Audi A4: Repair Information
Guidelines for Clean Working Conditions
- Thoroughly clean connection points and their surrounding
areas with engine or brake cleaner before loosening and allow
the cleaned connection points to dry completely.
- Clean the transmission and transmission components using
Cleaning Solution -D 009 401 04-.
- Use lint-free cloths when cleaning, for example, the "X70 /"
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 and paper. Use 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.
General Repair Information
- 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.
Guided Fault Finding, OBD and Test Instruments
- Before beginning any repair work on the transmission,
determine the exact cause of the damage using
Diagnostic. Refer to Vehicle
Diagnostic Tester.
Special Tools
For a complete list of special tools used in the repair
manual. Refer to Workshop Equipment and Special Tools.
Oil, Environmental and Disposal Regulations
- Handle transmission fluid, gear oil and other fluids with
care.
- Dispose of drained fluid properly.
- Follow the legal, environmental, and disposal regulations.
- Follow the instructions listed on the fluid packaging.
Transmission
- Do not run the engine or tow the vehicle when the
transmission fluid pan is removed or when there is no
transmission fluid.
- Thoroughly clean the connection points and the surrounding
area before loosening.
- During installation, make sure the alignment sleeves are
fitted correctly.
O-Rings, Gaskets and Seals
- O-rings, gaskets and seals must always be replaced.
- After removing the seals, examine the contact surface on the
housing or shaft for burrs resulting from removal or for other
signs of damage.
- Thoroughly clean the housing separating surfaces before
assembling.
- Always replace paper gaskets, completely remove an old seal
and thoroughly clean the sealing surfaces.
- Coat the seals with transmission fluid along the outer
circumference and along the sealing lip to install.
- Coat the O-rings with transmission fluid or Vaseline before
inserting to prevent them from being crushed during assembly.
- Do not use any other lubricants in the transmission fluid
area. Otherwise there is a danger of the hydraulic transmission
control malfunctioning.
- The open side of the gaskets point toward the fluid to be
sealed in.
- When installing the new shaft seal, make sure the sealing
lip does not run on the same point as the sealing lip from the
old seal (use press-in depth tolerance).
- Follow the guidelines for clean working conditions. Refer to
→ Chapter "Guidelines for Clean Working Conditions".
Circlips
- Do not stretch the circlips.
- Replace damaged or stretched circlips.
- The circlips must rest at the bottom of the groove.
Bolts and Nuts
- Loosen the bolts opposite the tightening sequence.
- Bolts or nuts for securing covers and housings should be
loosened and tightened diagonally in stages if no tightening
sequence is specified.
- Replace the self-locking nuts.
- Use a wire brush to clean the threads of the bolts that were
installed with locking fluid. Then insert the bolts with Locking
Fluid -AMV 185 101 A1-.
- The tightening specifications given apply to unoiled bolts
and nuts.
ATF Pump, Deactivating and Draining the Hydraulic Pump Reservoir
Special tools and workshop equipment required
- Vehicle Diagnostic Tester
WARNING
The system is under pressure.
The ATF transmission "7-Speed Dual Clutch
Transmission 0CJ, 0CK, 0CL" 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 the 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
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:
- Only original replacement parts are recommended. They are
checked and are compatible with aluminum.
- The use of Audi accessories is recommended.
- Contact corrosion damage is not covered under warranty.
Transmission Control Module Safety Functions
If one or more components and/or sensors malfunction, the
transmission control module activates the corresponding back-up
functions. This guarantees the non-destructive operation of the
transmission with the respective impact on the function and
quality of changing gears.
When malfunctions are detected by the transmission, there
are four possible situations:
- 1. The fault is stored and a substitute program permits
further driving (in some cases with restrictions). The driver is
not notified of this status, because it is neither critical for
the driving safety nor for the transmission. The transmission
range display in the instrument cluster provides a normal
display of the engaged selector lever position. The driver will
only notice the fault, if at all, in terms of handling problems
and should then consult an Audi Service partner immediately.
- 2. Individual selector lever positions will flash in the
transmission range display in the instrument cluster. This
signals to the driver that the gear selection is currently not
possible. This is the case if, for example the driving gear "D"
is engaged when driving in reverse (selector lever position "R"
and the vehicle is still rolling backwards). In this case the
"D" selector lever position flashes in the transmission range
display in the instrument cluster. The transmission control
module blocks the 1st gear from engaging to prevent damaging the
transmission. The 1st gear is engaged after the vehicle comes to
a standstill.
- 3. The transmission range display in the instrument cluster
is completely illuminated and flashing. The selector lever
position can be recognized in the instrument cluster, for
example "D" is highlighted. The transmission was overloaded in
this case and the maximum temperature in the transmission was
exceeded (overheating), for example, due to towing a trailer
with an excessively high load.
- 4. A fully illuminated and flashing transmission range
display in the instrument cluster is an indication of a serious
fault in the transmission. It can no longer be identified which
selector lever position is selected in the instrument cluster
display. The status is critical for driving safety or for the
transmission. Under certain conditions, none of the gears can be
engaged. The flashing transmission range indicator prompts the
driver to contact an Audi service partner immediately.
READ NEXT:
1 - Rear Final Drive
Only for AWD
Removing and installing. Refer to
→ Rear Final Drive; Rep. Gr.39; Final Drive; Final Drive, Removing and
Installing.
2 - D
Overview - Selector Mechanism
Selector Mechanism in the Vehicle Interior
1 - Selector Mechanism
With the following integrated components:
Selector Lever -E313-
Selector Lever Position
SEE MORE:
WARNING
Risk of injury and accident by accidentally engaging
a selector lever position with the engine running.
Before working with the engine running, move the
transmission into "P" and pull the parking brake button
to activate the electro-mechanical parking brake.
Pay attention to t
1 - Bolt
20 Nm + 90º
Replace after removing
Clean the threaded hole, for example, using a thread tap, before
installing the new bolt.
Install the bolt first by hand in the first threads. Check if the
steering intermediate shaft is seated correctly by pulling. Then tighten
the bol