Repair Instructions
Repair Instructions
To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. The usual basic safety precautions also naturally apply, when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Repair Manual, are summarized here. They apply to this Repair Manual.
Before working with engine running, place selector lever in "P" position and engage parking brake.
Contact corrosion
Contact corrosion can occur if non-approved fasteners (bolts, nuts, washers), rivets, plugs, grommets, adhesives etc. are used on the vehicle.
For this reason, the manufacturer only uses compatible fasteners, coated with a special surface coating if necessary.
Rubber, plastic and adhesives also consist of non-conductive material.
These tested parts are also made available as replacement parts => Parts Catalog.
If you are not sure whether used parts can be re-installed, always install new parts.
• Accessories must be approved by AUDI AG!
• Damage resulting from contact corrosion is not covered by the warranty!
Environmental and disposal regulations for oil
Handle ATF, axle oil and other oils carefully. Dispose of drained oil properly. Always follow the legal environmental and disposal regulations.
Special tools and equipment
Complete list of special tools used in this Repair Manual => "Special Tools
Manual release of selector lever
If the battery has been disconnected or is discharged and the vehicle must be towed or pushed, it will be necessary to push the shift mechanism emergency release to shift the selector lever from position "P" to position "N" => [ Selector Mechanism, Performing Emergency Release ] Procedures.
Transmission
• Rules of cleanliness for working on automatic transmissions => [ Transmission Cleanliness Guidelines ] Transmission Cleanliness Guidelines.
• Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.
• If the transmission is removed from the vehicle, secure the torque converter to prevent it from falling out.
• Check installation dimension of torque converter before installing transmission Removal and Replacement.
• When installing transmission, make sure that the alignment bushings are installed correctly.
• When exchanging automatic transmission or components, all fluid levels should be checked and corrected, if necessary. Also, all transmission oil lines must be cleaned.
O-rings, shaft seals, sealing rings and seals
• Always replace O-rings, shaft seals, sealing rings and seals after removal.
• After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• Before installing radial shaft seal, fill space between sealing lips - arrow - halfway with grease (G 052 128 A1).
• The open side of the shaft seals point toward the fluid to be sealed in.
• Before installing, lightly lubricate shaft seal outer circumference and sealing lips with ATF or gear oil, depending on installation location.
• Coat O-rings with ATF before inserting to prevent crushing rings during installation.
• Only use ATF for automatic transmission components. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• Replace paper seals, always clean sealing surfaces and remove old seals completely.
• After installing, check the relevant fluid levels and top off if necessary.
Bolts, nut
• Loosen bolts in reverse order of tightening.
• Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
• The tightening torques stated apply to unoiled bolts and nuts.
• Replace self-locking bolts and nuts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with locking fluid (AMV 185 101 A1).
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are installed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
Locking elements
• Do not over-stretch circlips.
• Always replace circlips which have been damaged or over-tensioned.
• Circlips must be properly seated in the base of the groove.
• Replace spring pins. Installation position: Slot is longitudinal to line of force.
Bearings
• Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
• Insert bearing with axle oil or ATF, depending on installation location.
• Do not interchange the outer or inner races of bearings of the same size.
• Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
Adjustment shims
• Use a micrometer to measure the shims at several points. Varying tolerances make it possible to measure the required shim thickness exactly.
• Inspect for burrs and signs of damage. Install only shims that are in perfect condition.
Mechatronic unit
• Always discharge static by touching a grounded object, e.g. vehicle ground, before touching or removing mechatronics unit.
• Connector terminals in connector must not be touched by hand under any circumstances because control module and therefore Mechatronic may be destroyed by static discharge.
• Replace the transmission if any of the shift elements are scorched.
• The mechatronics unit is allocated according to the code letters of the transmission.
Guided fault finding, On Board Diagnostic (OBD) and measuring technology
Before performing repairs on the automatic transmission, the malfunction cause must be determined as exactly as possible via the Vehicle Diagnostic, Testing and Information System (VAS 5051B) in the operating modes "Guided Fault Finding", "Vehicle Self-Diagnosis" and "Test Instruments".
