Automatic Transmission/Transaxle: Service and Repair

Removing and installing Tiptronic transmission A 96/00




Tools

Removal
1. Disconnect battery.
2. Lift the vehicle. When lifting, make sure that the fastening screws of the diagonal braces are accessible.
3. Remove multi-function switch console.





4. Fix crankshaft using special tool 9595/1 (short). To do this, turn crankshaft until one of the bores U4, U5 or U6 in the pulley is aligned with the centering bore in the crankcase and special tool can be inserted.





5. Hold the converter in installation position with special tool 9595/1 (long).





6. Install special tool 9596 and two of the six converter fastening screws using a 6-mm wrench insert (long) for hexagon socket head screws.

Note: For the remaining four fastening screws, remove special tool 9595/1, rotate crankshaft through a further 120° in each case (to pulley marking U4, U5 or U6) and fix again.

7. Remove underbody covers (center and rear) and side covers (rear left and right).





8. Pull off vacuum pipe (B) at switch-over valve.
9. Unscrew stabilizer at the side parts of the rear-axle support.





10. Remove cross member (A), diagonal braces (B) and rear-axle support (C).
12. Unscrew the lower fastening screws on the transmission bell housing.





13. Secure the engine in installation position with holding device. To do this, fasten special tool 9624/1 with four screws and turn the thrust screw until the pressure disc is in contact with the crankcase.
14. Uncouple drive shafts on the transmission side.
15. Place collection pan under the transmission.








16. Clamp shut coolant hoses with special tool 3094, relieve spring band clamps and pull off hoses.





17. Lever off cable on transmission lever using a commercially available removal tool.





18. Disengage cable at support bracket.





19. Disengage plug connection for multi-function switch and disconnect.





20. Disconnect plug from transmission socket. To do this, turn round plug (bayonet lock) counterclockwise and pull it off.
21. Place transmission jack under the transmission and fasten fixing strap.








22. Remove transmission holder and transmission support.
23. Unscrew transmission engine fastening screws. To do this, use a long 3/8 inch extension.





Note: The engine may be lowered by up to 25 mm in order to improve accessibility to the upper screws.

24. Pull transmission to the front and lower it carefully.

Installation
Installation is performed in reverse order, taking the following points into account.
1. Ensure perfect seating of dowel sleeves in crankcase.





2. Fix the converter in installation position with special tool 9595/1 (long).
3. Grease converter bearing journal with a thin coat of Olista Longtime 3 EP (available as spare part).





4. Carefully move transmission in and fasten to engine.
5. Remove fixing pins (special tool 9595/1).
6. Push vacuum pipe onto switch-over valve.





Note: The two vacuum pipes must not be confused. Otherwise, transmission cooling will be inadequate.

7. Press end piece of selector lever cable onto the transmission lever using a pair of pliers. The end piece must be felt to engage.
8. Check adjustment of selector lever cable.
9. Check engine coolant level.




Tightening torques