Audi A4 Owners & Service Manuals

Audi A4: General, Technical data

Repair Information

General Repair Information

Using the Repair Manual

Refer to the "7-Speed DSG Transmission 0CK" repair manual for all special procedures with the transmission installed, depending on the model. The servicing repair manual either does not describe them or describes them only partially. Both repair manuals are needed for a successful repair.

The highest level of care and cleanliness along with tools that function properly are required to ensure a proper and successful transmission repair. Of course the general safety precautions also apply when carrying out repair work.

Some general repair information that applies to several procedures throughout this manual is summarized here. They apply to this repair manual.

Oil, Environmental and Disposal Regulations

  • Handle ATF, transmission fluid and other oils carefully.
  • Dispose of drained fluid properly.
  • Follow the legal, environmental, and disposal regulations.
  • Follow the instructions listed on the fluid packaging.

Special Tools

Refer to Workshop Equipment and Special Tools for a complete list of special tools used in the repair manual.

Transmission

  • Follow all the guidelines for clean working conditions. Refer to → Chapter "Rules for Cleanliness When Working on DSG Transmission".
  • Do not run the engine or tow the vehicle when the transmission is open or when there is no transmission fluid.
  • If installing parts that can be used again, clean and check them and replace if necessary.
  • During installation, make sure the alignment sleeves are fitted correctly.

O-Rings, Shaft Seals, Seals

  • Always replace the O-rings, shaft seals and seals.
  • After removing the seals, examine the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
  • Clean the housing separating surface thoroughly before assembling.
  • Before installing, lightly lubricate shaft seal outer circumference and sealing lips with ATF or gear oil, depending on the installation location.
  • Depending on the component location, coat the O-rings lightly with ATF or transmission fluid to insert them. This prevents them from being crushed when being installed.
  • Use only ATF in the ATF area. Other lubricants cause malfunctions in the hydraulic transmission control.
  • The open side on the shaft seals faces the fluid to be sealed off.
  • After installing check the ATF level or the transmission fluid level with the transmission installed and correct. Refer to "7-Speed Dual Clutch Transmission 0CK" → Rep. Gr.34; ATF; ATF Level, Checking or for transmission fluid level checking and correcting, refer to → Rep. Gr.34; Transmission Fluid. Specification. Refer to the Parts Catalog.

Bolts and Nuts

  • Loosen the bolts opposite the tightening sequence.
  • Nuts and bolts which secure covers and housings should be tightened in steps according to the specified tightening sequence or method.
  • Bolts or nuts for securing covers and housings should be loosened and tightened diagonally in stages if no tightening sequence is specified.
  • Always replace self-locking bolts and nuts.
  • If nothing else is specified: use a wire brush to clean the threads of bolts that were screwed in with locking compound. Use locking fluid when installing the bolts. Refer to the Parts Catalog.
  • If self-locking bolts were installed or if regular bolts were installed with locking fluid, then the threaded holes must be cleaned, for example with a thread tap. Otherwise there is the risk that the bolts could break off the next time they are removed.
  • The tightening specifications given apply to unoiled bolts and nuts.

Circlips, Snap Rings

  • Do not stretch the circlips.
  • Replace damaged or stretched circlips.
  • The circlips must rest at the bottom of the groove.

Bearings

  • Install needle bearings with the lettered side (thicker metal) facing the fitting tool.
  • Coat and install the bearings with gear oil or with ATF, depending on the installation location.
  • Do not interchange the outer or inner races of bearings of the same size.
  • Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.

Shims

  • Measure the shims at several locations with a micrometer. Different shim thicknesses make it possible to select the required thickness precisely; install two shims if necessary.
  • Check for burrs or damage. Only install flawless shims.

Mechatronic

  Caution

There is a risk of destroying the transmission control module (Mechatronic) with electrostatic discharge.

  • Always discharge "static electricity" before working with connectors or the Mechatronic. Do this by touching a grounded object, for example vehicle ground, the heater or the hoist.
  • Do not touch connector terminals in the transmission connector with hands.

Contact Corrosion

Contact corrosion can occur if inadequate fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only fasteners with a special surface coating may be installed.

Furthermore, only rubber or plastic parts and adhesive made of electrically non-conductive materials are used.

If there are doubts about whether parts can be used or not, use new parts. Refer to the Parts Catalog.

Note:

  • Original replacement parts are recommended because they have been tested.
  • The use of Audi accessories is recommended.
  • Contact corrosion damage is not covered under warranty.

ATF Pump, Deactivating and Draining the Hydraulic Pump Reservoir

  WARNING

The system is under pressure.

The ATF transmission "7-Speed Dual Clutch Transmission 0CK" is equipped with an electronic ATF pump and a hydraulic pressure reservoir.

The electronic ATF pump can start up at any time.

The ATF system also remains under pressure with the ignition switched off due to the hydraulic pressure reservoir.

  • The electronic ATF pump must be deactivated every time before opening the transmission, and the hydraulic pressure reservoir is drained.
  • When the system status is not clear, for example the cause of a faulty transmission control module or transmission is unknown, only loosen the mechatronic bolts to a minimal degree, so that the oil pressure in the pressure reservoir can decrease slowly.
  • Disconnect the Transmission Control Module -J217- connector before removing the oil pan.
  • Wear protective eyewear.

ATF Pump, Deactivating and Draining the Hydraulic Pump Reservoir

- Connect Vehicle Diagnostic Tester with the vehicle and start the Diagnostic mode.

  • Select vehicle test
  • 02-Transmission electronics, functions
  • 02 ATF pressure reduction/Disabling the ATF pump or 02-ATF level ⇒ Draining ATF

Rules for Cleanliness When Working on DSG Transmission

  • Thoroughly clean the connection points and the surrounding area before loosening.
  • Clean the transmission and transmission components using Cleaning Solution -D 009 401 04-.
  • Use lint-free cloths for cleaning, for example, the "WYPALL X70/WORKHORSE" cloth made by Kimberly-Clark Professional.
  • Seal all open lines and connections immediately with clean plugs or caps from the Engine Bung Set -VAS6122-.
  • Place the removed parts on a clean surface and cover them. Use foil or lint-free cloths.
  • Carefully cover or seal opened components if the repair will not be done immediately.
  • Only install clean parts: remove the replacement parts from their packaging just before installing them.
  • Protect the disconnected connectors from dirt and moisture and only connect when they are dry.

    READ NEXT:

     Clutch

     Overview - Flywheel and Dual Clutch

    1 - Flywheel Refer to the Parts Catalog because there are different versions depending on the date of manufacture. Removing an installing. Refer to → Chapter "Flywheel, Removing

     Flywheel, Removing and Installing

    Special tools and workshop equipment required Puller - Clutch Module -T40176- Clutch Disc Shaft Spline Lubricant -G 000 100- Sealing Grease. Refer to the Parts Catalog. Removing   Note T

    SEE MORE:

     Fender

    Overview - Fender 1 -  Nut 8 Nm 2 -  Outer Fender Brace Removing and installing. Refer to → Chapter "Brace and Outer Fender Brace, Removing and Installing". 3 -  Bolt 8 Nm 4 -  Bolt 8 Nm Quantity: 2 5 -  Fender Brace Removing and in

     Drive Axle, Removing and Installing

      Caution This procedure contains mandatory replaceable parts. Refer to component overview and parts catalog prior to starting procedure. Mandatory Replacement Parts Bolt - Outer CV Joint to Drive Axle Clamp - CV Boot to Outer CV Joint Clamp - CV Boot to Drive Axle Bolts - Backing Plat

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