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Discussion Starter · #1 ·
Have been running my 4motion as a 2motion for about a year now.

Vag com never showed a fault, but a local vw specialists diagnostic system detected a mechanical fault on the clutch on the Haldex coupling, the whole rear diff and coupling was swapped for a S3 unit in may. that didnt fix it pointing to the Haldex controller also.

Souced a second hand controller from a front end write off 53 plate R32. that was fitted on moday. coming home today thought id check i had a 4motion again and im not convinced.

should i be getting wheel spin when nailing it in the pi55ing rain. turned the ESP off and i can light the tyres up![cry]

Vag com still not showing a fault. where do i go from here.

please help, this care is cost a fortune, getting very annoyd with Mk4's again and there crap build quility

Jambo
 

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find a wet empty car, roll in, give it full lock, dab the hand break, dip the clutch with plenty of revs and if your 4x4 is working youll have a very big smill on your face and all the young lads will love you for it.hehe.[H]
 

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Discussion Starter · #3 ·
well its deffinatly 2wd still, wheelspinning everywhere last nite, infact its spinning up in 2nd and 3rd from rolling when it hits about 3-4k rpm[:mad:]

come on guys there must be some one on here who clue'd up on the haldex system

why wont anything show up on the VAG COM?
 

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YOU NEED MORE THAN VAG COM[:S] damn caps

can you connect to the haldex controller? if yes what are the model nos etc... if not is the haldex getting power?

have you checked all the fuses, we need somone to post the engineering diagrams for a haldex car or the bentley instructions for diagnosing a haldex system... it may be worth asking over at the TTforum... though we seem to have more technical people here ..

Ill wait for BigAl to pipe in next
 

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Discussion Starter · #5 ·
Just ran a scan and got this

00526 - Brake light switch-f

27-10 - implausible signal intermitent

01155 - clutch

04 -10 - mechanical malfunction intermitent

dont like the sound of that clutch fault... again!
 

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YOU NEED MORE THAN VAG COM[:S] damn caps

can you connect to the haldex controller? if yes what are the model nos etc... if not is the haldex getting power?

have you checked all the fuses, we need somone to post the engineering diagrams for a haldex car or the bentley instructions for diagnosing a haldex system... it may be worth asking over at the TTforum... though we seem to have more technical people here ..

Ill wait for BigAl to pipe in next
Sorry, I have no relevant experience, or manuals, for the the Haldex system. I would recommend downloading the appropriate manual(s) from Erwin. It may be worth a quick look on http://www.volkswagen.msk.ru/to see if they have anything.
 

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Discussion Starter · #7 ·
YOU NEED MORE THAN VAG COM[:S] damn caps

can you connect to the haldex controller? if yes what are the model nos etc... if not is the haldex getting power?

have you checked all the fuses, we need somone to post the engineering diagrams for a haldex car or the bentley instructions for diagnosing a haldex system... it may be worth asking over at the TTforum... though we seem to have more technical people here ..

Ill wait for BigAl to pipe in next
Sorry, I have no relevant experience, or manuals, for the the Haldex system. I would recommend downloading the appropriate manual(s) from Erwin. It may be worth a quick look on http://www.volkswagen.msk.ru/to see if they have anything.
Erwin wont tell me what they have on offer untill a register and that 15 quid just for the gearbox option

The Russian site covers the 02m gearbox and mentions the transfere box but thats the range on 4wd doesnt cover the rear box, well not in English anyway. anyone speak Russian[:D]
 

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Change the brake light switche for a strart they are a known problem and an intrinsic part of the 4motion and DBW system... all kinds of whacky things happen when the fail... oh and are only 6 quid
 

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YOU NEED MORE THAN VAG COM[:S] damn caps

can you connect to the haldex controller? if yes what are the model nos etc... if not is the haldex getting power?

have you checked all the fuses, we need somone to post the engineering diagrams for a haldex car or the bentley instructions for diagnosing a haldex system... it may be worth asking over at the TTforum... though we seem to have more technical people here ..

Ill wait for BigAl to pipe in next
Sorry, I have no relevant experience, or manuals, for the the Haldex system. I would recommend downloading the appropriate manual(s) from Erwin. It may be worth a quick look on http://www.volkswagen.msk.ru/to see if they have anything.
Erwin wont tell me what they have on offer untill a register and that 15 quid just for the gearbox option

The Russian site covers the 02m gearbox and mentions the transfere box but thats the range on 4wd doesnt cover the rear box, well not in English anyway. anyone speak Russian[:D]
You do not need to register with Erwin to find out what is in the manuals, if you click the "i" button next to the manual description it brings up a PDF of the index pages of the manual. I've just looked at the index for the 02M gearbox and it lists repair information and diagnostics for the clutch, gearbox, haldex and rear diff all in the gearbox manual for 18.40 euros.

I find the Erwin site absolutely infuriating trying to find the correct manuals, I found the 02m manual by the following process:

Set both site options to English
Select Search
Select 1998-2005 Golf/Bora
Select Manual Transmission

You should then get a list of the various gearboxes.
 

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You know, this may piss you off.  But the brake switch is probably the cause.  The haldex controller disables the 4wd on braking. 
 

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Discussion Starter · #11 ·
Have already replaced the brake light switch twice since in 2yrs, but at 6 quid ill be swapping it again. hope this clutch fault is all part and parcel, ive already swapped the haldex clutch once!

cheers guys will let you know tomorrow whether the switch does the trick[:D]
 

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Just as a quicky guys i have a friend with vagcom & a 4mo Bora with 4wd problems that went away when we cancelled faults out of the can fault system,but i've forgotten the addresse word.

(you never know)

V5 Bora std no toys yet!!!!!!!!
 

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Discussion Starter · #13 ·
Right

re scanned the car this morning and no fault codes showed up. cleared everything anyway. fitted the new switch and re scanned still clear. took the car for a five minute blast.

managed to get big wheelspin but esp cut in, turned that off and tried again and got even bigger wheelspin well more a burnout!. [:mad:]

re scanned again but still all clear!!!

where the bloody hell do i go from here.

[cry]
 

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start from basics and see if there is power to the haldex controller, get the multimeter out.

scan the abs system and make sure there are no faults on that.

post the problem in vwvortex r32 forums.. see if anyone can help there.
 

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sorry to go off topic here but when the 4 w d isnt working does that mean you get all the power ie. 204bhp to the wheels albeit the front 2 , just a wee thought i had , meaning less traction but slighltly quicker
 

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Discussion Starter · #16 ·
well bit of an update,

last week found a fault code on the ABS.

control module part number: 1C0 907 379 F

component and version ESP ALLROAD MK 60 01

Software code: 0023046

Workshop code: wsc 31414

01324 - Control module for ALL WHEEL DRIVE (J492)

004 - No signal/communication - intermittent.

Got the car jacked up and checked the Haldex plug, found it cracked and terminals exposed. seperated the plugs and found one of the pins totally retracted, no way it was connecting. dismantled the plug and sorted that out. rebonded the plug up and tested. while under the car got a second person to go through the output tests, could hear the Haldex changing state/ operating on the different test states, great i thought sorted[Y].

put the car back on the road did a full scan of all modules, all clear.

took the car out............ wheelspin[N]

so where the bloody hell do i go now.

does anyone know exactly what happens to the cars systems to bring to rear wheels into play. does the signal to the Haldex come from the ESP. what happens when, what tells the Haldex to engage and how much! where can i find the techy answers without having to deal with VW because they will just want to take ?90 and hour from me to tell me what i already know.

have been onto Haldex traction.com asking them, they never got back to me!

HELP
 

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Are you 100% certain that connector is alright? It seems highly likely that is the problem if it wasn't even connected before. Also, it seems likely to me it is something related to ABS problem (module?) because I think the Haldex gets the info from the wheelspeed sensors (ie the ABS sensors) to detect wheelspin, wherupon it would send power to the back wheels.

Maybe it is worth getting the ABS checked by someone who really knows how to use VAGCOM? Is your ABS module one of the ones that can be affected (read - knackered) by the use of aftermarket VAGCOM product? (Can't remember the name now).
 

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Discussion Starter · #19 ·
Are you 100% certain that connector is alright? It seems highly likely that is the problem if it wasn't even connected before. Also, it seems likely to me it is something related to ABS problem (module?) because I think the Haldex gets the info from the wheelspeed sensors (ie the ABS sensors) to detect wheelspin, wherupon it would send power to the back wheels.

Maybe it is worth getting the ABS checked by someone who really knows how to use VAGCOM? Is your ABS module one of the ones that can be affected (read - knackered) by the use of aftermarket VAGCOM product? (Can't remember the name now).
Well i cant be 100% but pretty close. i have scanned the car several time after sorting the plug and no faults have come back. while i was sorting it deliberatly kept disconnecting it testing and reconnecting to make sure it was seeing the controller, all seemed good and like i said the controller could be heard operating when running an output test.

ESP/ABS does look like the next port of call, but my ABS and Traction control still works, the ESP light goes mental all the time although when the haldex was working, if i overcooked it in a tight bend and the ESP ticked in it would cut the front understeer, now it just carrys on understeering, but i suppose that is because there are no rear wheels to get involved with sorting it out.

does the handbrake switch show on VAG COM like the pedal switch does

Take it that the ESP is controlled by the main ECU.

Who is sh*t hot with VAG COM and lives in the Chester, Wrexham, Liverpool, Manchester way and would be able to have a look and give some guidence?

Jambo[Y]
 
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