Audi Workshop Service and Repair Manuals

Checking gear oil level and topping up Special tools and workshop equipment required

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

t  Diagnostic tester, e.g. vehicle diagnostic, testing and information system -VAS 5051B-

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. Test conditions l  Gearbox must not be in emergency running (backup) mode. l  Vehicle must be absolutely horizontal (on a four-pillar lifting platform or over an inspection pit). l  Selector lever in position “P”, handbrake applied. l  Exhaust hose(s) of an exhaust gas extractor (switched on) must be connected. l  Engine idling. l  Air conditioner and heating system switched off. l  Diagnostic tester connected up; Vehicle self-diagnosis and vehicle system 02 - Gearbox electronics selected → vehicle diagnostic tester. l  The gearbox oil temperature at the beginning of the test must not be higher than 30° C. If necessary, allow the gearbox to cool down before testing.   Note t  The gearbox oil temperature is taken from the reading on the diagnostic tester. t  The gear oil level varies according to temperature. t  Checking the gear oil level with the temperature too low results in overfilling. t  Checking the gear oil level with the temperature too high results in underfilling. t  Both overfilling and underfilling will impair the function of the gearbox.

Reading off gearbox oil temperature: Display on diagnostic tester: –  From menu -1-, select function Measured values and advance by pressing → button.

Display on diagnostic tester: –  Using keypad -1- press buttons 19 for “Display group 019” and confirm entry by pressing Q button.

Display on diagnostic tester: –  Read off gearbox oil temperature in display zone -1-.

Checking gear oil level l  All safety precautions and test requirements must be observed. –  Remove noise insulation -1- → General body repairs, exterior; Rep. Gr.50.   Note Depending on version, different types of noise insulation may be fitted. –  Press and hold brake pedal. –  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. –  Place used oil collection and extraction unit -V.A.G 1782- below gearbox.

Display on diagnostic tester: –  Read off gearbox oil temperature in display zone -1-.

–  Unscrew oil inspection plug -B- when gear oil reaches a temperature of 35°C.   Note The inspection plug -B- is located next to the pendulum support.

Gear oil in overflow pipe -arrow 2- will drain off first.   Note Even when the gear oil level is too low a small amount of oil will first drain out of the overflow pipe, as it fills up during operation. –  Check that the overflow pipe is correctly screwed into the gearbox; tighten if necessary.   Note If the overflow pipe is not correctly secured, the oil level cannot be correctly read. –  Allow excess gear oil to drain off. The gear oil level is correct when a small amount of gear oil still drains out when the oil temperature is between 35 °C and 45 °C (the level rises as the oil warms up). In this case, the gear oil does not need to be topped up; oil level is OK.   Note t  Every 30 seconds a small surge of oil will come out of the oil level pipe regardless of the oil level (cause: intermittent cooling oil supply to the clutch). The surge of oil is no indication for the correct oil level and should therefore be disregarded. t  Gear oil that has drained off must not be refilled or reused. Dispose of the gear oil properly. If no gear oil drains out when the oil temperature is between 35°C and 45°C, top up gear oil → Anchor.

Continuation when gear oil level is correct: –  Always renew the seal -arrow- for the gear oil inspection plug.

–  Fit inspection plug -B- with new seal and tighten. The gear oil check is now completed. –  Exit from function Measured values by pressing ← button. –  Press End output. –  Switch off ignition and unplug diagnostic connector. Topping up gear oil l  All safety precautions and test requirements must be observed. l  Selector lever in position “P”, handbrake applied. l  Exhaust hose(s) of an exhaust gas extractor (switched on) must be connected. l  Engine idling.

Display on diagnostic tester: –  Read off gearbox oil temperature in display zone -1-.

If no gear oil drains out of the overflow pipe -arrow 2- when the engine is running and the oil temperature is between 35°C and 45°C, the gear oil must be topped up.   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.

Now check the gear oil level (check as often as necessary): –  Detach quick-release coupling on adapter for oil filling -VAS 6262 A- and plug the hose using a clean plug or a finger. Gear oil in overflow pipe -arrow 2- will drain off first. –  Allow excess gear oil to drain off. The gear oil level is correct when a small amount of gear oil still drains out when the oil temperature is between 35 °C and 45 °C (the level rises as the oil warms up). In this case, the gear oil does not need to be topped up further; oil level is OK.   Note t  Every 30 seconds a small surge of oil will come out of the oil level pipe regardless of the oil level (cause: intermittent cooling oil supply to the clutch). The surge of oil is no indication for the correct oil level and should therefore be disregarded. t  Gear oil that has drained off must not be refilled or reused. Dispose of the gear oil properly. If no gear oil drains out of the inspection plug hole, you must continue to top up and check the oil until the oil level is OK (make sure gear oil temperature is correct).

Continuation when gear oil level is correct: –  Unscrew the adapter for oil filling -VAS 6262 A- from gearbox. –  Always renew the seal -arrow- for the gear oil inspection plug.

–  Fit inspection plug -B- with new seal and tighten. The gear oil check is now completed. –  Exit from function Measured values by pressing ← button. –  Press End output. –  Switch off ignition and unplug diagnostic connector.