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Audi Q5 2008, Repair Manual

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Audi Q5 2008 Repair Manual Download Page 149

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

3

Special Tools

Special tools and workshop equipment required
♦ Puller - Sealing Sleeve - T10271-

♦ Engine/Gearbox Jack - Gearbox Support - T10337-

♦ Oil Sump Assembly Pin - T40199-

♦ Engine and Gearbox Jack - VAS6931-

Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤

8-Speed Automatic Transmission 0BK AWD - Edition 04.2017

3. Special Tools    

145

Summary of Contents for Q5 2008

Page 1: ...AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Repair Manual Audi Q5 2008 Audi Q5 China 2010 8 Speed Automatic...

Page 2: ...l Data 32 Torque Converter 37 Controls Housing 38 Gears Control 39 Final Drive Differential Technical information should always be available to the foremen and mechanics because their careful and cons...

Page 3: ...Mechanism 15 1 2 Overview Selector Lever Handle 18 1 3 Overview Selector Lever Cable 20 1 4 Gearshift Mechanism Checking 21 1 5 Emergency Release from P 24 1 6 Selector Mechanism Removing and Install...

Page 4: ...nsmission Fluid Pan Removing and Installing 140 2 Mechatronic 144 3 Special Tools 145 39 Final Drive Differential 146 1 Final Drive 146 1 1 Overview Final Drive 146 1 2 Front Final Drive Cover O ring...

Page 5: ...ge 1 1 1 Transmission Identification Code Letters Location on Transmission Transmission code letters are located on the lower type label on the transmission Type label location arrow Transmission Code...

Page 6: ...shift the transmission into P and press the parking brake but ton to lock the electro mechanical parking brake Danger of poisonous exhaust gas when the engine is running When engine is running an exh...

Page 7: ...ing Equipment Safety Precautions If Testing Equipment Must be Used During A Road Test Observe the Following WARNING Distraction and testing equipment that is not secured properly can cause accidents T...

Page 8: ...UDI AG 2 5 Towing Notes Caution Danger of causing damage to the transmission Move the selector lever into N whenever towing the ve hicle The vehicle may not be towed further than 50 km 31 miles and no...

Page 9: ...r packaging Protect the disconnected connectors from dirt and moisture and only connect when they are dry 3 2 General Information Transmission The 8 speed automatic transmission 0BK AWD is equipped wi...

Page 10: ...ne braking effect with a specific gear engaged for ex ample when driving downhill with a trailer 3 3 General Repair Information The maximum possible care and cleanliness and proper tools are essential...

Page 11: ...Press in new shaft seal so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal use insertion depth tolerances Check the following fluid levels after installati...

Page 12: ...cations with a micrometer Tolerance variations make it possible to find the exact shim thickness required Check for burrs and damage Only install flawless shims 3 4 Contact Corrosion Contact corrosion...

Page 13: ...vailable as a replacement part Refer to the Parts Catalog Refer to 6 Automatic Transmission Fluid page 110 Front Final Drive When the Oil System Is Separated Capacities Automatic Transmission 0BK Init...

Page 14: ...the correctness of information in this document Copyright by AUDI AG Refer to 2 Gear Oil page 150 4 2 Oil Distribution Caution Incorrect gear oil level increases the risk of damaging the transmission...

Page 15: ...il in the protective pipe 2 Transmissions with a single oil system do not have an oil over flow hole arrow A transmission with separate oil system can be identified by the oil overflow hole arrow On t...

Page 16: ...y liability with respect to the correctness of information in this document Copyright by AUDI AG 5 Overview Powertrain 5 1 Overview Powertrain AWD page 12 5 1 Overview Powertrain AWD 1 Rear Final Driv...

Page 17: ...any liability with respect to the correctness of information in this document Copyright by AUDI AG 32 Torque Converter 1 Torque Converter For All Procedures on the Torque Converter Refer To Serv icin...

Page 18: ...espect to the correctness of information in this document Copyright by AUDI AG 2 Special Tools Special tools and workshop equipment required Pulling Hook T20143 2 Puller Clutch Module T40176 Seal Inst...

Page 19: ...ving and Installing page 34 1 9 Selector Lever Transmission Range Position Display Unit Y26 Removing and Installing page 43 1 10 Selector Lever Cable Removing and Installing page 43 1 11 Selector Leve...

Page 20: ...ving and In stalling page 43 6 Nut 10 Nm Securing the shift mechanism to the body Quantity 4 7 Seal 8 Selector Lever Sensor System Control Module J587 Removing and installing Refer to 1 7 2 Selector L...

Page 21: ...Lock Washers Always replace For securing the noise insulation to the shift mechanism function unit Quantity 4 14 Retaining Clip Secure the selector lever cable to the selector mechanism function unit...

Page 22: ...instal ling Refer to 1 8 Selector Lever Handle Removing and Installing page 34 2 Trim Ring Removing and instal ling Refer to 1 8 2 Selector Lever Boot Separating from Selector Lever Handle Vehicles th...

Page 23: ...3 Selector Lever Handle with Side Lock ing Button Removing and Installing Vehicles from MY 2013 page 36 3 Selector Lever Boot Removing and installing together with the selec tor lever handle Removing...

Page 24: ...g the se lector lever cable to the selector lever cable bracket 7 Selector Lever Cable Depending on the ver sion with heat shield Refer to Fig Selector Lever Cable Heat Shield Tightening Specifica tio...

Page 25: ...ctor mechanism functionality Refer to page 21 2 Check ignition key withdrawal lock Refer to page 22 3 Check the closing locks Refer to page 23 4 Check locking button on the selector lever handle Refer...

Page 26: ...a short wait time The selector lever is locked and cannot be shifted out of position P even if the locking button on the selector lever handle is pressed The Shift Lock Solenoid N110 blocks the select...

Page 27: ...n E408 briefly to get ignition on Do not move the selector lever into P but rather for example into N Turn off the ignition A warning message must appear in the instrument cluster The vehicle cannot b...

Page 28: ...n if the specified values are not reached Refer to 1 8 Selector Lever Handle Removing and Installing page 34 Perform Guided Fault Finding using the Vehicle Diagnostic Tester and check the Shift Lock S...

Page 29: ...cking lever 1 when the selector lever is in P If the cylinder arrow on the Shift Lock Solenoid N110 is covered by insulation or a wire then move the insulation or the wire to the side 1 6 Selector Mec...

Page 30: ...ion Remov ing and Installing Vehicles with A Single Pipe Exhaust System Caution Danger of causing damage to the decoupling element inside the front exhaust pipe Do not bend decoupling element in front...

Page 31: ...may only be used during assembly and must not sit unsupervised under the vehicle Remove the bolts from the tunnel crossmember arrows Lower the transmission with the VAG1383A just far enough until the...

Page 32: ...AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Vehicles with a selector lever heat shield remove the bolts arrows re...

Page 33: ...selector lever cable with Polycarbamide Grease G 052 142 A2 before installing Do not bend or kink the selector lever cable Adjust the selector lever cable Refer to 1 11 Selector Lever Cable Checking...

Page 34: ...ling page 32 1 7 3 Transmission Park Selector Switch F305 Removing and Installing page 33 1 7 1 Shift Lock Solenoid N110 Removing and Installing Removing Move the selector lever into P Remove the fron...

Page 35: ...retaining tab 1 on the cover in direction of arrow over the bracket B and remove the cover A upward Disconnect the connector on the Shift Lock Solenoid N110 Press the hooks A into the selector mechani...

Page 36: ...Lock Solenoid N110 and carefully lock it in 1 through 3 Connect the electrical connectors Check the shift mechanism function before completing as sembly Refer to 1 4 Gearshift Mechanism Checking page...

Page 37: ...the Selector Lever Transmission Range Position Display Unit Y26 arrows Install the front ashtray Refer to Body Interior Rep Gr 68 Center Console Front Ashtray Removing and Installing Install the sele...

Page 38: ...n Re moving and Installing Vehicles from MY 2013 page 39 1 8 5 Selector Lever Handle Locking Button Servicing Vehi cles from MY 2013 page 41 1 8 1 Selector Lever Handle Removing and Installing Vehicle...

Page 39: ...intentionally left unsecured Position the compressed air gun under the handle and press the locking button out with compressed air Place the new clamp arrow on the selector lever handle Install the sh...

Page 40: ...m the selector lever Installing Install in reverse order of removal Note the following Selector lever boot installed position The longer side of the selector lever boot frame faces the driv er side In...

Page 41: ...ure it with a cable tie A or an as sembly aid B as illustrated Note The assembly aid B is already installed at the factory when a new handle is ordered Remove the assembly aid only after the new handl...

Page 42: ...m suction cup Remove the adhesive pad or the two sided tape after the han dle has been installed Make sure there is no adhesive left over Push on the adhesive surface using a tool 3 with a clean flat...

Page 43: ...m the function test If the selector lever positions cannot be reached remove the handle again Refer to 1 8 Selector Lever Handle Removing and Installing page 34 Pull the selector lever boot downward a...

Page 44: ...t above one another The locking button points in the drive direction Caution The selector mechanism could get damaged The locking button 2 on the selector lever handle must stick out when installing I...

Page 45: ...ing button may have an increased resistance to pres sure when it is pushed the first time after installing the handle Press the locking button 1 in the selector lever handle Fold the boot downward and...

Page 46: ...T40203 all the way into the handle 1 The cut out on the T40203 faces the locking button and the hook toward the left Hold the handle A tighten and turn the T40203 180 in di rection of arrow 1 Hold the...

Page 47: ...ut the selector lever boot on the side using the 3409 or a small screwdriver arrows and then fold it upward Release the spring 2 and remove the Selector Lever Trans mission Range Position Display Unit...

Page 48: ...ctor lever cable approximately one turn Note Only loosen the clamping screw do not remove it The clamping screw is only accessible when the selector lever is in D or D S The selector lever must remain...

Page 49: ...the circlip arrows re move noise insulation 1 Remove the circlip 1 from the selector lever cable Remove the selector lever cable 2 from the selector mech anism Installing Install in reverse order of r...

Page 50: ...lector lever cable 2 with the circlip 3 Installed position the angled end of the circlip 1 faces the selector mechanism Push the selector lever 1 on the transmission all the way to the back in directi...

Page 51: ...r Rep Gr 66 Molding Trim Extensions Trim Panels Overview Heat Shield Check and adjust the selector lever cable Refer to 1 11 Selector Lever Cable Checking and Adjusting page 47 Check the selector mech...

Page 52: ...Check the selector mechanism Refer to 1 4 Gearshift Mechanism Checking page 21 If shift mechanism does not function properly after adjusting se lector lever cable Bring the selector lever cable into t...

Page 53: ...ever cable Refer to 1 11 Selector Lever Cable Checking and Adjusting page 47 If the individual displays cannot be reached by adjusting the se lector lever cable Selector Lever Cable Bringing Into Basi...

Page 54: ...elector lever cable Push the selector lever 1 on the transmission all the way to the back arrow until the parking lock locks into place Note When parking lock is engaged it must not be possible to tur...

Page 55: ...tor lever position This releases the tension in the selector lever cable Select the following menu entries on the Vehicle Diagnostic Tester in the Guided Functions 02 Transmission Electronics 0BK I J2...

Page 56: ...se Insulation Overview Noise Insulation 1 13 Selector Shaft Seal Replace Special tools and workshop equipment required Pry lever 80 200 Procedure Tightening specification Refer to Fig Selector Lever C...

Page 57: ...or lever cable Remove the spring pin 2 on the shaft for the selector lever using a pin punch 1 Remove the selector lever and shaft arrow Pry out the shaft seal using a small screwdriver Apply ATF to t...

Page 58: ...ing latch at the same time in direction of arrow 1 Install the spring pin 2 flush on the shaft for the selector lever using a pin punch 1 Install the Mechatronic Refer to Servicing 8 Speed Auto matic...

Page 59: ...ssion Removing Vehicles with 3 0L TFSI En gine page 71 2 1 5 Transmission Removing Vehicles with 3 0L TDI En gine page 89 2 1 1 Transmission Removing Vehicles with 2 0L TFSI Engine Generation II Speci...

Page 60: ...Caution Risk of damaging electronic components when disconnecting the battery Complete the steps for disconnecting the battery Disconnect the battery Refer to Electrical Equipment Rep Gr 27 Battery Ba...

Page 61: ...pair manual Remove the driveshaft Refer to repair manual Rear Final Drive 0BC Rear Final Drive 0BC 0BD 0BE 0BF Rep Gr 39 Driveshaft Driveshaft Removing and Installing or Rear Final Drive 0BF and 0BE S...

Page 62: ...nal heat shield depends on the engine and on the date of manufacture Mark the installed position of the additional heat shield in color before removing it If equipped mark the installed position of th...

Page 63: ...to Suspension Wheels Steering Rep Gr 48 Steering Column Overview Steering Column Remove the bolts 1 and 2 and the bracket for the catalytic converter Disconnect connectors from the heated oxygen senso...

Page 64: ...onnections with clean plugs from the VAS6122 Caution There is a risk of destroying the transmission control module Mechatronic with static discharge Do not touch contacts in transmission connector wit...

Page 65: ...d 5 also attach the wire bracket on the trans mission The bolt 2 attaches the starter to the transmission and has an additional spacer sleeve arrow Remove the sleeve when removing the bolt at the top...

Page 66: ...ut after loosening the starter Remove the engine transmission connecting bolt arrow 2 Remove the engine transmission bolts 6 8 9 and 10 but leave one bolt 7 installed hand tight Caution Danger of leak...

Page 67: ...smission from the engine to the rear While doing this pay attention to the left transmission side steering pinion steering gear B and the power steering hy draulic line A Use spindles on the T40173 to...

Page 68: ...at the shorter side faces up as illustrated The bracket 2 must be turned so that the longer side faces up as illustrated The bracket 3 must be turned so that the shorter side faces up as illustrated R...

Page 69: ...Converter Removing and Installing Remove bolts 2 to 5 connecting the engine and transmission Note The bolts 3 and 5 also attach the wire bracket on the trans mission The bolt 2 attaches the starter t...

Page 70: ...rrect rear final drive repair manual Remove the driveshaft Refer to repair manual Refer to Rear Final Drive 0BC Rear Final Drive 0BC 0BD 0BE 0BF Rep Gr 39 Driveshaft Driveshaft Removing and Installing...

Page 71: ...lts arrows and remove the right drive axle heat shield Remove left and right drive axles from transmission flange shafts Remove the steering intermediate shaft from the steering gear and push splines...

Page 72: ...risk of destroying the transmission control module Mechatronic with static discharge Do not touch contacts in transmission connector with hands To discharge static electricity touch the transmission...

Page 73: ...w Remove the 3 torque converter bolts arrow on the drive plate while turning the crankshaft 120 further in the direction of en gine rotation Remove the bolt 1 from the bottom of the starter on the en...

Page 74: ...ind the opening in the transmission housing for the torque converter on the left side of the trans mission Mount the bracket 1 on the front final drive on the right side of the transmission Secure the...

Page 75: ...sioning Strap T10038 Crankshaft Socket T40058 Gearbox Support T40173 Preparing the T40173 The bracket attached to 1 must be removed The bracket 2 must be turned so that the longer side faces up as ill...

Page 76: ...ve the engine covers 1 and 2 upward Remove the plenum chamber bulkhead Refer to Body Ex terior Rep Gr 50 Bulkhead Overview Bulkhead Remove the front wheels Remove the left and right drive axle cover 1...

Page 77: ...ft Driveshaft Removing and Installing or Rear Final Drive 0BF and 0BE Sport Differential Rep Gr 39 Remove the bolt arrow from the ATF pipes 1 and 2 Remove the left and right front muffler Refer to Rep...

Page 78: ...s and connections with clean plugs from the VAS6122 Vehicles with Coolant Recirculation Pump V50 unlock the tab in direction of arrow remove the Coolant Recirculation Pump V50 from the bracket and set...

Page 79: ...cket Note Ignore item 1 Caution There is a risk of destroying the transmission control module Mechatronic with electrostatic discharge Do not touch contacts in transmission connector with hands To dis...

Page 80: ...the bolts 1 2 and 3 and then remove the right drive axle heat shields Remove the bolts arrows and the left drive axle heat shield Remove the left and right drive axles from the transmission flange sha...

Page 81: ...ire Note Ignore item 1 Vehicles with a selector lever heat shield remove the bolts arrows remove the heat shield Remove the ball socket 1 on the selector lever cable from the selector shaft lever usin...

Page 82: ...ter by the crankshaft drive plate using the T40058 when loosening the bolt Note When mounting turn the crankshaft only in the direction of engine rotation arrow Remove the six torque converter bolts a...

Page 83: ...repared T40173 Refer to page 71 on the bottom of the transmission The transmission support must be placed at the front as fol lows The bracket 2 fits into the dual mass flywheel on the trans mission h...

Page 84: ...st bolt from the transmission to engine connec tion Press the transmission off the engine and lower it carefully using the VAG1383A 2 1 4 Transmission Removing Vehicles With 3 0L TDI Biturbo Engine Sp...

Page 85: ...at the longer side faces up as illustrated Removing Position the front wheels so they are straight Caution Risk of damaging electronic components when disconnecting the battery Complete the steps for...

Page 86: ...over 1 inside the wheel housing Remove the left and right bolts arrows and the heat shield 1 Note Check the vehicle data label or the designation on the rear final drive itself to determine which one...

Page 87: ...h to catch any leaking coolant Loosen hose clamps 2 and 3 and remove the Coolant Hose 1 and 4 from the Heater Core Note Ignore Hose Clamps Up To 25mm 3094 Disconnect electrical connectors 1 through 4...

Page 88: ...Differential Pressure Sen sor G505 Note Ignore item 1 and arrow Remove the left and right bolt 1 Loosen the left and right bolt 3 from the bracket 2 for the turbocharger bracket Remove the bolts 4 5 c...

Page 89: ...n transmission by rotating screw connections counter clockwise arrow Free up the wiring harness on the transmission Slide the retainer toward the rear arrow and press down the release in order to disc...

Page 90: ...Rep Gr 40 Drive Axle Drive Axle Removing and Installing Remove the lower cover 1 from the transmission arrow Note It is necessary to loosen the threaded connection for the torque support and crossmemb...

Page 91: ...the crankshaft only in the direction of engine rotation arrow Remove the six torque converter bolts arrow while turning the crankshaft 60 further in the direction of engine rotation Remove the bolt ar...

Page 92: ...t as fol lows The bracket 2 fits into the dual mass flywheel on the trans mission housing on the left side of the transmission The transmission mount is positioned on the differential hous ing on the...

Page 93: ...Gearbox Support T40173 Crankshaft Turning Tool T40257 Wrench 21mm T40263 Adapter T40314 Preparing the T40173 The bracket attached to 1 must be removed The bracket 2 must be turned so that the longer...

Page 94: ...Catalytic Reduction SCR Catalytic converter Refer to Engine Mechanical Fuel Injection and Glow Plug Rep Gr 26 Exhaust Pipes Mufflers Overview Muffler Remove the front wheels Remove the left and right...

Page 95: ...e top Seal the open lines and connections with clean plugs from the VAS6122 Note Check the vehicle data label or the designation on the rear final drive itself to determine which one is installed in t...

Page 96: ...n its wheels if the subframe mount steering gear or subframe crossbrace are not in stalled correctly Remove the steering intermediate shaft from the steering gear and push splines together Refer to Su...

Page 97: ...r 1 from the Power Steering Control Module J500 Free up the wiring harness Remove the ball socket 1 on the selector lever cable from the selector shaft lever using the 80 200 Remove the bolts 3 and re...

Page 98: ...the direction of engine rotation arrow Remove the six torque converter bolts arrow while turning the crankshaft 60 further in the direction of engine rotation Remove the bolt arrow 1 from the starter...

Page 99: ...flywheel on the trans mission housing on the left side of the transmission The transmission mount is positioned on the differential hous ing on the right side of the transmission Insert a flat piece...

Page 100: ...positions Transmission Installation Tightening Specifications Refer to 2 3 Transmission Tightening Specifications page 102 Before installing a replacement transmission always clean out the ATF cooler...

Page 101: ...ustrated Note There is only 1 notch on the circumference rotate the torque con verter as needed Insert the T40170 in the transmission housing from below and secure it on the flange shaft 1 Check if th...

Page 102: ...mbly overview pay attention that the locking piece are in the correct installed position with the starter if not the starter support bolts are difficult to install and the locking piece will no longer...

Page 103: ...tensioning strap and guide the VAG1383A with the T40173 under the transmission Note The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted...

Page 104: ...Nm Vehicle with 6 Cylinder Engine 6 bolts Turn the crankshaft on the vibration damper 180 in the direc tion of engine rotation With the crankshaft in this position install the bolt arrow and tighten...

Page 105: ...s Steering Rep Gr 40 Subframe Overview Subframe Install the driveshaft Refer to the repair manual Refer to Rear Final Drive 0BC Rear Final Drive 0BC 0BD 0BE 0BF Rep Gr 39 Driveshaft Overview Driveshaf...

Page 106: ...s Tightening specification tolerance 15 Other tightening specifications Component Nm Bolts and nuts M6 9 M7 15 M8 20 M10 40 M12 65 Refer to Fig Selector Lever Cable Heat Shield Tightening Specifica ti...

Page 107: ...the engine side Attaching Transmission on 6 Cylinder Engine Item Bolt Nm 1 M10 x 50 1 65 2 through 6 M12 x 100 2 30 90 7 M12 x 125 2 30 90 8 11 M10 x 60 2 15 90 9 M10 x 75 2 15 90 10 M10 x 95 2 15 90...

Page 108: ...e if the trans mission mount must be separated from the transmission support 2 Bolt 70 Nm 3 Bolt 40 Nm 4 Transmission 5 Nut 20 Nm 6 Transmission Support Removing and instal ling Refer to 3 3 Transmiss...

Page 109: ...k Gearbox Support T10337 Removing Remove the rear noise insulation 2 Refer to Body Exte rior Rep Gr 66 Noise Insulation Noise Insulation Remov ing and Installing Vehicles with 3 0L TDI Biturbo engine...

Page 110: ...ission Support with Transmis sion Mount Removing and Installing Removing Remove the tunnel crossmember Refer to 3 2 Tunnel Crossmember Removing and Installing page 105 Remove the bolts arrows and the...

Page 111: ...4 and remove the transmission mount 5 from the transmission support Installing Tightening specifications Refer to 3 1 Overview Subframe Mount page 104 Mount the transmission support 3 on the transmiss...

Page 112: ...e Transmission removed Caution Transmission components could be damaged if they are not set down correctly Do not set the transmission on the ATF pan WARNING An accident could result if the transmissi...

Page 113: ...VW309 Hook And Support Tool 3311 with Bolt 3311 1 Engine And Transmission Holder VAS6095 Procedure Hold the transmission with the VAS6100 Refer to 4 Transmission Transporting page 108 Attach the VW30...

Page 114: ...the transfer case 3 Sealing Plug Tightening specification Item 1 Item 1 page 150 For the hole for check ing and filling For the transmission flu id inside the transfer case 4 ATF Plug 30 Nm Always re...

Page 115: ...an 30 C 86 F at the beginning of the test If the temperature is higher let the transmission cool down first Note ATF temperature is read on the Vehicle Diagnostic Tester The ATF level will vary depend...

Page 116: ...pter must be clean Do not mix the ATF any other fluids Secure the oil container and the VAS6262A as high as pos sible on the vehicle For the correct ATF specification Refer to the Parts Catalog Cautio...

Page 117: ...n new sealing plug for the ATF check and fill hole The ATF level test is now complete Install the noise insulation Refer to Body Exterior Rep Gr 66 Noise Insulation Overview Noise Insulation If no ATF...

Page 118: ...t required Used Oil Collection and Extraction Unit VAG1782 Oil Filler VAS6262A Oil Filler Jointed Hose VAS6262A Original 1 liter container Protective eyewear Procedure The engine is off Move the vehic...

Page 119: ...ts Replace the ATF drain plug and seal Replace the plug for the ATF check and fill hole Tighten the new drain plug arrow B Fill Transmission with ATF Caution Danger of causing damage to the transmissi...

Page 120: ...t the engine Fill the ATF again using the adapter until the ATF starts to leak out of the check and fill hole Tighten the old plug for the ATF check and fill hole While pressing the brake pedal and wi...

Page 121: ...Engine page 117 7 1 2 Vehicles with a 3 0L TFSI engine page 119 Note Clean working conditions for the automatic transmission Re fer to 3 1 Clean Working Conditions Guidelines page 5 General repair in...

Page 122: ...ing Always replace Coat with ATF before in stalling 5 O ring Always replace Coat with ATF before in stalling 6 Bolt 5 Nm First insert the ATF lines with new O rings by hand as far as the stop 7 ATF Li...

Page 123: ...s with a 3 0L TFSI engine 1 Radiator ATF Cooler The ATF cooler is inte grated in the radiator Removing and instal ling Refer to Engine Mechanical Fuel Injec tion and Ignition Rep Gr 19 Radiator Cool a...

Page 124: ...ket 10 ATF Line Return Nuts on lines 29 Nm From the ATF cooler to the transmission Before removal mark the ATF lines in relation to each other so they are not switched The ATF lines are secured to eac...

Page 125: ...efore in stalling 8 ATF Line Removing and Installing page 129 7 4 Automatic Trans mission Fluid Lines Cleaning page 126 Install all the way by hand with new O rings 9 Bolt first insert the ATF lines w...

Page 126: ...lamps Up To 25 mm 3094 Used Oil Collection and Extraction Unit SMN372500 Removing Remove the subframe crossbrace Refer to Suspension Wheels Steering Rep Gr 40 Subframe Subframe Cross brace Removing an...

Page 127: ...e the ATF cooler Installing Install in reverse order of removal At the same time pay attention to the following Install the ATF lines all the way and then the clips 1 and 4 Loosen all three bolts from...

Page 128: ...lip is released Remove the ATF line Loosen the clamps 2 and 3 and then seal off and remove the coolant hoses Hose Clamps Up To 25mm 3094 Remove the bolts arrows and remove the ATF cooler Installing In...

Page 129: ...sion Wheels Steering Rep Gr 40 Subframe Overview Sub frame Check the ATF level Refer to page 110 7 3 ATF Filter Removing and Installing Special tools and workshop equipment required Used Oil Collectio...

Page 130: ...ransmission Fluid Pan Removing and Installing page 140 Fill the ATF Refer to 6 3 ATF Draining and Filling page 114 7 4 Automatic Transmission Fluid Lines Cleaning Special tools and workshop equipment...

Page 131: ...TFSI Engine page 128 7 5 1 ATF Pipes Removing and Installing Vehicles with 2 0L TFSI Engine Special tools and workshop equipment required Hose Clamps Up To 25mm 3094 Used Oil Collection and Extraction...

Page 132: ...order of removal Note the following Tightening specifications Refer to 7 1 Overview ATF Circuit page 117 Note Replace the O rings Check the ATF level Refer to 6 2 ATF Level Checking page 110 Install...

Page 133: ...s Caution Danger of causing damage to the transmission When disassembling remove all the plugs which were taken from the VAS6122 on the ATF pipes and on the transmission The ATF cooling function will...

Page 134: ...oximately 18 mm Compressed air gun commercially available Protective eyewear Removing and installing Place the Used Oil Collection and Extraction Unit SMN372500 under the transmission Vehicles through...

Page 135: ...es and on the trans mission that were installed during removal The ATF cooling function will not work and the transmis sion will be damaged if the plugs are forgotten Install the ATF lines all the way...

Page 136: ...attention to the following Caution Danger of causing damage to the transmission Remove all the plugs on the ATF lines and on the trans mission that were installed during removal The ATF cooling functi...

Page 137: ...ss of information in this document Copyright by AUDI AG 8 Special Tools Special tools and workshop equipment required Engine Support Bridge 10 222A Pry lever 80 200 Engine and Gearbox Jack VAS6931 Use...

Page 138: ...or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Pry lever 80 200 Engine and Gearbox Jack VAS6931 Tensioning Strap T10038 Counterhold Vibrat...

Page 139: ...y with respect to the correctness of information in this document Copyright by AUDI AG Pry lever 80 200 Engine and Gearbox Jack VAS6931 Engine Bung Set VAS6122 Tensioning Strap T10038 Crankshaft Socke...

Page 140: ...ility with respect to the correctness of information in this document Copyright by AUDI AG Socket And Key T40031 Clutch Module Transportation Lock T40170 Locking Button Removal Tool T40203 Crankshaft...

Page 141: ...th respect to the correctness of information in this document Copyright by AUDI AG Wrench 21mm T40263 for vehicles with 6 cylinder TDI en gine Adapter T40314 for vehicles with 6 cylinder TDI engine Ho...

Page 142: ...es not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Engine And Transmission Holder VAS6095 Shop Crane VAS6100 Oil Filler VAS62...

Page 143: ...UDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Hose Clamps Up To 25mm 3094 Hook And Support Tool 3311 Bolt 3311...

Page 144: ...1 1 Transmission Fluid Pan Removing and Installing page 140 For All Additional Procedures for the ATF System Refer to Servicing 8 Speed Automatic Transmission Rep Gr 38 ATF System 1 1 Transmission Fl...

Page 145: ...ace Refer to Suspension Wheels Steering Rep Gr 40 Subframe Subframe Cross brace Removing and Installing Caution Risk of damaging the suspension components Do not rest the vehicle on its wheels if the...

Page 146: ...trainer when the ATF pan is removed Refer to page 125 Otherwise the ATF strainer must be replaced only if it is damaged Clean both magnets arrows Make sure the magnets com pletely contact the depressi...

Page 147: ...e bolts and tighten in the specified tightening sequence Refer to Servicing 8 Speed Automatic Transmission Rep Gr 38 ATF System Overview ATF System Install the subframe crossbrace Refer to Suspension...

Page 148: ...antee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 2 Mechatronic For All Procedures on the Mechatronic Refer to Servicing 8 Speed Automa...

Page 149: ...th respect to the correctness of information in this document Copyright by AUDI AG 3 Special Tools Special tools and workshop equipment required Puller Sealing Sleeve T10271 Engine Gearbox Jack Gearbo...

Page 150: ...on page 6 1 Right Flange Shaft Removing and instal ling Refer to 4 2 Right Flange Shaft Removing and In stalling page 173 2 Circlip Always replace 3 Shaft Seal For the right flange shaft Replace Refer...

Page 151: ...Item 18 page 147 to the left flange shaft Is identified together as the left flange shaft mounting bracket 17 Bearings For the left flange shaft 18 Circlip For left flange shaft mount 19 Torque Conver...

Page 152: ...pair instructions Refer to 3 3 General Repair Information page 6 Place the SMN372500 under the transmission Remove the right flange shaft Refer to 4 2 Right Flange Shaft Removing and Installing page 1...

Page 153: ...is document Copyright by AUDI AG Tighten the front final drive cover bolts Refer to Fig Front Final Drive Cover Tightening Specifications and Sequence page 148 Install the right flange shaft Refer to...

Page 154: ...raining and Filling page 158 2 1 Overview Drain and Inspection Plugs for Gear Oil 1 Sealing Plug 27 Nm Always replace For the hole for check ing and filling For the transmission flu id inside the tran...

Page 155: ...page 154 2 3 3 ATF Level Checking Transmission with Combined Oil System page 156 2 3 1 Gear Oil Level Checking Front Final Drive Transmission with Separated Oil System Special tools and workshop equip...

Page 156: ...ation page 6 Pay attention to clean working conditions for the transmission Refer to 3 1 Clean Working Conditions Guidelines page 5 Always maintain the specified transmission fluid level The transmiss...

Page 157: ...with approximately 0 9 liters of gear oil and wait at least five minutes so that the internal oil level between the differential and oil fill space can equalize Then check the fuel level If the level...

Page 158: ...fferential are dependent on one another Procedure Gear oil temperature approximately 20 C 68 F room tem perature The engine must be switched off when working Move the vehicle onto a four column shop h...

Page 159: ...ttom of the oil fill hole Install the VAS6617 6 with the VAS6617 2 in the check and fill hole in the transfer case Note After repair or oil change fill the transfer case with approximately 0 8 liters...

Page 160: ...Depending on the version there are transmissions with separate or combined oil systems For vehicles with combined oil systems the steps for it must be followed because the oil level from the transfer...

Page 161: ...ATF drain plug and seal Replace the plug for the ATF check and fill hole Place the VAS6617 under the transmission WARNING Danger of eye injury Wear protective eyewear Note Place a cloth over the tunne...

Page 162: ...ion hole Immediately after oil flows out close the rear transfer case inspection hole Note Through overfilling the transmission fluid flows between the inner oil level from the front final drive to th...

Page 163: ...umn workshop hoist or over a work pit so it is completely level Gear oil temperature approximately 20 C 68 F room tem perature Tightening specifications Refer to 2 1 Overview Drain and Inspection Plug...

Page 164: ...arrow B from the front final drive and drain the transmission fluid Caution Danger of causing damage to the transmission Do not start the engine if there is no transmission oil in the front final driv...

Page 165: ...out Specified value The oil level is correct when the front final drive is filled up to bottom edge of oil filler hole Fill the gear oil once more if necessary Tighten the new drain plug arrow A for t...

Page 166: ...lace the plug for the ATF check and fill hole Place the SMN372500 under the transmission WARNING Danger of eye injury Wear protective eyewear Remove the drain plug arrow B and drain the transmission f...

Page 167: ...in out Specified value The oil level is correct when the transfer case is filled up to bottom edge of oil fill hole Fill the gear oil once more if necessary Tighten the new drain plug arrow A for the...

Page 168: ...Replace the plug for the ATF check and fill hole Place the VAS6617 under the transmission WARNING Danger of eye injury Wear protective eyewear Note Place a cloth over the tunnel crossmember to preven...

Page 169: ...pection hole for front final drive and fill the front final drive with approximately 1 0 liters of gear oil Gear oil specification Refer to the Parts Catalog Wait five minutes Note A waiting time of a...

Page 170: ...inutes Note The inside of the transfer case is divided into several oil cham bers The chambers must be filled equally A waiting time of at least 5 minutes is required so that the in ternal oil level b...

Page 171: ...on removed and mounted to the engine transmis sion holder Refer to 5 Securing on Engine and Transmission Holder page 109 Note Clean working conditions for the automatic transmission Re fer to 3 1 Clea...

Page 172: ...cover together with the tapered roller bearing outer race and the adjustment shim Note The shim must be the correct size and must not be replaced by a shim with a different thickness Remove the diffe...

Page 173: ...uter circumference of shaft seal otherwise the contact surface in transmission housing will be damaged Guide the release lever carefully while prying out Examine shaft seal seat in transmission housin...

Page 174: ...the left flange shaft Refer to 4 1 Left Flange Shaft Removing and Installing page 172 Install the right flange shaft Refer to 4 2 Right Flange Shaft Removing and Installing page 173 Add axle oil to th...

Page 175: ...mference of the new shaft seal with axle oil Installed position The open side of the shaft seal faces the transmission Push in the new shaft seal until it stops When doing this do not bend the shaft s...

Page 176: ...o the VAS6095 Refer to 5 Securing on Engine and Transmission Holder page 109 Tilt the transmission back on the engine transmission holder so the transmission fluid does not drain out Remove the bolts...

Page 177: ...p Gr 32 Torque Converter Torque Converter Removing and Installing Install the left flange shaft 1 into the transmission in direction of arrow B When doing this insert the flange shaft centrally into t...

Page 178: ...and Extraction Unit VAG1782 M10 nut quantity 2 Sealing Grease G 052 128 A1 Removing Remove the rear noise insulation 2 Refer to Body Exte rior Rep Gr 66 Noise Insulation Noise Insulation Remov ing and...

Page 179: ...ransmission Remove the right flange shaft by attaching the T10037 to the final drive cover arrow Installing Install in reverse order of removal Note the following Note Replace the circlip on the right...

Page 180: ...and In stalling Special tools and workshop equipment required Engine and Gearbox Jack VAS6931 Transmission Support 3282 Protective Eyewear Removing The transmission is installed Caution Risk of damag...

Page 181: ...eshaft Removing and Installing Caution Danger of damaging the transmission fluid pan Never use the transmission fluid pan as a support for the transmission Install the two flat mounts 1 and 2 in the 3...

Page 182: ...ht by AUDI AG Remove the nuts arrows and the tunnel crossmember Drain the transmission fluid from the transfer case by loosen ing the drain plug arrow B Tighten the new drain plug arrow B Refer to pag...

Page 183: ...differential 1 was removed Position the center differential on the input shaft splines Ro tate the center differential slightly when doing this Make sure the center differential can be turned by hand...

Page 184: ...accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 6 Transfer Case For All Procedures on the Transfer Case Refer to Servicing 8 Speed Automatic T...

Page 185: ...n The Mechatronic unit is bolted to the bottom of the transmission housing and is covered by the ATF pan The Mechatronic includes the hydraulic control the electronic control and sensors and actuators...

Page 186: ...Refer to Servicing 8 Speed Automatic Transmission Rep Gr 38 Mechatronic Mechatronic Removing and Installing Hydraulic Impulse Memory A with Accumulator Solenoid N485 Present Depending on the Date of M...

Page 187: ...lling page 32 Shift Lock Solenoid N110 Installed location The Shift Lock Solenoid N110 1 is clip ped to the selector mechanism Refer to 1 7 1 Shift Lock Solenoid N110 Removing and Installing page 30 T...

Page 188: ...nsors are integrated inside the accelerator pedal module arrow Note The accelerator pedal module must be replaced if the accelerator pedal position sensor is faulty Refer to Rep Gr 20 Accel erator Ped...

Page 189: ...nformation in this document Copyright by AUDI AG 8 Special Tools Special tools and workshop equipment required Press Plate VW401 Press Plate VW402 Press Piece Multiple Use VW412 Press Piece Bushing 50...

Page 190: ...iability with respect to the correctness of information in this document Copyright by AUDI AG Press Plate VW401 Press Plate VW402 Press Piece Multiple Use VW412 Press Piece Front Control Arm 2040 Pres...

Page 191: ...liability with respect to the correctness of information in this document Copyright by AUDI AG Seal Installer Final Drive Gearbox T10139 Puller Crankshaft Power Steering Seal T20143 Seal Installer Ou...

Page 192: ...y with respect to the correctness of information in this document Copyright by AUDI AG Pressurized Gearbox Oil Filler Kit VAS6617 Used Oil Collection and Extraction Unit VAS6622 Engine and Gearbox Jac...

Page 193: ...I AG AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Puller Seal Lever VW681 Transmission Support 3282 Press Pie...

Page 194: ...c P 04 2 017 10 1 2 20 18 Fac tory Up date N A Juan S 03 2 016 06 3 0 20 17 Feed back 126 561 5 Updated bolt description within Overview ATF Sys tem Tightening Specifica tion and Sequence for Me chatr...

Page 195: ...fications are made applicable to earlier models Therefore part numbers listed in this manual are for reference only Always check with your authorized Audi retailer parts department for the latest info...

Page 196: ...r rings should be removed so that they cannot cause electrical shorts get caught in running machinery or be crushed by heavy parts x Before starting a job make certain that you have all the necessary...

Page 197: ...tically deploys an airbag in the event of a frontal impact The airbag is operated by an explosive device Handled improperly or without adequate safeguards it can be accidentally activated and cause se...

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