Great thread Bob & Arctic

I’ve tackled the Haldex 3 a few times but have a later model Freeby now.
This thread will be of great use next year,when I plan to have a go on the gen.4 Haldex. Back in the fold after 8 yrs. V8 Disco 300 series-Gone.07 Freelander 2 HSE Auto Rimini Red.
Gone.
2013 HSE Lux Havana ( Brown! )

Good work

Last edited by Mowog on 29th Dec 2023 10:01 am. Edited 1 time in total

There is a Utube video on haldex clutch disassembly - dont have a link - sorry Jules

Hi Guy's & gal's

So if you have read my other threads on Haldex & Diff oil changes, you may well know i managed to bag myself a spare rear diff & Haldex from a FL2 2010.



My intentions to learn more about the Haldex and rear diff, if you have read this thread from the beginning you will know i changed out the diff oil by using a pump works fairly well but is slow and time consuming, so the next time the oil change is due it will have been drilled and tapped a drain hole.



I used my spare diff to practice on albeit out of the car, the diff was first clean outside.
1



2



On the diff i have there is an ideal place to put a drain hole and plug, not all diff are the same in this area, it has an oblong flat spot.

3



Where my FL2 14 has a round spot for the drain hole in the same place.

4



The spare diff cleaned out side, i tried the 12mm drill bit into the hole already there it fits perfect

5



6



I did a little test drill not much.

7

The plan was then left for a few days while in concentrated on the Haldex.

With the Haldex sorted and out of the way i then went back to the diff, there are three oil ways in the area where the Haldex bolts to the diff, one is the filler hole.

8

I cut some clear tubing which i threaded through the diff filler hole.

9

10

11

The two other oil ways are in port of the diff & one on the outer edge just inside the diff.

12

13

The clear tube was pushed into these oil galleries.

14

15

The tube was fitted to a can of brake cleaner.

16

This was then spayed into the galleries, the fluid came out of the filler plug hole.

17

Same from the inner gallery.

18

19

20

That was allowed to dry out for another couple of days, before the drain hole can be drilled out completely.

Ok so back to the drilling of the drain hole, 12mm drill bit on slow speed in the drill, on a bench in the shed.

21

The hole was drilled very slowly checking all the time it was straight.

22

The drill bit broke through under control not knowing what is below inside.

23

24

Next it was time to tap the hole with a 14mm-1.5 tap, this again was done slowly and making sure it was straight.

25

It was tapped until it came to a stop, more or less the full length of the thread.

26

The thread looked nice and clean.

27

I had purchased three different drain plugs not knowing the depth.

28

The tap was again inserted so the tap showed no thread.

29

My thought was the middle plug, would be the best, but i tried them one by one.

30

The first one i tried was the Vw Skoda/Audi plug

[URL unfurl="true"]https://www.ebay.co.uk/itm/264964143891[/URL]

31

That came to a stop and did not mate flat.

32

The next one was the middle plug from above, Vauxhall/VW drain sump plug.

[URL unfurl="true"]https://www.ebay.co.uk/itm/202853526794[/URL]

33

That one went flat has it should.

34

The last drain plug was the magnetic one, VW/Vauxhall

[URL unfurl="true"]https://www.ebay.co.uk/itm/204575909825[/URL]

35

This too would not bottom out flat, it may have if it was tightened down by using a socket but the second one screwed in by hand.

36

Therefore the one i thought in the first place fitted best, even though the head is a 22mm would have liked a 17mm or 19mm so have ordered a few more to try waiting on there arrival.

The next step was to remove the bell housing to see what the gears looked like and remove any swarf from drilling, which there was bound to be, maybe doing it is situ on the car with the oil in the diff the swarf would drop out with the oil, i will know that when i come to do mine in the spring.

37


The above will be in the next post.

Hi all,

I just did the haldex service as demonstrated here, however now when I run the vehicle and have either full lock on in 2WD mode or use any of the different 4WD option, I have a clunking /knocking noise from the rear.

Any ideas?

Pull the fuse to the Haldex which stops the pump from activating when the engine starts. The FL2 is in 4WD at low speed even if none of the special programs are selected.

Thank you for the reply so quickly!

Yeah I’ve tried running the car with the haldex unplugged and I don’t get this issue at all so I definitely think it’s the haldex.

I just don’t understand why it would be doing it after the service when it wasn’t before.

When i removed the haldex and rotated it, it didn’t spin freely, it made a slight noise? Is this normal. I can try to attach the video.

Thanks again.

Assume proper haldex oil used and filled up sufficiently? Mine was clunky / grabby on one occasion when the haldex oil was low. Landrover - turning owners into mechanics since 1948

2014 Orkney grey Freelander SD4 GS.
2004 Zambezi silver Discovery 2 Td5 (Gone)
1963 Surf blue Morris Mini Minor Super de Luxe (my little toy)

Yeah I injected the oil until it dripped out, ran it for 5 minutes and then topped up again, but I’ll check it again tomorrow. Hopefully it’s as simple as low oil! Thanks for the reply.

Did you change the cartridge filter and remove the pump to clean the mesh on its inlet?

Yeah all of that’s been done

Then there will be a problem with the ecu on the Haldex. Have a look here https://www.haldexrepairs.co.uk/ecu-testing-repair-service/

or it could be you have over filled the haldex the procedure mentions removing some fluid . 2009 FL2 S now gone
2011 FL2 HSE AUTO
2012 FL2 XS AUTO
2000 Kawasaki er 5

I think we've established over the years that the removal of the 70ml or whatever of oil doesn't make the slightest difference to the operation of the haldex. Landrover - turning owners into mechanics since 1948

2014 Orkney grey Freelander SD4 GS.
2004 Zambezi silver Discovery 2 Td5 (Gone)
1963 Surf blue Morris Mini Minor Super de Luxe (my little toy)

Last edited by Bobupndown on 16th Sep 2024 8:52 pm. Edited 1 time in total

It's easy enough to set the Haldex level correctly, by following the filling process, then driving the car 20 miles to warm up the Haldex, then open the fill screw. Any expanded fluid it doesn't need will dribble out. This is accurate enough, and probably overkill really. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.