Audi Workshop Service and Repair Manuals

Draining and changing gear oil / filling up after performing repairs Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782-

t  Adapter for oil filling -VAS 6262 A- t  Safety goggles t  Protective gloves (acid resistant) Procedure l  Tightening torques → Chapter „Exploded view - drain plug, inspection plug and overflow pipe for gear oil“   Note t  → Chapter „Repair instructions“. t  → Chapter „Rules for cleanliness when working on the gearbox“. t  Observe notes on direct shift gearbox 02E, disposing of oil → Chapter.   WARNING t  When working close to the radiator always maintain a safe distance from the fan - danger of injury! t  Fan may switch on automatically. t  Wear safety goggles. t  Wear protective gloves (acid resistant).   Caution t  The engine must not be started if significant oil loss has occurred (e.g. during repairs) and there is little or no oil left in the gearbox. t  In this case, you must pre-fill the gearbox with a suitable quantity of gear oil for the direct shift gearbox. t  Only the gear oil for the direct shift gearbox (available as a replacement part) may be used for the direct shift gearbox 02E. Other types of oil will cause malfunctions and/or failure of the gearbox; for part number refer to → Electronic parts catalogue. Requirements l  Vehicle must be absolutely horizontal (on a four-pillar lifting platform or over an inspection pit). l  Selector lever is in position “P” l  Engine not running. l  The gear oil filter must always be renewed when changing the gear oil.   Note t  Observe all safety precautions, notes and test requirements → Chapter „Checking gear oil level and topping up“. t  Note regulations for the disposal of oil.

Draining off gear oil –  Renew gear oil filter → Chapter. –  Remove noise insulation -1- → General body repairs, exterior; Rep. Gr.50.   Note Depending on version, different types of noise insulation may be fitted.

–  Place used oil collection and extraction unit -V.A.G 1782- below gearbox. –  If fitted, remove drain plug -A-.   Note On more recent versions the drain plug -A- is no longer fitted. On these gearboxes the gear oil is drained off only via the inspection plug -B- → Anchor. –  Drain gear oil.

–  Renew seal -arrow- for drain plug.

–  Tighten drain plug -A-.

–  Remove inspection plug -B-.   Note

An overflow pipe -C- is screwed into the opening of the inspection plug. –  Remove overflow pipe -C-. –  Drain the remaining gear oil. –  Screw overflow pipe -C- into opening for inspection plug.

Filling up with gear oil l  Overflow pipe is screwed into opening for inspection plug -B-.   Caution The adapter for oil filling -VAS 6262 A- must be clean; the gear oil must not be mixed with any other types of oil.

–  Screw container of gear oil for direct shift gearbox onto adapter for oil filling -VAS 6262 A-; for part number refer to → Electronic parts catalogue.

–  Screw adapter for oil filling -VAS 6262 A- hand-tight into hole for inspection plug -B-. –  Hold container with gear oil as high as possible over gearbox and let gear oil run into gearbox.

–  Fill gearbox with 5.5 litres of gear oil for direct shift gearbox. –  Shift selector lever into position “P”, apply handbrake. –  Press and hold brake pedal. –  Start engine and run at idling speed. –  With brake pressed, select all gear positions “P, R, N, D, S” one after the other at idling speed, maintaining each position for at least 3 seconds. –  Shift selector lever into position “P”. –  → Chapter „Checking gear oil level and topping up“.