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Rules for cleanliness when working on the automatic gearbox > < Repair instructions

A4 Cabriolet Mk2

General repair instructions
General repair instructions
Proper tools and the maximum possible care and cleanliness are essential for satisfactory gearbox repairs. The usual basic safety precautions also naturally apply when carrying out repair work.
To avoid repetition, a number of generally applicable instructions for the various repair procedures are summarised here. They apply to the work described in this Manual.
Special tools
For a complete list of special tools used in this Workshop Manual → "Workshop equipment and special tools".
Gearbox
t  Rules for cleanliness when working on the automatic gearbox → Chapter.
t  Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the gearbox.
t  If gearbox has been removed from vehicle, secure torque converter to prevent it from falling out.
t  Thoroughly clean all joints and connections and the surrounding areas before dismantling.
t  Check position of torque converter (installed depth) before installing gearbox → .
t  When installing gearbox ensure dowel sleeves are correctly seated.
t  Carefully cover or seal open components if repairs cannot be carried out immediately.
t  When fitting a new automatic gearbox, check the following fluid levels and top up if necessary: ATF in the planetary gearbox → Chapter, the gear oil in the front final drive → Chapter, the gear oil in the transfer box → Chapter. Capacities and specifications → Chapter
t  When fitting a new rear final drive, check the oil level in the rear final drive and top up if necessary. Capacities and specifications → Rear final drive 01R; Rep. Gr.00.
O-rings, oil seals, gaskets
t  Always install new O-rings, oil seals and gaskets.
t  After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
   
t  Before installing oil seals, fill the space between the sealing lips -arrow- half full with sealing grease -G 052 128 A1-.
t  The open side of the oil seals faces toward the side with fluid filling.
t  Before installing, lightly lubricate outer circumference of seal and sealing lips with ATF or gear oil, depending on fitting location.
t  Lightly lubricate O-rings with ATF before installation to prevent them getting crushed during assembly.
t  Use only ATF for parts running in ATF. Other lubricants will cause malfunction of the gearbox hydraulics.
t  When installing a new oil seal, position the seal in the housing so that the sealing lip does not contact the shaft in the same place as the old seal (make use of installation depth tolerances).
t  Renew paper gaskets, clean all sealing surfaces thoroughly and remove previous gaskets completely.
t  After installing, check the relevant fluid levels and top up if necessary: ATF in planetary gearbox → Chapter, gear oil in front final drive → Chapter, gear oil in transfer box → Chapter, gear oil in rear final drive → Rear final drive 01R; Rep. Gr.39. Capacities and specifications → Chapter
Nuts, bolts
t  Slacken bolts in reverse sequence to the specified tightening sequence.
t  Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified.
t  The tightening torques stated apply to non-oiled nuts and bolts.
t  Always renew self-locking bolts and nuts.
t  Use a wire brush to clean the threads of bolts which are secured with locking fluid. Then apply locking fluid -AMV 185 101 A1- to bolts again before fitting.
t  Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing off the next time they are removed.
Locking elements
t  Do not over-stretch circlips.
t  Always renew circlips which have been damaged or over-stretched.
t  Circlips must be properly seated in the base of the groove.
Bearings
t  Lubricate bearings with gear oil or ATF, depending on fitting location.
Mechatronic unit
  Caution
t  Before touching or removing the mechatronic unit, always discharge any static electricity by touching an earthed metal part, such as vehicle earth, a heater radiator or lifting platform with your hand.
t  Never touch the 16 contacts in connector -B- with your hands, as static discharge would damage the control unit and mechatronic unit.
t  Renew the gearbox if any of the shift elements are scorched.
t  Select correct version of mechatronic unit according to gearbox code letters → Electronic parts catalogue.
  N32-0001
Guided fault finding, vehicle self-diagnosis and testing system
t  Before servicing the automatic gearbox, the exact cause of the failure must be determined as precisely as possible via the vehicle diagnostic, testing and information system -VAS 5051 A- in the modes “Guided Fault Finding”, “vehicle self-diagnosis” and “testing system”.
  W00-10224

Rules for cleanliness when working on the automatic gearbox > < Repair instructions