Haldex Control | Faults & Fixes For Your

Haldex Unit
Steven Kay | June 19, 2024

If you are having issues with your vehicle's Haldex system or would like to know more
information on what a Haldex unit is & how the system works, then this guide can help
you. We will touch on some of the different Haldex faults, the different vehicles it is fitted
too as well as the Haldex oil service & why it is so important.

A Brief History of Haldex

GEN I

First appearing in 1998 on the VW Golf 4Motion the Gen 1 Haldex system rolled out to
the mass car market after only being patented that same year. The following year it
would also appear on the Volvo S60 AWD models.

GEN II

As with all equipment in the car manufacturing world, improvements are constantly being
made and by 2002 the Haldex Gen 2 made it's appearance. With changes to the
solenoid operating system and the introduction of a pressure control sensor, allowed for
vast traction improvements over the Gen 1 set up.

GEN III

2004 saw the Gen 3 system, which gained a check valve for the feeder pump. This gave
the system the ability to be pre-emptive and give more instant torque to the clutch pack.
This ability was further increase later in the Gen 3's lifespan.

GEN IV

With cost driven developments being the key factor, the Gen 4 Haldex system, further
developed the pre-emptive torque design and removed the heavy differential pump
system. The introduction of a hydraulic accumulator, fed by the pre-charge pump could
now give more instantaneous coupling response, all kept in check by pressure reducing
valves.

GEN V

In 2012 the Gen 5 Haldex unit saw the market in the VAG range. A vastly stripped down,
simplified version of the AWD system was introduced further removing components from
previous generations.

Haldex Pump
Common Faults

Haldex Pump Failure:

 Very common
  Requires new pump and clean of Haldex system including new oil and filter gauze

This is by far the most common issue you will see with the Haldex awd system and one
of the easiest to rectify. Unfortunately the system builds up with contaminants and forms
a sludge which increases the strain on the pump and eventually wears out.

This can can sometimes happen without the customer realising. This is until they are in
need of the 4wd system, only to realise the Haldex system does not work, and they only
have front wheel drive.

You may some of the following fault codes relating to Haldex pump failure:

 00448 - Haldex Clutch Pump V181 - Lower Limited Exceeded. (Gen 4)

 00448 - Haldex Clutch Pump V181 - Open Circuit/Defective. (Gen 4)
 16670 - All Wheel Drive - Mechanical Failure. (Gen 5)
 16671 - Pump For Haldex Pump - Internal System Fault. (Gen 5)
 16666 - Pump For Haldex Clutch - Open Circuit. (Gen 5)
 16668 - Pump For Haldex Clutch - Mechanical Failure. (Gen 5)

When replacing pumps it is vital to renew the Haldex filter and oil. This will prevent the
new pump from failing within a very short period of time.
Haldex Controller
Common Faults

Haldex Controller Water Damage/Corrosion:

  Very common
 Requires strip down of Haldex controller & repair or replacement of unit

Water ingress and corrosion damage on the Haldex Gen 2, Gen 3, Gen 4 & Gen 5
controllers are unfortunately very common . The damage to the circuit board can cause
an array of fault codes, some of which can lead to a misdiagnosis of the pump and vice
versa.

You may have some of the following fault codes relating to Haldex controller failure:

 00003 - Control Module Faulty - Defective

 00448 - Haldex Clutch Pump V181 - Defective
 01324 - All Wheel Drive Module - No Communication/Signal
 02248 - Valve For Controlling Clutch Operating Angle - Defective
 02249 - Sensor For Oil Pressure / Oil Temperature - No Signal
 16347 - Control Module - EEPROM Error
 65535 - Internal Control Module Memory Error

Haldex Coupling
Common Fault

Haldex Coupling Wear:

 Uncommon
 Requires replacement Haldex coupling with oil and filter

Faults with the Haldex coupling itself isn't very common. Vehicles modified outside of the
manufacturer's parameters do see issues as the unit is only rated to a certain threshold.
Failing Haldex pumps and controllers will also shorten the lifespan of the system.

Haldex Oil Change

Common Faults

Haldex Oil Change:

 Very Common
 Lack of Haldex oil & filter servicing leads to damage to pump

The importance of an oil an filter service is crucial, and can prevent almost all of the
Haldex problems listed previously in this article. It is an item normally overlooked as most
customers do not know it is even required on their vehicles.

A thorough clean is required, by removing the pump to clean any gunge that
accumulates on the pump, as well as new oil and filter gauze where applicable. This
should be done every 20,000 miles to ensure that excessive wear to the pump does not
occur.

VW Haldex (VAG)
As we will touch briefly on the manufacturers that use the Haldex system, the VAG range
have numerous models fitted with both front and rear Haldex systems. The main issues
with Audi Haldex and VW Haldex is the lack of driver warning when there is an issue with
the system. Drivers can do thousands if not tens of thousands of miles and not realise
there is an issue with the vehicle.

This issue is surprising as the VAG range is usually very strong when it comes to
onboard diagnostics and information presented to the driver. The issue is also partly with
drivers and the modern day car. Most if not all drivers know the basics when it comes to
servicing a vehicle, they know it needs engine oil and various filters.

However as the modern day vehicle becomes even more advanced, most drivers do not
know the technology in their cars, let alone maintenance that is required for it. We see
this time and time again dual clutch transmissions as well as Haldex units. There also
seems to be a very troubling pattern emerging where main dealerships as well as
independent garages who regularly service their customers vehicles, are missing these
important component service points.

We see many customers with full main dealer service history but know entries for Haldex
oil servicing. This is sometimes missed by independent garages due to the lack of
information on the subject and requirements rather than any sort of negligence.

Freelander 2 Haldex Unit

A very common enquiry we get is from the owners of the Freelander 2 having Haldex
problems. The Haldex unit is fitted on a few different versions of the Land Rover range,
but this seems to be the most common one we see.

Communication errors with the rear differential control module (RDCM) are normally
seen with the accompanying fault codes:

 RDCM - P0961-02
 ATCM - U0437-94
 ABS - U0114-68
 P1889 - (Haldex Pump Fault)

Haldex pump failure is also common on the Freelander 2 as well as the other Land
Rover models. It is important to complete the Haldex oil change as required including the
filters to prevent premature failure.

Ford Kuga AWD

If you own a Ford Kuga you may be reading this because you have seen the AWD
malfunction warning light on your dashboard. Or you may have been in the situation
where the Haldex 4WD system would of got you out of a spot of bother, to notice that
you've only got the front wheels providing power.
This is another instance of the "sealed for life" failure that so many manufacturers fall
short on. The Ford Kuga AWD systems are not sealed for life and simple maintenance
has the potential to save very expensive repair work in comparison.

Common fault codes for faults with the Haldex controller:

 P0606- ECU Short or Open Circuit

 P0960 - PCS Control Circuit Open
 P0961 PCS Control Circuit Range Performance

The most common issue with this system, as with all Haldex units is the pump, this
brings up an P1889 fault code when the vehicle is scanned.

Haldex AWD Volvo

Volvo systems run a very similar pattern and fault diagnosis as the Land Rover models
and Ford Kuga. These show a visual warning on the dashboard (Anti Skid Service
Required) when there is an issue with the Haldex unit, or differential electronic module,
as Volvo has named it.

Common Fault codes:

 DEM - 0002
 DEM - 0003
 DEM - 0006
 DEM - 0007
 DEM - 0008
 CEM - 1A64
 BCM - 00094
 BCM - 00095

The last three fault codes on this list are communication errors with the central control
module (CEM) and the body control module (BCM). These often appear due to the lack
of signal from the Haldex controller and are a good indication that the fault lies there.

If you think your vehicle might be suffering from a Haldex fault and as with all
transmission issues, it is best to get it looked at straight away as it could save the
customer substantial amounts on their repair bill.

Eco Torque offer an initial electronic diagnostic service with our main dealer equivalent
machine. This shows us live data from the Hladex controller as well as a report for the
customer to see the fault codes with the vehicle. This essential first step is £90 including
VAT and takes around 1 hour to complete.

All of our Haldex repairs or reconditioned units come with a 12 Month 12'000 Mile
Warranty. We also offer 0% finance through Omni Capital Finance* to spread the cost of
the repair bill. Eco Torque can also provide courtesy cars** as well as recovery*** of your
vehicle.
Contact Eco Torque Today