General Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. 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 service information, are summarized here. They apply to this repair information.

Transmission 

• Follow the rules for clean working conditions when working on the transmission, refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .
• Clean the ATF pipes and the ATF cooler after performing repairs on the transmission, refer to AUTOMATIC TRANSMISSION FLUID LINES, CLEANING and OVERVIEW - ATF CIRCUIT .

• Reusable components must be cleaned, checked and reconditioned if necessary before installation, refer to INPUT SHAFT, CHECKING FOR WEAR .

When installing the transmission, the following fluid levels should be checked and corrected if necessary:

• ATF level, refer to ATF LEVEL, CHECKING .

• For the gear oil in front final drive, refer to GEAR OIL, CHECKING LEVEL .

• Capacity, refer to TECHNICAL DATA .

O-rings, Gaskets, Seals 

• O-rings, gaskets and seals must be replaced.
• After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• The open side of the seals point toward the fluid to be sealed in.
• To install, thinly coat gaskets along outer circumference and on sealing lip with Automatic Transmission Fluid (ATF).
• Coat o-rings with transmission fluid or Vaseline before inserting to prevent crushing rings during installation.
• Always only use approved Automatic Transmission Fluid (ATF) or Vaseline. Other types of lubrication cause faults to occur in the transmission hydraulics.
• When installing the new shaft seals, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
• Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals.

Bolts and Nuts 

• Loosen the bolts opposite the tightening sequence.
• Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Always replace self-locking nuts and bolts.

Fasteners 

Fig 1: Identifying Spring Pins

Courtesy of AUDI OF AMERICA, LLC

• Do not overstretch the circlips.
• Always replace damaged or stretched circlips.
• The circlips must fit completely inside the groove.
• Replace the adapter sleeves. Installed position: Slit is longitudinal to direction of force.

Bearings 

• Coat bearing with ATF before inserting.
• Only use Vaseline for the bearing and adjusting ring. Other types of lubrication lead to faults in the transmission hydraulics.

Adjusting Shims 

• Measure the adjusting 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 and damage. Only install perfect shims.