Active On Demand Coupling (AOC), Replacing

Active On-demand Coupling (AOC), replacing

Note: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Removal
Removing the exhaust system
Remove the exhaust system.

Removing the propeller shaft





Remove the propeller shaft from the flange for Active On-demand Coupling.
Remove the screw for the front mounting for the final drive housing.
Position a mobile jack in light contact against the final drive housing. Press the anti-roll bar to one side so that the screw is exposed. Use a jimmy bar.

Caution: Protect the surface of the anti-roll bar from damage.

Remove the mobile jack.





Disconnect the connector from the wiring.
Position a container underneath the Active On-demand Coupling (AOC)/final drive.
Remove the screws for the Active On-demand Coupling. Pull the coupling straight out of the final drive housing.

Installation
Preparations for installing the Active On-demand Coupling





Clean the final drive housing.
There must not be any lint from any paper or cloths.
Check that the mating surface is undamaged.





Check that the surface of the Active On-demand Coupling (AOC) is undamaged. Place the new gasket on the coupling. Apply a little grease.

Installing the Active On-demand Coupling





Install the coupling on the final drive housing.
Tighten the screws crosswise to light contact.
Then tighten to 25 Nm crosswise.
Connect the connector to the wiring.





Press the final drive up against the sub-frame.
Install the screw. Use a jimmy bar to move the anti-roll bar to one side. Tighten to 80 Nm.

Caution: Protect the surface of the anti-roll bar from damage.

Remove the mobile jack.

Filling and checking the oil in the Active On-demand Coupling





Only oil P/N 116 1641 (0.3 liter containers) may be used.
Tighten the level plug. Tighten to 35 Nm.
Volume approximately 0.8 liters.

Caution: If the Active On-demand Coupling (AOC) has been replaced with a new one, the car must be driven carefully in tight circles in both directions and then driven for a few kilometers after the oil is filled. Recheck and top up the oil level as above.

Installing the propeller shaft
Install the propeller shaft.

Installing the exhaust system
Install the exhaust system.