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 summarised here. They apply to this Workshop Manual.

Special tools

A list of the special tools used in the Workshop Manual are listed in folder: "Workshop equipment and tools" or "Special tools".

Gearbox

• ◆ Rules for cleanliness when working on the automatic gearbox .
• ◆ Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the gearbox.
• ◆ If the gearbox is removed from the vehicle, secure the torque converter to prevent it dropping out.

• ◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
• ◆ Check the fitting dimensions of the torque converter before installing the gearbox => Page 32-7.
• ◆ When installing gearbox, ensure that the dowel sleeves are fitted correctly.
• ◆ Place removed parts on a clean surface and cover. Use sheeting and paper. Use lint-free cloths.
• ◆ Carefully cover or seal open components if repairs cannot be carried out immediately.
• ◆ Only install clean components: do not remove replacement parts from their wrapping until you are ready to install them.
• ◆ Check and if necessary correct the following levels on replacing automatic gearbox: ATF in planetary gearbox => Page 00-30 onwards.
• ◆ When exchanging the rear final drive the oil level in rear final drive must be checked and, if necessary, corrected => Page 00-31.

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.

• ◆ → Before installing oil seals (radial shaft seals), pack space between sealing lips -arrow- with grease.
• ◆ 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 types of lubricant can cause problems with the hydraulic actuation of the gearbox.
• ◆ When replacing oil seals, always vary the point at which the sealing lips make contact (use insertion depth tolerances).

• ◆ After installation, check and if necessary correct the following levels in the area affected: ATF in planetary gearbox => Page 00-30 onwards.

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.
• ◆ Replace 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. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

Locking elements

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

Mounting

• ◆ Attach the needle bearing with the written side (greater plate thickness) to the installing tool.
• ◆ Lubricate bearings with gear oil or ATF, depending on fitting location.
• ◆ The taper roller bearings for the output shaft and the differential in rear final drive are low-friction bearings. Do not additionally oil new taper roller bearings when measuring friction torque. The bearings are pre-treated at the factory with a special type of oil for this purpose.
• ◆ Do not interchange inner or outer 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 up to stop when installing so there is no axial clearance.

Adjustment shims

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

Valve body

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

Self-diagnosis

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

The self-diagnosis is described in the Booklet Audi A4 1995 ä, Automatic Gearbox 01V, Self-diagnosis.

=> Automatic Gearbox 01V, Self-diagnosis; Repair group 01; Performing self-diagnosis