General Repair Instructions
General Repair Instructions
To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools are 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.
CAUTION!
Before work is done with engine running, place selector lever in " P" position and press parking brake button to engage electromagnetic 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 materials.
These tested parts are also made available as replacement parts.
If you are not sure whether used parts can be re-installed, always install new parts.
CAUTION!
• Accessories must be approved by Audi of America!
• 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 Tool"
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".
Transmission
• Rules of cleanliness for working on automatic transmissions => [ Clean Working Conditions ] Clean Working Conditions.
• Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.
• With left flange shaft removed, secure torque converter against falling out.
• When installing torque converter, check installation dimension => [ Installation dimension: ] Torque Converter.
• When installing transmission, make sure that the alignment bushings are installed correctly.
• When installing the transmission, the following fluid levels should be checked and corrected if necessary? ATF in planetary gearing, ATF fluid in front final drive, and ATF fluid in transfer case. Capacities and specifications => [ Capacities ] Capacity Specifications.
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 shaft seals point toward fluid to be sealed in.
• Before installing, lightly lubricate shaft seal outer circumference and sealing lips with ATF or ATF fluid, 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 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 relevant fluid levels and top off if necessary: ATF in planetary gearing, ATF fluid in front final drive, and ATF fluid in transfer case. Capacities and specifications => [ Capacities ] Capacity Specifications.
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 base of groove.
• Replace spring pins. Installation position: Slot is longitudinal to line of force.
Bearings
• Install needle bearings with lettering on the bearing (side with thicker metal) facing towards drift.
• Insert bearing with axle oil or ATF, depending on installation location.
• Do not interchange outer or inner races of bearings of same size.
• Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.
Adjustment shims
• Use a micrometer to measure 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.
Mechatronics unit
CAUTION!
• Always discharge static by touching a grounded object, e.g. vehicle ground, before touching or removing mechatronics unit.
• Never touch contacts in 16-pin connector, as the static charge could destroy the control module and thus the mechatronics unit.
• Replace 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 Vehicle Diagnostic, Testing and Information System (VAS 5051B) in operating modes "Guided Fault Finding", "Vehicle Self-Diagnosis" and " Test Instruments".