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Haldex Hell - Help needed

Discussion in 'A3/S3/Sportback (8P Chassis)' started by Was, Dec 1, 2012.

  1. Was
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    Was Member

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    [Dec 1, 2012]
    I have a 2006 A3 2.0T with what seems like a Haldex issues:

    When I pull away everything is fine, then when the rear wheels are required to be engaged (by the front wheels losing grip) there is a clunking noise. I have completed serveral tests:

    1. Pull Handbrake and the haldex is disengaged car drives fine (front wheel drive only)
    2. Push the brake pedal when driving, this is meant to complete the same as point 1, nothing happens
    3. Changed Haldex controller, again no change
    4. Pull Fuse 31 out and car runs fine, as ESP light stay on and AWD system is disabled.- This is how I'm using it currently.

    I am told the following

    1. Try changing the oil - I found out the car had Haldex oil changed at 20K and this problem occured at 60K when it should had been changed at its 40K server, it was 20K to early so this may have caused the issue to occur.
    2. Try changing the pre charge pump - This seems to be the case for 8L engines, so unsure if this is the case with 8P engines?
    3. New Rear Diff - Money and effort in this, but happy to do this if it is 100% the haldex and not a speed/ABS senor, which can alos cause issues?

    My conclusion is the haldex is not releasing, or the signal is not getting to it to tell it to release, so its stuck on hence the noise.

    I need to find someone around the kent/Essex area who has Vagcom or can help diagnosis the issue, spoke to my local Audi dealers and they want 160 Per hour for diagnostic, which I can't afford. (annoying as Jaguar do a full diagnostics for a fix price of £60)

    I live near Orpington in kent, but am happy to travel to someone if they can help me understand what the actual issue is before I start changing stuff.
    #1
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  3. S3AMK20VT
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    [Dec 1, 2012]
    most likely just needs a haldex service (filter and oil), when the oil level is low teh car only drives on front two wheels
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  4. Was
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    [Dec 1, 2012]
    but it wants to drive on 4 Wheel drive hence the noise, it only goes in to 2 wheel when I remove fuse 31. Its undrivable with the fuse in, could oil still be the issue?
    #3
  5. gen.heinz guderian
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    gen.heinz guderian Well-Known Member Regional Rep VCDS Map User

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    [Dec 1, 2012]
    Have you checked the earth strap on the rear diff?
    #4
  6. bmh.01
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    [Dec 1, 2012]
    Haldex oil change is every 40k so should have been done again.
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  7. Was
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    [Dec 1, 2012]
    hi BMH - yep aware of that, I bought it at 55K, and wasn't aware of Haldex until it broke, and not once when I got it serviced did anyone mention it was changed early and was now 40K late.
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  8. OVRA3
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    OVRA3 Well-Known Member

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    [Dec 1, 2012]
    It's pot luck with the Haldex, I bought mine with 64k Haldex had never been done and I didn't know about it till I read it on the forum. Had mine done at 68k and its fine guess I got very lucky
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  9. DeckedS3
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    DeckedS3 Active Member

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    [Dec 1, 2012]
    Hi, I posted over on VAGOC as well, but I live in Orpington with vagcom....
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  10. Was
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    [Dec 3, 2012]
    Hi Decked - Yep seen that post, I'm told that the Haldex issue shouldn't give up any errors, but I'm keen to give it a go if thats ok? I'm also keen to see your beast, as if I can fix the issue I have on mine then an S3 is looking like the way forward :)

    I'll PM you on here
    #9
  11. S3Alex
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    S3Alex Rarely neutral

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    [Dec 3, 2012]
    I've also replied over at VAGOC,and if you need more help,give Ben at AMDTuning a call if there are mechanical or electrical issues with the Haldex.
    #10
  12. Was
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    [Dec 3, 2012]
    All booked in with AMD this Wedensday AM, fingers crossed its not what I think it is, as it coming up to 90'000 so looking at cost to repair vs value it may not be worth it, unless its a complete rear diff change and I can get a part for under £600. I'll keep you posted.

    Thanks for all your help.
    #11
  13. S3Alex
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    S3Alex Rarely neutral

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    [Dec 3, 2012]
    A pleasure.....they've always looked after my car extremely well,and I'm sure they'll sort yours out.
    #12
  14. Was
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    [Dec 3, 2012]
    OH and BTW S3 Alex - I have done no work today due to your build thread..!!
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  15. S3Alex
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    S3Alex Rarely neutral

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    [Dec 3, 2012]
    Many thanks.....another task completed!
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  16. RobinA3
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    RobinA3 Well-Known Member

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    [Dec 3, 2012]
    With VAGCOM you can run the haldex system through a test so make sure the garage does this, the system has a feedback system so vagcom will show whether the pre pump is operating or not - you will also hear noises as the test is started so thats a good sign of whether things are working correctly.

    I doubt it will be the pre-pump though, i had to change lots of components on the wife's R32 due to the 4WD not working, i changed the oil and filter then the haldex controller and this did not solve the problem, i then changed the pre pump as that wasn't making a noise when i did the test on VAG COM which didn't solve the problem so i then changed the rear diff which then solved the problem (did all this on the driveway on axle stands - horrible job!!) so in the end it was the pre pump and rear diff that had died. As you are saying the 4wd does work then the pre pump will be working.

    Having said all that i just read your post again - am i right in saying that the problem you are investigating is the fact that the 4wd doesn't disengage when you apply the brakes?

    Or are you worried about the clunk?

    I am slightly confused now...............
    #15
  17. Was
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    [Dec 3, 2012]
    the noise, its more than clunking, but its the noise I need to work on solving.

    the disengage when pressing the brake is one of the haldex tests on the Audi manual to perform. As is the handbrake one.

    Changing the whole diff is what a number of people say will fix it.....so like you it will be axle stands on the drive way.
    #16
  18. MrLapou
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    MrLapou Well-Known Member

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    [Dec 3, 2012]
    Clunking noises are also associated with a failing rubber coupling. But I think they cannot be bought on own.
    It may only come with a complete drive shaft..
    Whatever the outcome, do keep us posted.
    #17
  19. RobinA3
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    RobinA3 Well-Known Member

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    [Dec 3, 2012]
    Ah I understand now.

    Sounds like the prop is the problem, I am pretty sure that a few members have had the same problem and it ended up to be the propshaft - do a search.
    #18
  20. Was
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    [Dec 4, 2012]
    Thanks to S3Decked I have the following read out errors, so its still booked in with AMD tomorrow morning.

    Note: I will also be treating it to a clean after being a little shown up by S3Decked gleaming ride!

    -------------------------------------------------------------------------------
    Address 01: Engine Labels: 06F-907-115-AXX.lbl
    Part No SW: 8P0 907 115 K HW: 8P0 907 115 E
    Component: 2.0l R4/4V TFSI 0040
    Revision: --H10--- Serial number: AUX7Z0ENFNT0OK
    Coding: 01030003180F0060
    Shop #: WSC [​IMG]00359 210 82611
    VCID: 3A70E5EB75FC76C82F1


    3 Faults Found:
    008801 - Boost Pressure Control Valve (N249)
    P2261 - 008 - Mechanical Malfunction - Intermittent
    Freeze Frame:
    Fault Status: 00101000
    Fault Priority: 0
    Fault Frequency: 20
    Mileage: 131189 km
    Time Indication: 0
    Date: 2012.09.03
    Time: 18:04:37


    Freeze Frame:
    RPM: 2220 /min
    Load: 12.2 %
    Speed: 30.0 km/h
    Temperature: 75.0°C
    Temperature: 11.0°C
    Absolute Pres.: 990.0 mbar
    Voltage: 14.351 V


    012599 - Intake Manifold Runner Control
    P3137 - 001 - Basic Setting not Completed - Intermittent
    Freeze Frame:
    Fault Status: 00100001
    Fault Priority: 0
    Fault Frequency: 1
    Mileage: 138737 km
    Time Indication: 0


    Freeze Frame:
    RPM: 230 /min
    Load: 58.4 %
    Speed: 0.0 km/h
    Temperature: 59.0°C
    Temperature: 51.0°C
    Absolute Pres.: 1010.0 mbar
    Voltage: 10.541 V


    001602 - Sensor Reference Voltage A: Circuit
    P0642 - 002 - Low - Intermittent
    Freeze Frame:
    Fault Status: 00100010
    Fault Priority: 0
    Fault Frequency: 1
    Mileage: 138737 km
    Time Indication: 0


    Freeze Frame:
    RPM: 230 /min
    Load: 58.4 %
    Speed: 0.0 km/h
    Temperature: 59.0°C
    Temperature: 51.0°C
    Absolute Pres.: 1010.0 mbar
    Voltage: 10.795 V


    Readiness: 0000 0000


    -------------------------------------------------------------------------------
    Address 03: ABS Brakes Labels: 1K0-907-379-MK60-A.lbl
    Part No SW: 1K0 907 379 AB HW: 1K0 907 379 AB
    Component: ESP 4MOTION MK60 0102
    Revision: 00H13001
    Coding: 0021122
    Shop #: WSC 06314 000 00000
    VCID: 72E00DCB6D0CCE88271


    1 Fault Found:
    01324 - Control Module for All Wheel Drive (J492)
    004 - No Signal/Communication - Intermittent


    -------------------------------------------------------------------------------
    Address 08: Auto HVAC Labels: 8P0-820-043.lbl
    Part No SW: 8P0 820 043 P HW: 8P0 820 043 P
    Component: KlimavollautomatH17 0260
    Revision: 039919 Serial number: 8P0820043P
    Shop #: WSC 06314 000 00000
    VCID: 3972FAE770FA7DD026B


    No fault code found.


    -------------------------------------------------------------------------------
    Address 09: Cent. Elect. Labels: 8P0-907-279-23-H.lbl
    Part No SW: 8P0 907 279 F HW: 8P0 907 279 F
    Component: Bordnetz-SG H44 1102
    Revision: 00H44000 Serial number: 00000002340422
    Coding: 018C4F01B014100000160000160000000008FE175C0100
    Shop #: WSC 06314 000 08192
    VCID: 4084970313202C18615


    Subsystem 1 - Part No: 8P2 955 119 B Labels: 1KX-955-119.CLB
    Component: Wischer AU350 H01 0130
    Coding: 00062736
    Shop #: WSC 06314


    No fault code found.


    -------------------------------------------------------------------------------
    Address 15: Airbags Labels: 8P0-959-655-94.lbl
    Part No SW: 8P0 959 655 C HW: 8P0 959 655 C
    Component: Airbag 9.41 H12 3760
    Revision: 91H12376 Serial number: 00362005JUE-
    Coding: 0071612
    Shop #: WSC 06314 000 00000
    VCID: 42809D0B1D2C3E08771


    No fault code found.


    -------------------------------------------------------------------------------
    Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
    Part No SW: 1K0 953 549 AH HW: 1K0 953 549 AH
    Component: J0527 034 0070
    Coding: 0000012
    Shop #: WSC 06314 000 00000
    VCID: 78F43FE30B70A4D8195


    No fault code found.


    -------------------------------------------------------------------------------
    Address 17: Instruments Labels: 8P0-920-xxx-17-MY7.lbl
    Part No SW: 8P0 920 981 D HW: 8P0 920 981 D
    Component: KOMBIINSTR. VDO H80 0420
    Revision: D06 Serial number: 224NED06003877
    Coding: 0005413
    Shop #: WSC 01160 067 57207
    VCID: 3972FAE770FA7DD026B


    No fault code found.


    -------------------------------------------------------------------------------
    Address 19: CAN Gateway Labels: 1K0-907-530-V2.clb
    Part No SW: 1K0 907 530 G HW: 1K0 907 951
    Component: J533__Gateway H10 0140
    Revision: H10 Serial number: 3000105C0284AF
    Coding: BD3F034207002103
    Shop #: WSC 06314 000 00000
    VCID: 2B5ED0AF8AA6DF40A47


    1 Fault Found:
    01324 - Control Module for All Wheel Drive (J492)
    004 - No Signal/Communication - Intermittent
    Freeze Frame:
    Fault Status: 00100100
    Fault Priority: 2
    Fault Frequency: 254
    Reset counter: 24
    Mileage: 121152 km
    Time Indication: 0
    Date: 2012.05.10
    Time: 15:14:27




    -------------------------------------------------------------------------------
    Address 22: AWD Labels: 1K0-907-554.lbl
    Part No: 1K0 907 554 C
    Component: HALDEX 4Motion 0108
    Coding: 0000001
    Shop #: WSC 00000 000 00000
    VCID: 2D5ADEB7B4B2D170BA3


    1 Fault Found:
    01073 - Clutch Pressure System
    002 - Lower Limit Exceeded - Intermittent
    #19
  21. DeckedS3
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    [Dec 4, 2012]
    Fingers crossed AMD can sort it out straight away!
    #20
  22. Was
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    [Dec 5, 2012]
    Not the case the only good news it is took them 30mins to tell me what I thought which means £36 instead of Audi £160

    The following error codes: For Haldex test.

    2 faults found
    01703 - Clutch Pressure system
    002 - Lower limit Exceeded - Intermittent
    01155 - Clutch
    003 - Mechanical Failure
    003 - Mechanical Failure

    Cost to fix £2900 give or take a few quid.

    So the question is what now, I still have quite a bit owning on it, so even if sold I doubt I would break even. Threrfore I need to run it another 6 months then should be abe to sell or P/X for enough to cover the outstanding.

    Any other options - Can I rebuild the clutch? Get a secondhand rear diff? Take it down Audi and do a Part Ex.

    Happy Christmas BTW
    #21
  23. S3Alex
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    S3Alex Rarely neutral

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    [Dec 5, 2012]
    You can find used diffs but what you dont know is how good it is.....have you discussed rebuilding it with AMD?
    #22
  24. Was
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    [Dec 5, 2012]
    Nope - but have heard thats an option, Ben was the guy who stated cost etc, so I'll contact him. think his on here?
    #23
  25. S3Alex
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    S3Alex Rarely neutral

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    [Dec 5, 2012]
    Not often.....best way is to phone or email him.
    #24
  26. Was
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    [Dec 5, 2012]
    any ideas what its worth 2006 880000 miles, full server history 1/2 leather.

    one small scratch thanks to a lday and a shopping trolley.

    Haldex broke....I'm thinking 7200fixed - 2900 = not a lot. Seems the only option is to keep it and run it in to the ground.

    Going to try and unplug the haldex to see if ESP will work again but with out rear wheel drive. At least it will just be a two wheel version with some grip
    #25
  27. Was
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    [Dec 5, 2012]
    ^ Server WTF service even

    Lday = Lady

    Long day
    #26
  28. Was
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    [Dec 6, 2012]
    Managed to find a secondhand rear diff fitted for £690 with 90days warrenty and new Haldex oil?
    Place called Nirro Ltd.

    Might go with this option
    #27
  29. Was
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    [Dec 6, 2012]
    Erm no I won't just seen threads on this site saying they are a nightmare to deal with. I'll shop around
    #28
  30. S3Alex
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    S3Alex Rarely neutral

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    [Dec 6, 2012]
    Why not just get AMDTuning to sort it for you.
    #29
  31. Was
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    [Dec 6, 2012]
    I don't have £2900 laying around, and they won't put in secondhand parts when it comes to the rear diff
    #30
  32. RobinA3
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  33. S3Alex
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    S3Alex Rarely neutral

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    [Dec 6, 2012]
    Got it.

    Sorry!

    I can see why they won't use secondhand parts but the price is also pretty serious.

    Hope you find a good way out of this.
    #32
  34. Was
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    [Dec 6, 2012]
    They didn't state the details, I asked if thats a new rear diff and they said "yep just about"
    #33
  35. RobinA3
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    RobinA3 Well-Known Member

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    [Dec 6, 2012]
    I'd get a break down on exactly what is being changed before making a decision.
    #34
  36. Was
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    [Dec 7, 2012]
    Good point - Mail sent this morning

    Looking at options and getting it fixed and sold and replaced with a Focus ST is the viable option...did I just swear on an Audi forum!!!
    #35
  37. Was
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    [Dec 7, 2012]
    Ben@:AMD has come back stating they quoted for the whole rear diff, but a haldex on its own is a little over a grand + VAT.

    So its 1200 (New Haldex) vs 700 (rear diff second hand). Rest of the Car is sound so lets see if I get an XMAS bonus.
    #36
  38. S3Alex
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    S3Alex Rarely neutral

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    [Dec 7, 2012]
    That sounds like a good result.
    When I needed a new transfer case for mine,Ben did a lot of digging around and came up with some very keen pricing,so I'm pleased they've done well for you too.
    #37
  39. RobinA3
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    RobinA3 Well-Known Member

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    [Dec 7, 2012]
    I would personally go for a 2nd hand haldex and save yourself a massive amount.
    #38

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