Volvo Guide to Haldex fault finding, ECU repairs and replacement
We can test, repair and replace Haldex units for the Volvo vehicles fitted with Haldex like the XC90, XC70, XC60, XC40 S40, S60, S80, S90, V50, V60, V70, V90 including Cross Country models etc.
We can repair all HAP542 units which are Gen 3 and 4 Haldex, and we can repair all HAP511 Gen 2 Haldex units. So if your exact part number is not on the list but is a HAP542 or HAP511 we can still do it.
The part numbers we see often are:-
| Volvo hap511 5wp22201-01 (Gen 2) Volvo hap511 5wp22201-02 (Gen 2) Volvo hap511 5wp22201-03 (Gen 2) Volvo hap511 5wp22201-04 (Gen 2) Volvo hap511 5wp22201-05 (Gen 2) Volvo hap511 5wp22211-01 (Gen 2) Volvo hap511 5wp22211-02 (Gen 2) Volvo hap511 5wp22220-01 (Gen 2) Volvo hap511 5wp22227-01 (Gen 2) Volvo hap511 5wp22228-02 (Gen 2) Volvo hap511 5wp22229-01 (Gen 2) Volvo hap511 5wp22245-01 (Gen 2) Volvo hap511 5wp22246-01 (Gen 2) |
Volvo hap542 5wp33502-01 (Gen 3) Volvo hap542 5wp33512-01 (Gen 4) |
What Generation of Haldex is on what Volvo model?
(This list is a guide only, see the image table below)
Generation 2 – HAP511 – Volvo DEM Part Number 36001750 was 30787954 was 30713310
Volvo S40 2005 – 2010 Volvo S40
Volvo V50 2006 – 2010 Volvo V50
Volvo S60 2003 – 2006 Up to Chassis -522546 (Last 6 digits of VIN)
Volvo V70 2004 – 2006 Up to Chassis -554316 (Last 6 digits of VIN)
Volvo S80 2004 – 2006 Up to Chassis -435568 (Last 6 digits of VIN)
Volvo XC70 2003 – 2006 Up to Chassis -220976 (Last 6 digits of VIN)
Volvo XC90 2004 – 2006 Up to chassis -257057 (Last 6 Digits of VIN)
Generation 3 Volvo DEM Part Number 36001751 was 30783061 was 30713163 was 30759702
Volvo S60 2006 – 2009 After Chassis 522547- (Last 6 digits of VIN)
Volvo S80 2006 – 2008 After Chassis 335000- (Last 6 digits of VIN)
Volvo V70 2006 – 2008 After Chassis 554317- (Last 6 digits of VIN)
Volvo XC70 2006 – 2008 After Chassis 220977- (Last 6 digits of VIN)
Volvo XC90 2006 – 2008 After Chassis 257058 till 494999 (Last 6 digits of VIN)
Generation 4 Volvo DEM Part Number 36001750 was 30787954 was 30713310
Volvo S60 2010 – 2012 (pre 2013 facelift) Chassis 000194-115694 Build dates 2010w20-2011w48
Volvo V70 2008 – 2012 (pre 2013 facelift)
Volvo S80 2009 – 2012 (pre 2013 facelift) Chassis 087101-157261 Build dates 2008w20-2011w48
Volvo XC60 2009 – 2012 (pre 2013 facelift) Chassis 018829-288205 Build dates 2009w05-2011w48
Volvo XC70 2008 – 2012 (pre 2013 facelift) Chassis 047601-132422 Build dates 2008w20-2011w48
Volvo XC90 2008 – 2014 (Mk1) Chassis 495000 onward Build dates 2008w20-2011w48
Generation 5 Volvo DEM Part Number 36012520 ex 31367185 ex 31380867
Volvo V60 & Cross Country 2015 onwards
Volvo V70 2013 onwards (facelift type)
Volvo S60 2013 onwards (facelift type)
Volvo S60 Cross Country 2016 onwards
Volvo S80 2013 onwards (facelift type)
Volvo XC60 2013 onwards (facelift type)
Volvo XC70 2013 onwards (facelift type)
Volvo XC90 2015 onwards (Mk2)
Volvo DEM Haldex Control Unit Repairs and Testing
‘Anti-Skid Service Required’
It is common to get the “Anti Skid Service Required” message on the dashboard instrument cluster when there is an issue with the Haldex controller called the DEM (Differential Electronic Module) on Volvo vehicles. Common fault codes are DEM-0002 / DEM-0003 / DEM-0006 / DEM-0007 / DEM-0008 / CEM-1A64 / BCM-0095 / BCM-0094
DEM-0006 is normally a fault with the Pump, but sometimes can be caused by the control unit if the electronics that drive the pump fail.
DEM-0007 is often the pressure sensor, but sometimes can be caused by the pump or the control unit for the same reasons as DEM-0006
Volvo 30783079 and 8689664 Generation 2 and 3 Haldex Pump S40 S60 S80 V50 V70 XC70 XC90
Volvo 30783079 and 8689664 Generation 2 and 3 Haldex Pump S40 S60 S80 V50 V70 XC70 XC90
Volvo 31256757 Generation 4 Haldex Pump S60 S80 V70 XC60 XC70 XC90
Volvo 31256757 Generation 4 Haldex Pump S60 S80 V70 XC60 XC70 XC90
Volvo Generation 5 Pump for Rear Haldex Differential 31367750 31367749
Volvo Generation 5 Pump for Rear Haldex Differential 31367750 31367749
Faulty Haldex ECU’s always cause the CEM-1A64 and/or BCM-0095 and/or BCM-0094 faults because the unit is not talking to the rest of the car. We can repair these units. Buy Haldex ECU Repair Service Here
Follow this Youtuber’s journey on diagnosing this issue, and by sheer luck using our repair services!
The most important part of Volvo Haldex unit repairs is the unit must be the original one for the car. There are lots and lots of different software variations, a 2004 one will not work on a 2005 one, a diesel one will not always work on a petrol one, and Auto Trans one will not work on a Manual gearbox vehicle, an XC90 will not work on an XC60. They will not communicate with the rest of the vehicle. We can replace your ruined unit, but we must have the original one to clone, we can even clone totally non booting shorted out units.
Later Volvos Give Fault codes like these:-
DEM-P056017 System Voltage. General Electrical Failures. Circuit voltage above threshold
DEM-P060254 Powertrain Control Module Programming Error. System Programming Failures. Missing calibration
DEM-P060749 Control Module Performance. System Internal Failures. Internal electronic failure
DEM-P063468 PCM / ECM / TCM Internal Temperature Sensor Circuit. Algorithm Based Failures. Event information
DEM-P064F05 Unauthorized Software/Calibration Detected. General Failure Information. System Programming Failures
DEM-P066611 PCM / ECM / TCM Internal Temperature Sensor Circuit. General Electrical Failures. Circuit short to ground
DEM-P066615 PCM / ECM / TCM Internal Temperature Sensor Circuit. General Electrical Failures. Circuit short to battery or open
DEM-P066727 PCM / ECM / TCM Internal Temperature Sensor Range/Performance. General Signal Failures. Signal rate of change above threshold
DEM-P074812 Pressure Control Solenoid A Electrical. General Electrical Failures. Circuit short to battery
DEM-P07481D Pressure Control Solenoid A Electrical. General Electrical Failures. Circuit current out of range
DEM-P096162 Pressure Control Solenoid A Control Circuit Range/Performance. Algorithm Based Failures. Signal compare failure
DEM-P163568 Tire/Axle Out of Acceptable Range. Algorithm Based Failures. Event information
DEM-P188912 Oil Pressure Pump Performance. General Electrical Failures. Circuit short to battery
DEM-P188914 Oil Pressure Pump Performance. General Electrical Failures. Circuit short to ground or open
DEM-P188918 Oil Pressure Pump Performance. General Electrical Failures. Circuit current below threshold
DEM-P188919 Oil Pressure Pump Performance. General Electrical Failures. Circuit current above threshold
DEM-P188949 Oil Pressure Pump Performance. System Internal Failures. Internal electronic failure
DEM-P18897A Oil Pressure Pump Performance. Mechanical Failures. Fluid leak or seal failure
DEM-P188971 Oil Pressure Pump Performance. Mechanical Failures. Intermittent
DEM-P188974 Oil Pressure Pump Performance. Mechanical Failure. Actuator Slipping
DEM-U000100 High Speed CAN Communication Bus. General Failure Information. No sub type information
DEM-U010000 Lost Communication With Engine control module. General Failure Information. No sub type information
DEM-U012100 Lost Communication With Brake Control Module. General Failure Information. No sub type information
DEM-U014000 Lost Communication With Central electronic module. General Failure Information. No sub type information
DEM-U030000 Internal Control Module Software Incompatibility. General Failure Information. No sub type information
DEM-U030046 Internal Control Module Software Incompatibility. System Internal Failures. Calibration / parameter memory failure
DEM-U03004A Internal Control Module Software Incompatibility. System Internal Failures. Incorrect component installed
DEM-U030054 Internal Control Module Software Incompatibility. System Programming Failures. Missing calibration
DEM-U040168 Invalid Data Received from ECM/PCM A. Algorithm Based Failures. Event information
DEM-U041568 Invalid Data Received From Anti-Lock Brake System Control Module. Algorithm Based Failures. Event information
DEM-U210000 Initial Configuration Not Complete. General Failure Information. No sub type information
DEM-U210100 Control Module Configuration Incompatible. General Failure Information. No sub type information
DEM-U300362 Battery Voltage. Algorithm Based Failures. Signal compare failure
Some scanners will read the code like this instead:-
P0748-12 Pressure Control Solenoid A Electrical. General Electrical Failures. Circuit short to battery
P0748-1D Pressure Control Solenoid A Electrical. General Electrical Failures. Circuit current out of range
P0961-62 Pressure Control Solenoid A Control Circuit Range/Performance. Algorithm Based Failures. Signal compare failure
P1635-68 Tire/Axle Out of Acceptable Range. Algorithm Based Failures. Event information
P1889-12 Oil Pressure Pump Performance. General Electrical Failures. Circuit short to battery
P1889-14 Oil Pressure Pump Performance. General Electrical Failures. Circuit short to ground or open
P1889-18 Oil Pressure Pump Performance. General Electrical Failures. Circuit current below threshold
P1889-19 Oil Pressure Pump Performance. General Electrical Failures. Circuit current above threshold
P1889-49 Oil Pressure Pump Performance. System Internal Failures. Internal electronic failure
P1889-7A Oil Pressure Pump Performance. Mechanical Failures. Fluid leak or seal failure
P1889-71 Oil Pressure Pump Performance. Mechanical Failures. Intermittent
P1889-74 Oil Pressure Pump Performance. Mechanical Failure. Actuator Slipping
No Fault Codes Stored AND scrabbling or grabbing or skipping or jumping or locked diff sensation going round tight turns, on lock etc
This is very common indeed, possibly the second most common Volvo Haldex fault after the p1889 issue. Often these scrabbling Volvos gets passed from pillar to post trying to find anyone to resolve it, and often the previous messing about has caused more problems along the way!
Quite simply, the very first test which should be done with this problem –
UNPLUG THE HALDEX ECU, LEAVE FOR 20 MINUTES, THEN DRIVE TO SEE IF THE SCRABBLING ISSUE STOPS:-
If it still scrabbles, then the Haldex clutch pack is mechanically defective as it is sticking together or jammed inside. Replacement of the coupling is required.
If it no longer scrabbles (but you will get warning messages on the dash), then you are mechanically good, and this is just a control system issue – most often the N373 control valve is stuck open (we sell them here), replace the N373, the filter and oil, ensure a good blow out the oil route between the N373 Valve and the filter with the air line while the filter is removed.
The most common cause of this issue is people using Diff/Gear oil (like a gear oil, e.g. 75w90 etc) in the Haldex coupling. We have people telling us every week that somewhere has supplied gear oil (often main dealers or transmission specialists) for doing a Haldex service, and now it scrabbles. Once gear oil has been used, we have not managed to stop the scrabbling problem, even after stripping the whole Haldex clutch basket and washing the plates down with various solvents, detergents and degreasers. We suspect the additives in the oil have an adverse reaction with the materials on the plates but this is just a suspicion.
P1889-74 and 7A error description, diagnosis and resolution. (GEN 2 + 3 ONLY)
It is often misunderstood and causes those with Gen 2 and Gen 3 Haldex systems expensive misdiagnosis. To quote the manufactures descriptions:-
“Oil Pressure Pump Performance. Mechanical Failures. Actuator slipping”.
Condition = The Differential electronic module (DEM) checks the oil pressure in the Haldex clutch using an oil pressure sensor.
When the engine speed exceeds 500 rpm, an initial pressure builds up in the clutch via an electric feed pump. The diagnostic trouble code (DTC) is stored if the control module detects that:
◾ Initial pressure not reached within 2-4 minutes.
◾ Four wheel drive is thus disengaged.
Possible Causes
◾ Pressure sensor is not functioning. (contacts problem or the sensor itself)
◾ Damaged feed pump. (e.g. there is no pressure being created although motor is running)
◾ Too low oil volume in clutch. (thus no pressure being made)
◾ Internal leak in the clutch. (thus the pressure is being lost somewhere)
This is a problem we have come across a few times now, the description is somewhat misleading! It describes it as “Mechanical Failure Actuator Slipping”, but this is in the contexts of the pump, not the clutch itself. Basically it is running the pump, but it isn’t making the required pressure to turn off, thus it is some kind of internal leak, or no/low fluid etc.
Solution
We have come across 3 examples of this where the Haldex has just had previous work elsewhere requiring the front drive flange to be removed (e.g pump replacement or servicing). But when the flange has been reinstalled, a bearing inside the coupling has been dislodged and then reassembled unknowingly incorrectly inside. This completely bends the working piston etc inside the coupling and the only solution is to replace the whole coupling itself. This is not a massive task – again about 3 hours work by a competent garage – remove the exhaust, swing the prop out of the way, withdraw the coupling and replace etc.
P0961-62 = Pressure Control Solenoid A – Control Circuit Range Performance – Algorithm Based Failure (Generation 4 Haldex Units)
This is a common issue with Volvos! Often the fault will present itself after the vehicle has been driven for 10 to 20 Minutes, then as the vehicle slows down for example to a junction or to stop, the message “anti skid service required”.
Solution
We have spent a lot of time experimenting with this issue as we have a glut of control units that have this exact fault. We have confirmed this is a fault on the Haldex Control unit circuit board, by swapping the “faulty units” software onto a new board, which then works flawlessly. Many many hours of experimentation has been invested into this issue, and it has been 100% concluded that it is a fault on the circuit boards somewhere (but have yet to pin that one down!). We can supply replacement Haldex units, fully pre programmed for plug and play installation. Buy Replacement Haldex Unit Here
P1889-14 = Oil Pressure Pump Performance – Circuit Short To Ground or Open Circuit
This is the most common issue with the Generation 4 Haldex systems on Volvo vehicles from 2008 to 2015, it is very common around 40k to 60k miles on the clock. Some scanners will just read it as “P1889 Pressure Pump Performance”, but a decent scan tool will give you the status bytes at the end “14” which tells you it is open circuit etc. Often this code will clear, but give it 3 days, 3 weeks or 3 months it’s always back! Just tapping the pump with a spanner often makes a totally non working pump spring back into life briefly.
Solution
This fault is caused by the brushes and commutator inside the Haldex pumps motor being worn out. The only real solution is to replace the pump, along with the oil and filter cartridge which we sell here (also see product links below). Most vehicles require the prop shaft to be removed in order to get the required space to swap the pump. The whole job takes around 2 to 3 hours by a competent garage. No coding or programming etc is required. No amount of servicing/oil changing will resolve this issue.
Volvo 31256757 Generation 4 Haldex Pump S60 S80 V70 XC60 XC70 XC90
Volvo 31256757 Generation 4 Haldex Pump S60 S80 V70 XC60 XC70 XC90
Volvo, Ford, Land Rover, Range Rover – Gen 4 Oil & Filter Service Kit
Volvo, Ford, Land Rover, Range Rover – Gen 4 Oil & Filter Service Kit
P1889-71 error description, diagnosis and resolution. (GEN 5 ONLY
The DEM checks the performance of the Haldex pump, the control module compares the current load (amps) when driven at various voltages against its predefined parameters saved within its computer memory. Possible causes are listed as “Internal Leak in the Oil Pressure Pump” or “Damage to Oil Pressure Pump”
P1889-18 TSB Technical Service Bulletin (GEN 5 ONLY
There was a TSB raised within the dealerships for P188918 with document reference number TJ28879. It states:-
“The fault-tracing for DTC DEM-P188918 is changed/modified in order to avoid unnecessary parts replacement (DEM-P188918 does not often need a parts replacement). The DTC can be set if air has entered the all wheel drive clutch package, which can happen during oil filling. This can be remedied by air-bleeding the system (ventilation of the all wheel drive clutch package).” APPLIES ONLY TO GEN 5 HALDEX SYSTEMS!!!
- Remove oil pump from AOC (Active On demand Coupling) and inspect the strainer.
- Clean strainer with lint-free cloth, do not use any cleaning liquids (this can contaminate the oil).
- Clean pump sump in AOC, do not use any cleaning liquids (this can contaminate the oil).
- Assemble cleaned pump to AOC.
- Fill up with new oil to correct oil level in AOC according to VIDA.
- Perform a calibration using VIDA.
- Check the oil level. If the oil level is low, check the all wheel drive clutch pack for leaks. Then top up with oil (This is also the first step in VIDA’s fault-tracing for DTC DEM-P188918).
NOTE: The oil level in the all wheel drive clutch package is very important for the function of the all wheel drive. - Do an air-bleeding of the system (ventilation of the wheel drive clutch package) by doing an calibration of DEM. Go to; DIAGNOSTICS\VEHICLE COMMUNICATION\DEM\Advanced\ Calibration of Differential Electronic Module (DEM).
- If this does not remedy the fault, change the oil pressure pump
