General, Technical Data - Direct Shift Automatic Transmission 02E Awd: Other Audi A3 8P facelift

SAFETY PRECAUTIONS

Observe the following to avoid personal injury and vehicle damage

To prevent personal injury and damage or destruction of electrical and electronic components, observe the following

1. Connect and disconnect test equipment only when the ignition is turned off.

Disconnect the battery. Refer to Removal and Installation .

When working on vehicles with the start/stop system, observe the following

If testing equipment must be used during a road test, observe the following

CLEAN WORKING CONDITIONS

1. Always clean connection places and surrounding areas with engine or brake cleaner before loosening and dry cleaned places.
2. Clean the transmission and transmission components using cleaning solution -D 009 401 04-.
3. Use lint-free cloths when cleaning, for example, the WYPALL X70/WORKHORSE cloth made by Kimberly-Clark Professional.
4. Seal all open lines and connections immediately with clean plugs or caps from the engine plug set VAS 6122.
5. Place removed parts on a clean surface and cover them. Use foil and paper. Use a lint-free cloth!
6. Carefully cover or plug unpacked components if repairs cannot be performed immediately.
7. Only install clean components: Remove the replacement parts from their packaging just prior to installing them.
8. Protect the disconnected connectors from dirt and moisture and only connect when they are dry.

TRANSMISSION CONTROL MODULE SAFETY FUNCTIONS

If one or more components and/or sensors malfunction, the automatic control module will activates the appropriate replacement function. This guarantees the non-destructive operation of the transmission with respective implications on shift function and quality.

When malfunctions are detected by the transmission, a distinction is made between 4 possible statuses.

1. 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 selector lever position indicator in the instrument cluster provides a normal display of the current selector lever position arrow. The driver will only notice the fault - if it is noticed at all - in terms of handling problems and will then automatically consult Audi Service.
2. 2.: Certain selector lever positions will flash in the selector lever position display in the instrument cluster. The driver is shown that a desired gear selection is currently not possible. This is the case if, for example, a reverse drive (selector lever position R and the vehicle rolls backwards) is engaged in the driving gear D. The selector lever position D in the selector lever position indicator in the instrument cluster will blink in this case. The transmission control module prevents engaging the 1st gear in order to avoid damaging the transmission. The 1st gear is engaged after the vehicle comes to a standstill.
3. 3.: The selector lever position indicator in the instrument cluster is completely illuminated and blinks. The selector lever position can be recognized in the instrument cluster, for example, D is emphasized. The transmission was overloaded and the maximum temperature in the transmission was exceeded (overheating), for example, due to towing a trailer with an excessively high load.
4. 4.: Fully illuminated, flashing selector lever position display in instrument cluster is an indication of a serious fault in the transmission. In the display in the instrument cluster, you can no longer recognize which position is selected on the selector lever. The status is critical for driving safety or for the transmission. Under certain conditions, all gears can no longer be engaged. Through the blinking gear selection indicator, the driver is told to visit an Audi Service.

Transmission

The DSG transmission 02E is also called a double-clutch transmission. The engine torque is transferred to the transmission via the dual-mass flywheel. The transmission is built like a 6-gear manual transmission. The alternating hydraulic actuation of the two wet multi-plate clutches permits operation similar to that of an automatic transmission. The gears are engaged automatically or manually with the Tiptronic mode. Clutch pedal is not available. The direct manual transmission 02E.

Selector Mechanism

In contrast to the automatic transmission, the selector lever position is no longer transmitted mechanically to the transmission via the selector lever cable and multi-function transmission range (driving range sensor). Selector lever positions and shifts are transmitted via a separate control module in the selector mechanism to the transmission control module via the CAN-Bus. The shifter occurs without a cable. Only in selector lever position P is the parking lock engaged mechanically via the selector lever cable.

Transmission Fluid

The transmission fluid levels inside the transmission and inside the front final drive are checked and filled at the same time. Refer to TRANSMISSION FLUID, CHECKING AND FILLING .

1. Exclusive use is to be made for the direct-shift gearbox 02E of the transmission fluid available from the parts list. Using other oils can lead to function problems or can even cause the transmission to fail.

Oil level in bevel box is checked and filled separately. Refer to OIL LEVEL IN BEVEL BOX, CHECKING AND TOPPING OFF .

1. Only the gear oil available as a replacement part may be used for the bevel box. Using other oils can lead to function problems or can even cause the bevel box to fail, for the specification.

Shift Point Changes on Inclines and Declines

An additional gear change map automatically selects the gear changes for gradients dependent upon accelerator pedal position and driving speed.

1. The gear change map for extreme uphill stretches is matched to engine output
2. The gear change map for extreme downhill stretches is matched to the braking effect of the engine.
3. Direct gear selection by way of the Tiptronic function permits utilization of engine braking action with a specific gear engaged, for example, on a downhill gradient with a trailer.

CONTACT CORROSION

Contact corrosion can occur if non-approved fasteners are used such as bolts, nuts, washers, etc.

For this reason, only connecting elements with a special surface coating are installed.

In addition, rubber or plastic parts and adhesive are made of materials that do not conduct electricity.

If you are not sure about the suitability of parts, install new parts.

Note. We recommend using original replacement parts only. They have been inspected and are compatible with aluminum. It is recommended to use Audi accessories. Damage resulting from contact corrosion is not covered by the warranty.

REPAIR INFORMATION

1. The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.
2. Some general repair information that applies to several procedures throughout this information is summarized here. They apply to this repair manual.

Guided Fault Finding, OBD and Test Instruments

1. Try to determine the exact cause of the fault using Guided Fault Finding , Vehicle Self-Diagnosis and Test Instruments

Special Tools and Equipment

For a complete list of special tools used in the Repair Manual, see Service Net under Special Tools

Oil, Environmental and Disposal Regulations

1. Handle ATF, axle oil and other fluids with care.
2. Dispose of drained ATF properly.
3. Follow the legal environmental and disposal regulations.
4. Follow the information provided on oil packaging.

Transmission

1. Do not run engine or tow the vehicle when the oil pan is removed or when there is no transmission fluid.
2. When replacing the transmission, the transmission fluid must be checked and filled, if necessary. Refer to «TRANSMISSION FLUID, CHECKING AND FILLING»(ref-496080-S01472541842012082100000) . Capacities, refer to «CAPACITIES»(ref-496121-S12213163252012082100000) .
3. Always clean the connection locations and the area around them before loosening.
4. During installation, make sure that the alignment bushings are fitted correctly.

O-rings, Shaft Seals, Seals

1. O-rings, shaft seals and seals must be replaced.
2. After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
3. Thoroughly clean housing joint surfaces before assembling.
4. Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals.
5. When installing seals, apply transmission fluid to the outer edge and sealing lip.
6. Coat the O-rings with transmission fluid or Vaseline before inserting them so they are not crushed during installation.
7. Never use any other lubricants in the same areas as the transmission fluid. Otherwise, there is a risk that the transmission could malfunction or fail.
8. The open side of the shaft seals point toward the fluid to be sealed in.
9. Follow the rules for clean working conditions. Refer to «CLEAN WORKING CONDITIONS»(ref-496121-S40141727362012082100000) .
10. Check the transmission fluid level and fill if necessary. Refer to «TRANSMISSION FLUID, CHECKING AND FILLING»(ref-496080-S01472541842012082100000)

Fasteners

1. Do not overstretch the circlips.
2. Replace damaged or stretched circlips.
3. The circlips must fit completely inside the groove.

Bolts and Nuts

1. Loosen the bolts opposite the tightening sequence.
2. Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
3. Replace the self-locking nuts.
4. Clean threads of bolts that were applied with locking fluid using a wire brush. Install the bolts with locking fluid AMV 185 101 A1.
5. The tightening specifications stated apply to non-oiled nuts and bolts.

TOWING

Note. Tow-starting the engine, for example when the battery is too weak or the starter is faulty, is not possible.

CODE LETTERS, TRANSMISSION ALLOCATIONS, RATIOS AND EQUIPMENT

OVERALL TRANSMISSION RATIO I, CALCULATING

Example

i = Z 2 : Z 1 (Z 1 = Number of teeth on the drive gear, Z 2 = number of teeth on the driven gear)

i G = gear ratio = ZG 2 : ZG 1 = 33 : 40 = 0.825

i A = axle ratio = ZA 2 : ZA 1 = 72 : 20 = 3.6

i total = total ratio= i G x i A = 0.825 x 3.6 = 2.97