washer -B-
• Final group installation position
“Top rear” and “lower front”bonded rubber bush installation posi‐
tion:
♦ The “top rear” ⇒ Item 2 (page 36) bush pivots -A- must point
up
♦ The “lower front” ⇒ Item 5 (page 36) bush pivots -A- must point
down
Stop washer installation -B-
– Insert the pivots -A- through the hole of the stop washers
-arrows-.
The stop washer -B- most be firmly joined to the bush.

2.5 Installing sealing rings for left and right

propeller shafts (with rear axle drive in‐
stalled)
Removing ⇒ page 41 .
Install ⇒ page 42 .
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72

40 Rep. Gr.39 - Final drive - rear differential

 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

Special tools and workshop

equipment required
♦ Release lever -VW 681- ,
see equivalent
⇒ page 72
♦ Puller -T10037- , see equiv‐
alent ⇒ page 72
♦ Locking pin -T10049-
♦ Recipient tray -VAS 6208- ,
see equivalent
⇒ page 72
♦ Grease ⇒ Parts catalogue

Removing
The left and right hand seals are replaced in the same manner.
– Remove the propeller shaft ⇒ Running gear, shafts, steering;
Rep. Gr. 42 ; Removing and installing drive shafts .
– Place the drip tray -VAS 6208- under the final group.
Removal of flanged shaft, left hand side:
– Place an M8 nut on the thread of the extractor -T10037-
-arrow- until it is flush with the start of the thread.
– Remove the flanged shaft using the extractor -T10037 - .
Removal of flanged shaft right hand side:

2. Rear final group 41

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Final drive 0AV and 0BR - Edition 04.2010

– Place an M8 nut on the thread of the extractor -T10037-

-arrow- until it is flush with the start of the thread.
– Remove the flanged shaft using the extractor -T10037 - .
Both sides (continued)

– Extract the flanged shaft seal using the lever -VW 681- .
Installing .

– Lightly oil the outside diameter of the new seal and insert it
until it reaches the end using the pressure element -T10049-
without bending the seal.
– Fill space between the sealing lip and the dustcap halfway with
grease ⇒ Parts catalogue .

– Fasten the flanged shaft in a vice using protective jaws.

– Remove the old safety ring from the flanged shaft groove by
pushing with a new ring -A-.
– Insert the flanged shaft by tapping with a plastic hammer and,
if necessary, with a punch.
– Install propeller shaft ⇒ Chassis, Axles, Steering; Rep. Gr.
42 ; Removal and installation of propeller shaft .
– Check the rear final group oil level ⇒ page 54 .

2.6 Replacing sealing ring on propeller shaft

connection to rear axle drive (with axle
drive installed)
Removing ⇒ page 44 .
Install ⇒ page 45 .
Tightening torque ⇒ page 46 .

42 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

Check the tool and equipment equivalence table according to the

applicability between Seat / VW / Audi / Skoda, see equivalent
⇒ page 72

Special tools and workshop

equipment required
♦ Release lever -VW 681- ,
see equivalent
⇒ page 72
♦ Drift sleeve -30-20-
♦ Retention tool -3415- , see
equivalent ⇒ page 72
♦ Locking pin -T10019-
♦ Extractor -Kukko 12/1-
♦ Torque wrench -V.A.G
1601- , see equivalent
⇒ page 72

♦ Belt tensioner -T10038-

2. Rear final group 43

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Final drive 0AV and 0BR - Edition 04.2010

♦ Engine and gearbox jack -V.A.G 1383 A- , see equivalent

⇒ page 72 , with universal gearbox support assembly -
V.A.G 1359/2- .

♦ Fastening product ⇒ Parts catalogue

♦ Bolt M10 x 25
♦ Allen key M8 x 15
Removing
– Separate the rear section of the propeller shaft ⇒ page 13 .
– Secure the vehicle to the lift with the securing tool -T10038-
belts -T10038- .

WARNING

If the vehicle is not properly secured, it could fall from the lift.

– Unscrew the hexagonal nut on the propeller shaft flange.

A - Hexagonal bolts M10 x 25
B - Allen key M8 x 15 (screws into the counterhold -3415- from
behind, see equivalent ⇒ page 72 )

WARNING

This flange is positioned relative to the toothed shaft.

44 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

– Mark the flange with respect to the toothed shaft before re‐
moving in order to avoid subsequent vibrations in the propeller
shaft.

– Remove the propeller shaft flange. If this continues, use the

extractor -Kukko 12/1- .

– Remove the seal with the extraction lever -VW 681- .

Installing .
– Before fitting the new seal, lightly lubricate it around the outer
diameter and between the sealing lips with high performance
oil for Haldex clutches ⇒ Parts Catalogue

2. Rear final group 45

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– Fit new seal in as far as it will go using the tool -T10019- . Do

not bend the seal during the procedure.

– Fit the propeller shaft flange with the sleeve -30 - 20- so that
the marks - arrow - are in line.

– Install a new hexagonal nut with a fastener product ⇒ Parts

catalogue and tighten it to the proper torque ⇒ page 46 .
A - Hexagonal bolts M10 x 20
B - Allen key M8 x 15 (screws into the counterhold -3415- from
behind)
– Couple the propeller shaft rear part ⇒ page 13 .
– Install the exhaust system and align without tensioning ⇒ Rep.
Gr. 26 ; Components of the exhaust system; removal and fit‐
ting .
– Check the Haldex clutch oil level ⇒ page 57 .
Tightening torque
Component Nm
Rear final group propeller shaft flange 210

46 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

3 Haldex clutch: rear axle drive

3.1 Haldex clutch: assembly summary

Final group installed

1 - 50 Nm hexagonal bolt
❑ 4 unit
2 - Haldex clutch
❑ With control unit
❑ Removing and fitting
⇒ page 47
3 - O-ring
❑ Renew ⇒ page 47
❑ Moisten with high per‐
formance oil for Haldex
clutches before instal‐
ling
4 - Final group
❑ Removing and fitting
⇒ page 25

3.2 Removal and installation of Haldex

clutch
Removing ⇒ page 48 .
Install ⇒ page 49 .
Tightening torque ⇒ page 50 .
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72
Special tools and workshop equipment required

3. Haldex clutch: rear axle drive 47

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♦ Recipient tray -VAS 6208- , see equivalent ⇒ page 72

♦ Torque wrench kit -SAT 8010- ⇒ page 72

Removing
– Separate the rear section of the propeller shaft ⇒ page 13 .
– Disconnect the connector -2- on the four-wheel drive control
unit -J492- .

– Place the drip tray -VAS 6208- ⇒ page 72 under the final
drive.
– Unscrew the drain plug-A- and allow the high performance oil
for Haldex clutches to completely drain ⇒ Parts catalogue .
– Screw in the drain plug-A- after installing a new seal and tight‐
ening it to 30 Nm.

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– Unscrew the attachment bolts -arrows- and separate the Hal‐

dex clutch from the rear final group.

– Remove the O-ring -arrow- from the Haldex clutch.

Installing .
Installation is carried out in reverse sequence; note the following:

– Install a new O-ring -arrow- and lightly oil it with high perform‐
ance oil for Haldex clutches ⇒ Parts catalogue .

Caution

The O-ring can be damaged during assembly. The clutch

should be handled with care to ensure that it fits correctly.

– Install the Haldex clutch in the rear final group.

– Tighten the bolts -arrows- to the required torque
⇒ page 50 .

3. Haldex clutch: rear axle drive 49

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– Connect the connector -2- on the four-wheel drive control unit

-J492- .
– Couple the propeller shaft rear part ⇒ page 13
– Install the exhaust system and align without tensioning ⇒ Rep.
Gr. 26 ; Components of the exhaust system; removal and fit‐
ting .
– Add high performance oil for Haldex clutches ⇒ Parts cata‐
logue once more and compare the oil level ⇒ page 57 .
Tightening torque
Component Nm
Haldex Clutch to the rear final group 50

50 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

4 Haldex clutch II: function check, rear

axle drive “0AV”
Before carrying out repairs on the Haldex clutch, determine the
cause of the fault by using the “Guided fault finding”, the “Vehicle
self-diagnosis” or the “Measurement module”of the central diag‐
nosis -VAS 5051B- or the central diagnosis -VAS 5052- .

4.1 Check the operation of the Haldex clutch

II closed
Test conditions:
♦ Check the Haldex clutch oil level ⇒ page 57 .
♦ Check the code and identification number of the engine control
units and the ABS.
– Position the vehicle on the lift.

Caution

For safely reasons, position the vehicle on the lift so the wheels
are not touching the ground.
Carry out test with care to avoid damage.

– Step on the clutch.

– Start the engine.
– 2. Gear engaged.
– While using the hand brake or the parking brake, ensure the
clutch is gradually responding.
The engine should stop itself.
• If the engine has stopped:
the Haldex clutch is closed; it is operating correctly.
• If the engine has not stopped:
the Haldex clutch is open. Possible fault cause:
♦ The main pressure regulation valve may be clogged
♦ Mechanical fault in the Haldex clutch
♦ The four-wheel drive control unit -J492- in the rear final group
is faulty

4.2 Check the operation of the Haldex clutch

II open
Test conditions:
♦ Check the Haldex clutch oil level ⇒ page 57 .
♦ Check the code and identification number of the engine control
units and the ABS.
– Position the vehicle on the lift.

4. Haldex clutch II: function check, rear axle drive “0AV” 51

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Caution

For safely reasons, position the vehicle on the lift so the wheels
are not touching the ground.
Carry out test with care to avoid damage.

– Step on the clutch.

– Start the engine.
– Step on the clutch pedal, place in first gear and slowly start.
All 4 wheels should be turning.
– Use the hand brake or the parking brake
The rear wheels should stop and the front wheels should continue
to turn.
• If the rear wheels are not turning:
the Haldex clutch is open; it is operating correctly.
• If the rear wheels are turning:
the Haldex clutch is closed. Possible fault cause:
♦ The main pressure regulation valve may be clogged
♦ Mechanical fault in the Haldex clutch
♦ The four-wheel drive control unit -J492- in the rear final group
is faulty
♦ The hand brake indicator lamp -F9- is faulty

52 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

5 Haldex clutch IV: function check, rear

axle drive “0BR”
Identification marking on rear final drive “0BR”

Note

♦ The identification -arrow- on the “underside” of the final drive

unit indicates which final drive version is installed.
♦ The Haldex clutch can checked by road-testing the vehicle
using vehicle diagnostic, testing and information system - VAS
5051B- .

WARNING

To avoid any risk of accident, observe the

⇒ “3 Safety precautions”, page 6 when road-testing the vehicle
and using test equipment.

– Connect the vehicle diagnostic, testing and information sys‐

tem -VAS 5051B- to the diagnostic connector with the ignition
switched off.
Access to the “guided functions”:
– Switch on the ignition.
– Touch the symbol or button “Guided Functions” on the screen.
– Select the options on the tester in this sequence:
♦ Mark
♦ Model
♦ Model year
♦ Version
♦ Engine code letters
♦ Confirm the data entered.
♦ 22 - Four-wheel drive electronics
♦ 22 - Final control diagnosis
– Start final control diagnosis and follow instructions appearing
on tester.

5. Haldex clutch IV: function check, rear axle drive “0BR” 53

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6 Oil level

6.1 Checking oil level in rear axle drive

“0AV”; replenishing if required
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331- , see equivalent ⇒ page 72

Prior condition:
• The final group should be in its original installation position.
Rear final group oil specification ⇒ Parts catalogue .
– Unscrew the oil level test bolt for gears -arrow-.
The oil level is correct if the oil level in the rear final group reaches
the lower edge of the filling hole.
– If necessary, fill with oil up to the lower edge of the fill hole.
– Install the bolt -arrow- and tighten to a torque of 40 Nm.

6.2 Checking oil level in rear axle drive

“0BR”; replenishing if required
Check the tool and equipment equivalence table according to the
applicability between SEAT / VW / Audi / Skoda ⇒ page 72 .

54 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331- , see equivalent
⇒ page 72 .
♦ Recipient tray -VAS 6208- ,
see equivalent
⇒ page 72
♦ Charging device for Haldex
clutch 2 -VAS 6291-

Test prerequisites
• Vehicle parked on level ground.
• Gear oil specification for rear final drive ⇒ Electronic spare
parts catalogue .
Checking oil level
– Position drip tray -VAS 6208- under final drive.

6. Oil level 55
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– Remove the screw -1-.

The oil level is correct if the oil level in the rear final group reaches
the lower edge of the filling hole.
– Screw in plug -1- and tighten.
Tightening torque: 15 Nm
Topping up with oil:
– Using charging device for Haldex clutch 2 -VAS 6291- , fill up
with oil until oil comes out between final drive housing and
adapter of charging device.
– Remove charging device and adapter; a certain amount of
surplus oil may now come out.
The oil level is correct if the oil level in the rear final group reaches
the lower edge of the filling hole.
– Screw in plug -1- and tighten.

Tightening torque: 15 Nm

6.3 Checking oil level in Haldex clutch II and

IV; replenishing oil, if required
Check oil level in Haldex clutch ⇒ page 57
Topping up oil in Haldex clutch ⇒ page 58

Caution

Different types of high-performance oil for Haldex clutch

♦ The rear final drive units “0AV” and “0BR” have different
Haldex clutches and therefore different types of oil for the
Haldex clutch.
♦ The two different types of oil for the Haldex clutches must
not be interchanged or mixed together.
♦ Part number for high performance oil for Haldex clutch ⇒
Electronic parts catalogue .
♦ Note the distinguishing markings for the different rear final
drive units ⇒ page 1 .

Consult the equivalence table for tools and equipment according

to applicability among Seat / VW / Audi / Skoda ⇒ page 72 .

56 Rep. Gr.39 - Final drive - rear differential

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Final drive 0AV and 0BR - Edition 04.2010

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331- , see equivalent
⇒ page 72 .
♦ Line, 3m. -VAS 5051/5A-
♦ Vehicle diagnostic, testing
and information system -
VAS 5051B- or vehicle di‐
agnosis and service infor‐
mation system -VAS 5052-
♦ Drip tray -VAS 6208-
⇒ page 72
♦ Filling device -VAS 6291-

6.3.1 Checking oil level in Haldex clutch

Prior condition:
• The final group should be in its original installation position.
– Connect the central diagnosis -VAS 5051B- or the central di‐
agnosis -VAS 5052- .
– Select the following options on the screen, in this order:
– Select “Guided functions”.
– Select “22 - four-wheel drive with Haldex clutch ”.
– Select “Measured values reading”.
– When the temperature of the Haldex clutch displayed lies be‐
tween 20 and 40 °C:
– Place the drip tray -VAS 6208- under the Haldex clutch.

6. Oil level 57
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Final drive 0AV and 0BR - Edition 04.2010

– Unscrew the oil level control screw -arrow- (for the purposes
of clarity, the figure is shown with the final group removed).
The oil level is correct when the Haldex clutch is full up to the
lower edge of the inspection hole.
– Screw in the bolt -arrow- with a new seal and tighten it to a
torque of 15 Nm.

6.3.2 Replenishing oil in Haldex clutch

Prior condition:
• The final group should be in its original installation position.
• Only add high performance oil for Haldex clutches ⇒ Parts
catalogue .
– Raise the vehicle.
– Place the drip tray -VAS 6208- under the Haldex clutch.
– Remove oil filler plug -arrow-. (For improved understanding,
the system is shown in the figure with the final group removed).

– Position the filling device -VAS 6291- as shown in the figure:

– Screw in the adapter -A- until the limit.
– Insert the elbow -B- into the adapter -A-.
– Fit the flexible hose on top of the drive shaft.
• The flexible hose should not be left hanging. It should be left
on top of the rear left wheel of the vehicle.
– Lower the vehicle.

58 Rep. Gr.39 - Final drive - rear differential

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– Ensure that the valve -arrow- is closed.

– Attach the oil tank -A- to the filling device -VAS 6291- .
– Open the valve -arrow- and, keeping the oil tank high, move it
to help the oil drain.
– Lift the vehicle for a few minutes.

Note

♦ If oil has drained from the adapter -A-, the Haldex clutch has
been filled correctly.
♦ If no oil has drained out, lower the vehicle and repeat the filling
process again.

– Raise the vehicle after filling the Haldex clutch.

– Place the oil tank below the Haldex clutch (e.g. by resting it on
a tool trolley) to allow the excess oil to return to the deposit.

– When no more oil flows back, remove the filling device for the
Haldex clutch -VAS 6291- once again.
– Check the oil level of the Haldex clutch as follows
⇒ page 57 .
– Screw in the bolt -arrow- with a new seal and tighten it to a
torque of 15 Nm.

6. Oil level 59
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Final drive 0AV and 0BR - Edition 04.2010

7 Electrical and electronic compo‐

nents, rear final drive “0AV”

7.1 Electrical and electronic components

and their location
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72

1 - Four-wheel drive control

unit -J492-
❑ Location ⇒ page 61
❑ Forms a unit with the
valve that controls the
opening of the clutch -
N373-
❑ The control unit is also
integrated with the pres‐
sure sensor
❑ Removing and fitting
⇒ page 63
❑ Through the data bus,
the four-wheel drive
control unit -J492- re‐
ceives signals from the
engine control units and
the ABS with EDS
2 - Pump to the Haldex clutch
-V181-
❑ Location ⇒ page 61
❑ This can be verified us‐
ing the central diagnosis
-VAS 5051B- or central
diagnosis -VAS 5052-
using the “Guided fault
finding”
❑ Removing and fitting
⇒ page 66
3 - Diagnosis connector
❑ Installation location: in
the footwell, to the front
left next to the lever to
open the bonnet
4 - Handbrake control switch -
F9-
❑ Fitting location from ⇒ page 62
❑ This can be verified using the central diagnosis -VAS 5051B- or central diagnosis -VAS 5052- using the
“Guided fault finding”
❑ Removing and fitting ⇒ Rep. Gr. 46
5 - Brake light switch -F-
❑ Fitting location up to ▸2008 ⇒ page 61
❑ Fitting location from 2009▸: ⇒ page 61
❑ This can be verified using the central diagnosis -VAS 5051B- or central diagnosis -VAS 5052- using the
“Guided fault finding”
❑ Removing and fitting ⇒ Rep. Gr. 45

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Four-wheel drive control unit -J492-

Installation location: control unit -A- is located on the rear final
drive, front left.

Pump to the Haldex clutch -V181-

Installation location: pump of the Haldex clutch -arrow- is located
on the rear final drive, front right.

Brake light switch -F- Up to ▸2008

Installation location: Brake light switch -F- is located on the pedal
assembly above the brake pedal.

Brake light switch -F- From ▸2009

Installation location: Brake light switch -F- is located on the brake
pump.
Removal ⇒ Rep. Gr. 45

7. Electrical and electronic components, rear final drive “0AV” 61

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Handbrake control switch -F9-

Installation location: switch -arrow- is located on handbrake lever.
Removal ⇒ Rep. Gr. 46

7.2 Control unit for all-wheel drive: -J492- assembly summary

1 - Four-wheel drive control

unit -J492-
❑ It is calibrated using the
valve that controls the
opening of the clutch -
N373-
⇒ Item 4 (page 62)
❑ It is always replaced to‐
gether with the valve
⇒ Item 4 (page 62)
❑ Removing and fitting
⇒ page 63
2 - Bolt, 6 Nm
3 - Panel
❑ With an integrated joint
for vulcanisation
❑ Always renew
4 - Valve that controls the
opening of the clutch -N373-
❑ It is calibrated using the
four-wheel drive control
unit -J492-
❑ It is always replaced to‐
gether with the control
unit ⇒ Item 1 (page 62)
5 - Seal
❑ Diameter 12 mm
❑ For the valve that con‐
trols the opening of the
clutch -N373-
❑ Moisten with high per‐
formance oil for Haldex
clutches and install
❑ Always renew
6 - Seal
❑ Diameter 11 mm
❑ For the valve that controls the opening of the clutch -N373-
❑ Moisten with high performance oil for Haldex clutches and install
❑ Always renew

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7 - Seal
❑ In the Haldex clutch casing
❑ Moisten with high performance oil for Haldex clutches and install
❑ Always renew
8 - Seal
❑ For the pressure sensor
❑ Moisten with high performance oil for Haldex clutches and install
❑ Always renew
9 - Pressure sensor
❑ This can be reused when replacing the control unit
10 - Plate spring
❑ In the installation position, the mark -arrow- must point up towards the pressure sensor ⇒ page 63

Installation position of the plate spring

• The mark -arrow- is located on the convex side of the plate
spring -2-.
• On the convex side the mark -arrow- must point up towards
the pressure sensor -1-.
• In the installation position, the mark -arrow- must be pointing
up.
Remove and install the four-wheel drive control unit -J492-
⇒ page 63 .

7.3 Removal and installation of four-wheel

drive control unit -J492-
Removing ⇒ page 64 .
Install ⇒ page 65 .
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331- , see equivalent ⇒ page 72

7. Electrical and electronic components, rear final drive “0AV” 63

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♦ Recipient tray -VAS 6208- , see equivalent ⇒ page 72

Removing

Note

When removing the control unit -1- also remove the cover -2- and
the plate spring -5-. Remove the pressure sensor -4- and the
valve -3- separately.

– Switch ignition OFF.

– Disconnect the connectors -1- and -2- from top of the control
unit.
– Place the drip tray -VAS 6208- ⇒ page 72 under the final
group.

– Unscrew bolts -arrows-.

Ensure that none of the parts fall when removing the control unit.
– Carefully remove the control unit -A-.

64 Rep. Gr.39 - Final drive - rear differential

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– Using pliers, carefully grab onto the valve that controls the
opening of the clutch -N373- -A- by the metal casing -arrow-
and remove it.
– Remove the pressure sensor -B-.

– Remove the seal from the casing for the valve that controls the
opening of the clutch -N373- -arrow-.
Installing .
Installation is carried out in reverse sequence; note the following:

– Moisten the new seal for the valve that controls the opening of
the clutch -N373- -arrow- with high performance oil for Haldex
clutches and insert it into the casing.

– Replace the O-rings -1- and -2-.

– Note the different diameters:
♦ Inside O-ring diameter -1- = 11 mm
♦ Inside O-ring diameter -2- = 12 mm

7. Electrical and electronic components, rear final drive “0AV” 65

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– Replace the O-ring -arrow A- for the pressure sensor.

Note

In the installation position, the mark -arrow B- on the convex side

of the plate spring -2- must point up towards the pressure sensor
-1-.

– Insert the plate spring -2- with the convex side over the pres‐
sure sensor -1-.

– Install a new cover -5- on the control unit -6-.

– Install the pressure sensor -4- with plate spring on the new
cover -5- and insert it into the connector. The convex side of
the plate spring should face the pressure sensor.
– Apply a thin layer of high performance oil for Haldex clutches
to the new pressure sensor O-ring -4-.
– Install the valve -1- on the new cover -5- and on the control
unit -6- and attach it to the connector.
– Apply a thin layer of high performance oil for Haldex clutches
to the new O-rings -2- and -3-.

– Carefully install the control unit -A- and tighten the bolts
-arrows- to the prescribed torque ⇒ Item 2 (page 62) .
– Check the Haldex clutch oil level ⇒ page 57 .

7.4 Removing and installing pump for Hal‐

dex clutch -V181-
Removing ⇒ page 67 .
Install ⇒ page 68 .
Tightening torque ⇒ page 70 .
Check the tool and equipment equivalence table according to the
applicability between Seat / VW / Audi / Skoda ⇒ page 72
Special tools and workshop equipment required

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♦ Torque wrench -V.A.G 1331- , see equivalent ⇒ page 72

♦ Recipient tray -VAS 6208- , see equivalent ⇒ page 72

Removing
– Switch ignition OFF.
– Place the drip tray -VAS 6208- under the final group.
– Unscrew the drain plug-A- and allow the high performance oil
for Haldex clutches to drain.
– Screw in the drain plug-A- after installing a new seal and tight‐
ening it to 30 Nm.

– Loosen the attachment bolt about 7 turns -arrow- from the final
group front support block to slightly lower the final group.

7. Electrical and electronic components, rear final drive “0AV” 67

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Final drive 0AV and 0BR - Edition 04.2010

– Disconnect the connector -arrow- from the pump housing in

the control unit.

– Remove the cable harnesses, with the support -A-, from the
casing and loosen it.
– Squeeze the locking tabs -B- and insert them completely into
the casing hole.

– Retighten the attachment bolt -arrow- by hand.

– Place a container under the final group.

– Unscrew the bolts -1- that fasten the pump.

– Remove the pump -arrow- from the Haldex clutch casing along
with the cabling protection -2-.
Installing .
Installation is carried out in reverse sequence; note the following:

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 Altea XL 2009 ➤ , Altea XL Freetrack 2008 ➤ , Altea XL Freetrack 2009 ➤
Final drive 0AV and 0BR - Edition 04.2010

– Replace the O-rings -1- and -2-.

– Apply a thin layer of high performance oil for Haldex clutches
to the O-rings -1- and -2-.

– Insert the pump -arrow- as far as it will go. When doing this,
check that the cabling protection -2- stays properly routed.
– Tighten the bolts -1- to the required torque ⇒ page 70 .

– Unscrew the attachment bolt -arrow- from the right support

block.

– Hook the cable harness to the top of the Haldex clutch and
connect the connector -arrow- to the control unit.

7. Electrical and electronic components, rear final drive “0AV” 69

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– Fasten real axle drive with new bolt -Arrow- to assembly sup‐
port ⇒ Chassis, Axles, Steering; Rep. Gr. 42 ; Removal and
installation of rear assembly support .
– Add high performance oil for Haldex clutches and compare the
oil level ⇒ page 57 .
Tightening torque
Component Nm
Pump to the Haldex clutch 6

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Final drive 0AV and 0BR - Edition 04.2010

8 Electrical and electronic components and fitting locations, rear final

drive “0BR”

1 - Four-wheel drive control

unit -J492-
❑ Important signals are
transferred to four-
wheel drive control unit
from the engine control
unit and the ABS with
EDL control unit -J104-
via data bus.
2 - Valve that controls the
opening of the clutch -N373-
3 - Pump to the Haldex clutch
-V181-
❑ Can be checked in “Gui‐
ded fault finding”, using
vehicle diagnostic, test‐
ing and information sys‐
tem -VAS 5051B- .
4 - Diagnosis connector
❑ Fitting location: front
footwell (left-side)
5 - Accelerator position sender
-G79-

8. Electrical and electronic components and fitting locations, rear final drive “0BR” 71
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9 Conversion table by relevance

VW / AUDI tool SEAT tool
retention tool -3415- retention tool -T20018B-
Torque wrench -V.A.G 1331- Torque wrench -SAT 8010-
Torque wrench -V.A.G 1332- Torque wrench -SAT 8010-
Engine/gearbox jack -V.A.G Hydraulic column jack -SAT
1383 A- , Drip tray -1359/2- 1040-
Torque wrench -V.A.G 1601- Torque wrench 100-550 nm) -
SAT 8020- with adaptor -SAT
8020/1-
Drip tray -VAS 6208- Drip tray -T20173-
Lever for releasing -VW 681- Extractor kit -T20143-
.
Extractor -T10037- Extractor -T20101-
Support equipment -3300A- Support equipment -T20111-
Support equipment -T10036- Support equipment -T20185-

9.1 Graphical information on the use and

VW units, Seat equivalents
9.1.1 Torque wrench -SAT 8010-

9.1.2 . Hydraulic column jack -SAT 1040-

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Final drive 0AV and 0BR - Edition 04.2010

9.1.3 Drip tray -T20173-

Application

9.1.4 Extractor kit -T20143-

Application

9. Conversion table by relevance 73

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9.1.5 Extractor -T20101-

Application

9.1.6 retention tool -T20018B-

Application

74 Rep. Gr.39 - Final drive - rear differential