VW Audi Haldex ECU Controller Testing and Repair Specialist

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Here at Auto Fault Finder we have constructed a bespoke test rig to bench test the Haldex controller. It tests CAN BUS communications with the module, and monitors the oil pressure and temperature sensor system, and we can actuate the oil pump and solenoid driver controls to ensure all input, output and communication systems function correctly. This proves which parts of the control unit require repair, and which parts work correctly.

After initial testing we open the Haldex controller, and inspect the PCB and components to survey the scale of the corrosion damage. Not all units are viable for repair as corrosion may have caused damage beyond effective and reliable repair, we currently have around a 90% success rate in Gen2 and Gen4 Haldex units.

Once repaired, we re-varnish the PCB to ensure it will not corrode in the future, and we apply waterproof sealant to the rear electrical connectors to ensure they do not leak in the future – if all Haldex units were sent to us before they actually fail we could ensure they would not fail from this design oversight in the future! We clean up the cases to ensure a successful bond of the lid and we repair any corrosion holes or replace the front cover if required to ensure a water tight Haldex controller.

If you are concidering a Blue Haldex reflash or would just like to ensure your Haldex units life span, for our test and inspection fee we will refurbish your Haldex unit with cleaning, re-laquering and re-sealing to stop future water ingress damage which will save expensive future repair bills.

Haldex Testing and Repair Service Process and Costs

WE DO NOT REPAIR GEN 1 HALDEX UNITS

WE DO NOT REPAIR GEN 1 HALDEX UNITS

We test and inspect all Haldex units within 48 hours of being received, typically units are tested, inspected and dispatched on the same day as received but due to popular demand for this service it cannot be guaranteed same day turn around.

Firstly you send your Gen 2 or Gen 4 Haldex control unit to us, including a covering note stating your name, address, contact details and make/model/year of vehicle it was removed from.

Please send to:- Auto Fault Finder, The Railway Exchange, Weston Road, Crewe, CW1 6AA

Please call:- 07538 065845

  • If viable for repair we will repair your Haldex unit, and retest it to ensure full functionality, and return via Royal Mail Special Delivery – £127.50

AUDI A3 / S3 quattro / TT quattro / TTRS quattro – VW GOLF IV 4MOTION / R32 4MOTION / BORA 4MOTION / SHARAN 4MOTION / BEETLE RSi 4MOTION
SKODA OCTAVIA 4X4 / SEAT LEON 4×4 / SEAT ALHAMBRA 4X4

Screenshot-7Typical Failure Of Haldex Control Units

Every Haldex control unit is a ticking time bomb, sooner or later it will fail causing the loss of the AWD/4wd system operation and the dreaded ESP light on the dashboard. The main cause of failure in this system is the Haldex control ECU which is bolted to the side of the rear differential by two hex bolts. These Haldex units fail because the seals on the rear side of the ECU let salty road water to ingress inside the unit, which evaporates leaving a salt build up which eats away at the PCB inside causing components to fail and the PCB’s tracks to corrode away to nothing. Common fault codes which occur when scanning the vehicle with a system such as VCDS / VAG-COM or other generic scan systems are:-

  • 65535 – Internal Control Module Memory Error 00-10 – Intermittent
  • 01324 – All-Wheel Drive Control Module -J492- 013 – Read Fault Memory sporadic
  • 01324 – Control module for ALL WHEEL DRIVE (J492) 004 – No signal/communication – intermittent.
  • 02248 – Haldex Clutch Control Valve -N373- 014 – faulty sporadic
  • 00003 – Control Module 014 – Defective – Intermittent / Control module faulty sporadic
  • 02248 – Valve for Controlling Clutch Operating Angle (N373) 014 – Defective – Intermittent
  • 00448 – Haldex Clutch Pump (V181) 014 – Defective – Intermittent
  • 02249 – Sensor for Oil Pressure and Oil Temperature (G347) 014 – Defective – Intermittent
  • 02249 – Sensor for Oil Pressure and Oil Temperature (G437) 004 – No signal

Haldex Control units come in a few different types:-

haldex_gen1This is a Generation 1 Haldex Controller, these do not often fail internally but they do suffer from pump failure which is external to the controller and can easily be replaced. Fault codes which highlight pump failure are:-
00448 – Haldex Clutch Pump (V181) 014 – Defective – Intermittent
01155 – Clutch mechanical 00-04 – Intermittent
01155 – Clutch mechanical 00-00 – Failure

They also suffer corrosion to the wiring harness under the vehicle which connects directly to the Haldex unit. Fault codes which highlight this are:-
00526 – Brake Light Switch-F 27-10 – Implausible Signal – Intermittent
01324 – Control module for ALL WHEEL DRIVE (J492) 004 – No signal/communication – intermittent.

WE DO NOT OFFER A MAIL ORDER TEST AND REPAIR SERVICE FOR THIS TYPE OF CONTROLLER

IMAG2485

This is a Generation 2 Haldex Controller, these ALWAYS fail! They have terrible water sealing and the board inside corrodes. All or some of the fault codes in the list at the top of the page indicate failure, normally there is more than one fault code, and  communications fault codes on the ESP system, but not always. These rarely suffer from external pump failure. Usually they are made by Siemens VDO and have part numbers such as:-
1K0907554F  SW:0115  HW:H05  5WP22232-02  23.04.06
1K097554A   SW:0105  HW:H05  5WP22222-01  13.03.05

WE DO OFFER A MAIL ORDER TEST AND REPAIR SERVICE FOR THIS TYPE OF CONTROLLER

IMAG2486

This is a Generation 4 Haldex Controller, they look the same on the front as a generation 2 Controller, but notice there is no inductor (copper coil/doh-nut) below the blue capacitor, nor do they use the pressure/temp sensor. They are not forwards or reverse compatible with Gen 2 controllers. Usually they are made by Continental and have a part number such as:-
0BR907554C  SW:3018  HW:H43  5WP33523-04  HAP542
0BR907554B  SW:3017  HW:H43  5WP33523-03 HAP542

These fail exactly the same as Generation 2 Haldex controllers due to corrosion caused by water ingress.

WE DO OFFER A MAIL ORDER TEST AND REPAIR SERVICE FOR THIS TYPE OF CONTROLLER

These are just a small selection of some of the damaged Haldex units which we have repaired:-

IMAG2520

IMAG2559

IMAG2237

IMAG2568

IMAG2564

IMAG2523

IMAG2485