Get Power transmission -> The four-wheel drive Guide for Volkswagen Multivan SUV Fifth Generation (2003-2015)

Power transmission

The four-wheel drive

In the T5 2010, four-wheel drive is available in all vehicle variants in conjunction with the 2.0 l 103/132 kW TDI

engines.

It can be used with the 6-speed manual gearbox 0A5 and now, for the first time, also in conjunction with an

automatic gearbox - the 7-speed dual clutch gearbox 0BT.

A Haldex 4th generation coupling is used as the 4WD coupling.

Rear axle box

Haldex coupling

Rear axle box

The design of the rear axle box has been adapted for installation of the Haldex 4th generation coupling and for

the higher torque requirements in the T5 2010.

As an option, the T5 2010 is available with a mechanical differential lock comprising a dog clutch on the rear axle

box.

The picture shows the four-wheel drive system as an example in conjunction with

a dual clutch gearbox.

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Bevel drive

The bevel drive has been adapted for the higher torque requirements in the T5 2010.

Two different bevel drives are used, one of which is adapted for mounting on the manual gearbox and the other for

the dual clutch gearbox.

Propshaft

Bevel drive

Dual clutch gearbox 0BT

S453_043

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Power transmission

Bevel box

The housing structure, the bearings and the gears of the bevel box have been adapted for the higher torque

requirements in the T5 2010. At the same time, it has been possible to reduce the weight of the bevel box by 6.25 kg

compared to the previous type.

Structure and function

The bevel box is driven via a hollow shaft with inner spines. This hollow shaft is a component of the bevel box and

is positively connected to the housing of the differential via its splines. The spur gear on the hollow shaft transmits

the torque onto the intermediate shaft with hypoid gearing and subsequently to the propshaft via the pinion. The

stub shaft for the right front wheel runs inside the hollow shaft. This stub shaft is driven by the shaft bevel gear of

the differential.

The bevel boxes for the manual gearbox and the dual

clutch gearbox differ in the area of the attachment to

Powerflow

Haldex coupling/final drive

Differential

housing

the differential.

The picture shows a bevel box combined with a dual

clutch gearbox.

Hollow shaft with inner spines

Hollow shaft spur gear

to wheel

front left

to wheel

front right

Final drive

Front axle differential

Intermediate shaft with

hypoid and spur gearing

Shaft bevel gear

Stub shaft for

right front wheel

Pinion with hypoid gearing

to

rear final drive

S453_027

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Rear final drive

The design of the rear final drive has been adapted for installation of the Haldex 4th generation coupling and for

the higher torque requirements in the T5 2010, as far as the housing and the bearings are concerned.

The reservoir tank for the Haldex oil is an integral component of the final drive housing. This means it is protected

against mechanical damage from the outside.

The Haldex 4th generation coupling is similar in design to the Haldex coupling in the Caddy and Tiguan.

Optionally, the rear axle drive is available with a mechanical differential lock.

More information about the Haldex 4th generation coupling is available in self-study programme

no. 414 "4MOTION with generation IV 4WD coupling".

Rear axle box

Ventilation

Rear axle box

Haldex coupling

Ventilation

Haldex coupling

Mounting frame

S453_132

Output flange

left

Reservoir

Haldex oil (metal)

Drive flange

Four-wheel drive control unit J492

When service work is carried out on the rear axle box, refer to the information in ELSA (Electronic

Service Information System) or in the technical product information documents. This applies to the oil fills

in particular. Never mix up oils for the rear axle box and for the Haldex coupling with one another!

If oils are mixed up or there is no oil fill, there will be massive damage to the final drive and/or the

Haldex coupling.

25

Power transmission

Ventilation

Rear axle box

Cutaway view – rear axle box

Ventilation

Haldex coupling

The rear final drive of the four-wheel drive T5 2010

consists of the Haldex 4th generation coupling, the

final drive and the optionally available differential

lock. The transmission ratio is 2.466.

Drive

to left wheel

The Haldex coupling is integrated into the final drive

and can be renewed separately.

Differential

The oil supply to the Haldex coupling and the final

drive comes from two different oil circuits. Two oils

adapted to the particular requirements are used for

lubrication and cooling.

The two oil circuits are sealed off from one another

internally by a double oil seal.

This separates both the oil circuits from one another.

There is a spacer between the two halves of the

double oil seal, in order to guarantee that there will

be a narrow gap. The gap is connected to the

atmosphere by means of a breather hole in order to

equalise the pressure.

In the event of a leak of the pinion, it is possible for

leaking Haldex or final drive oil to reach the outside

via the breather hole.

The double oil seal prevents any mixing between the

two oils.

Crown wheel with

hypoid gearing

Mixing would impair the lubrication properties of

both oils, and could result in malfunctions in the final

drive or in the Haldex coupling.

Operating lever for

dog clutch

Drive to

right wheel

Pressure unit for

differential lock

Reed contact switches 1-3 for

differential lock F360-F362

For more information about the

differential lock, refer to self-study

programme no. 333 "4MOTION with

Haldex coupling".

For more information about the Haldex

4th generation coupling, refer to self-study

programme no. 414 "4MOTION with

Haldex 4th generation coupling".

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Four-wheel drive control unit J492

Pinion

Torsional vibration damper

Drive from

propshaft

S453_130

Multi-disc pack of the

Haldex coupling

Oil space

Haldex oil

Pump for

Haldex coupling V181

Double oil seal

Oil space

final drive oil

Double oil seal

Breather hole

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Power transmission -> The four-wheel drive for Your Volkswagen Multivan SUV Fifth Generation (2003-2015)

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