Hybrid Module - Replacing

Special tools and workshop equipment required

Hydraulic Press - Subframe Assembly Tools - Pressure Washer: T10365/5
Hydraulic Press - Ball Joint Assembly Tools - Nut: T10254/4
Hydraulic Press - Ball Joint Assembly Tools - Spindle: T10254/5
Assembly Tool: T40342/4
Bearing Installer - Multiple Use: 3062
Internal Puller: VAS251619
Counter Support: VAS251625

-- Remove the hybrid module. Refer to HYBRID MODULE, REMOVING .

If the hybrid module is being replaced, the differential bearing outer shell is needed for reinstallation.

Differential Bearing Outer Shell, Removing:

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-- Insert the : VAS251619 into the bearing shell -1- and tension it.

-- Position the : VAS251625 .

-- Remove the bearing shell.

If a new hybrid module is being installed:
Replace the release bearing shims for the clutches C1 -2- and C2 -4-.

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Replace the shim -1- for the differential bearing.

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New Shim Thickness, Determining:

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-- Measure and note the old shim thickness for the differential bearing: dimension L1_old

-- Measure and note the old shim thickness for the clutch C1 release bearing: dimension H1_old

-- Measure and note the old shim thickness for the clutch C2 release bearing: dimension H2_old

-- Measure and note the thickness of the old and new flange seal at three spots -arrows- : dimension M1_old , M2_old and M3_old ; dimension M1_new , M2_new and M3_new .

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Only measure at the edge and not over the depression.

-- Calculate the flange seal average: dimension M

M = M1+M2+M33

-- Note the G1, G2 and K1 dimensions from the old and new hybrid module.

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The manufacturer-dependent dimensions for the hybrid module are engraved on the housing.

-- Calculate the shim thickness for the differential bearing:

L1_new = C1_new - C1_old + L1_old + M_new - M_old

-- Calculate the shim thickness for the release bearing of clutch C1:

H1_new = G1_old - G1_new + H1_old + M_new - M_old

-- Calculate the shim thickness for the release bearing of clutch C2:

H2_new = G2_old - G2_new + H2_old + M_new - M_old

-- Order shims as specified in the Parts Information.

-- Insert the new shims for the clutch release bearing -2 and 4-.

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-- Align the seal -5- centrally on the shaft.

-- Align both release bearings -1 and 3- centered on the shaft.

Differential Bearing Outer Shell, Installing:

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-- Insert the new shim -1- and bearing shell -2-.

-- Place the : T40342/4 on the bearing shell.

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-- Guide in the : T10254/5 .

-- Position the : 3062 on the outside of the transmission and secure it on the spindle with the : T10254/4 .

-- Install the bearing shell slowly and carefully.

CAUTION:

The Bearing Shell Can Easily Tilt When Installing.

Risk of Damaging the Bearing Shell and the Bearing Seat.

- Use a moderate amount of force to drive in the bearing shell. If more force is used, the bearing shell becomes tilted.

- If tilted, bring the bearing shell into position by lightly tapping with a hammer.

- Then continue the procedure.

-- Install the hybrid module. Refer to HYBRID MODULE, INSTALLING .