Audi Workshop Service and Repair Manuals

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful gearbox repairs. 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 Workshop Manual, are summarized here. They apply to this Workshop Manual.

Special tools

For a complete list of special tools used in this Workshop Manual

=> Booklet; Special tools, Workshop equipment

Gearbox

• ◆ Observe rules for cleanliness when working on the automatic gearbox .
• ◆ Do not run the engine or tow the vehicle if the oil sump is removed or if the ATF has been drained from the gearbox.
• ◆ If the gearbox is removed from the vehicle, secure the torque converter to prevent it dropping out.

• ◆ Thoroughly clean all connections and the surrounding area before disconnecting.
• ◆ Before installing the gearbox, check the installed depth of the torque converter => Page 32-11.
• ◆ When installing gearbox, ensure that the dowel sleeves are fitted correctly.
• ◆ Place removed parts on a clean surface and cover over. Use sheeting and paper. Do not use fluffing cloths!
• ◆ If repairs cannot be completed immediately and components are left open, cover the components carefully or fit plugs as required.
• ◆ Install only clean parts: do not remove replacement parts from their wrapping until you are ready to install them.
• ◆ When fitting a new automatic gearbox, check the following fluid levels and top up as required: ATF in planetary gearbox ( => Page 00-11.

O-rings, seals, gaskets

• ◆ Always renew O-rings, seals and gaskets.
• ◆ 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.
• ◆ Thoroughly clean housing joint surfaces before assembling.
• ◆ The open side of the oil seals faces toward the side with fluid filling.
• ◆ Before installing, lightly lubricate outer circumference of seal and sealing lips with ATF or gear oil, depending on fitting location.
• ◆ Lightly lubricate O-rings with ATF before inserting to prevent them being trapped and damaged when assembling.
• ◆ Use only ATF in the parts of the gearbox where ATF is the specified lubricant; other lubricants will cause malfunctions in the gearbox hydraulics.
• ◆ When replacing oil seals, always vary the point at which the sealing lips make contact (use insertion depth tolerances).

• ◆ After installing, check fluid levels and top up as required: ATF in planetary gearbox ( => Page 00-11.

Nuts, bolts

• ◆ Slacken the bolts in reverse sequence to the specified tightening sequence.
• ◆ Nuts and bolts which secure covers and housings should be slackened and tightened crosswise in stages if no tightening sequence is specified.
• ◆ Parts which are particularly sensitive to distortion (e.g. valve body) must be kept straight when removing and installing; loosen or tighten diagonally in stages.
• ◆ The tightening torques stated apply to non-oiled nuts and bolts.
• ◆ Renew self-locking bolts and nuts.
• ◆ The threads of bolts which are secured by a locking fluid should be cleaned with a wire brush. Then apply AMV 185 101 A1 when inserting.
• ◆ Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

Locking elements

• ◆ Do not overstretch circlips.
• ◆ Always renew circlips which have been damaged or over-tensioned.
• ◆ Circlips must be properly seated in the base of the groove.

Bearings

• ◆ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift or other tool used for installing.
• ◆ Depending on fitting location, apply gear oil or ATF to bearings before installing.
• ◆ Do not interchange the outer or inner races of bearings of the same size.
• ◆ Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
• ◆ Heat inner races of taper roller bearings to approx. 100 °C before installing. Press in onto stop when installing so there is no axial clearance.

Shims

• ◆ Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain the exact shim thickness required.
• ◆ Check for burrs and damage.
• ◆ Only install perfect, undamaged shims.

Inner plates

• ◆ → Soak new inner plates in ATF for 15 minutes before installing.

Valve body

• ◆ Renew the valve body if any of the selector elements are scorched.

Clutches

• ◆ Clutches K1, K2 and K3 are to be disassembled only for cleaning; if individual parts are defective, renew entire clutch. Clutches are allocated according to gearbox code.

Self-diagnosis

• ◆ Before performing repairs to the automatic gearbox, determine the cause of the fault as precisely as possible using the Self-diagnosis.

=> Automatic gearbox 01N, Self-diagnosis; Repair group 01; Performing self-diagnosis.