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: