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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.
A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places in the Workshop Manual - are summarised here. They apply to the work described in this Manual.
Gearbox
t  Rules for cleanliness when working on the automatic gearbox → Chapter.
   
t  If gearbox has been removed from vehicle, secure torque converter using support bridge -30-211 A- to prevent it from falling out.
t  Use only ATF or vaseline on all parts running in ATF. Other lubricants will cause malfunction of the gearbox hydraulics.
t  Clean ATF pipes and ATF cooler after performing repairs on the gearbox and renew ATF strainer.
t  After installation, check the following fluid levels and top up if necessary: ATF in planetary gearbox → Automatic gearbox 01V, front-wheel drive and four-wheel drive; Rep. Gr.37, gear oil in front final drive → Automatic gearbox 01V, front-wheel drive and four-wheel drive; Rep. Gr.39, gear oil in transfer box → Automatic gearbox 01V, front-wheel drive and four-wheel drive; Rep. Gr.39. Capacities and specifications → Automatic gearbox 01V, front-wheel drive and four-wheel drive; Rep. Gr.00.
Procedure if ATF is dirty
If the ATF and related components are very dirty (caused by worn clutch linings):
t  Dismantle complete gearbox and clean all parts, renew ATF pipes.
t  Dismantle and check all clutches.
t  Renew torque converter (cannot be cleaned).
t  Renew valve body (cannot be cleaned).
t  Clean ATF pipes and ATF cooler and renew ATF strainer.
O-rings, oil seals and 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  The open side of the oil seal should face the side containing the fluid.
t  Lightly lubricate the outer circumference and sealing lip of oil seals with ATF before installing.
t  Lightly lubricate O-rings with ATF or vaseline before inserting to prevent them from getting crushed during assembly.
t  Use only ATF or vaseline on all parts running in ATF. Other lubricants will cause malfunction of the gearbox hydraulics.
t  When installing a new oil seal, position the seal such 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, remove previous gaskets completely and clean all sealing surfaces thoroughly.
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.
  N37-0702
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.
t  Renew spring pins. Installation position: slot must be in line with direction of force -arrow-.
Bearings
t  Lightly lubricate bearings with ATF before inserting.
t  Fit bearings and shims loosely with vaseline only. Other types of lubricant will cause the gearbox hydraulics to malfunction.
ATF/oil pipes
t  The removed oil pipes must always be renewed.
t  The oil pipes must be renewed if the gearbox is very dirty.
  V34-1515

Special tools > < Repair instructions