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 service 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 TRANSMISSION, CLEAN WORKING CONDITIONS .
Clean the ATF pipes and the ATF cooler after performing repairs on the transmission. Refer to ATF PIPES AND ATF COOLER, CLEANING .
Reusable components must be cleaned, checked and reconditioned if necessary before installation.

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

ATF level. Refer to ATF LEVEL, CHECKING AND CORRECTING .
Gear oil in front final drive. Refer to FRONT FINAL DRIVE GEAR OIL LEVEL, CHECKING .
Capacities and specifications. Refer to Maintenance, Diagnosis .

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 ATF.
Coat O-rings with transmission fluid or Vaseline before inserting to prevent crushing rings during installation.
Always only use approved 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: slot is longitudinal to line 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.