Automatic Transmission - Overhaul - o1j (multitronic Cvt)

IDENTIFICATION

Application	Transmission Model
A4 With 1.8L & 3.0L	01J Continuously Variable Transmission (CVT)

TRANSMISSION APPLICATION

The multitronic(R) CVT transmission type 01J (front-wheel drive) is installed in the Audi A4 from 2002 in combination with various engine types. See CODE LETTERS, TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT .

Location Of Code Letters On Transmission

Transmission code letters and transmission serial number are punched into the bottom of the transmission case (arrow). (Scheme 231)

Scheme 231

Scheme 231: Location Of Code Letters On Transmission

Note. The transmission code letters are also included on the vehicle data stickers.

Scheme 232

Scheme 232: CODE LETTERS, TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

LUBRICATION & ADJUSTMENTS

For lubrication and adjustments, see SERVICING - A/T (01J) article.

AXLE SHAFTS

For information on axle shafts, see AXLE SHAFTS - FRONT & REAR article.

TRANSMISSION COMPONENTS

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T (01J) article.

REPAIR INSTRUCTIONS

WARNING

Before working on the engine when it is running, move the selector lever into the "P" position and apply the parking brake.

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 performing vehicle repairs.

Observe rules for cleanliness when working on the transmission. See «RULES FOR CLEANLINESS»(/audi/a4/b6-2000-2006/remont/automatic-trans/#automatic-transmission-overhaul-o1j-multitronic-cvt__rules-for-cleanliness) .
Never run the engine or tow the vehicle with the end cover removed or without sufficient ATF (automatic transmission fluid).
Install only clean parts: do not remove replacement parts from their wrapping until you are ready to install them.
After installing a transmission, the following fluid levels must be checked and topped off if necessary: ATF in planetary gearbox, Gear oil in front final drive, and capacities and specifications. See «SERVICING - A/T (01J)»(/audi/a4/b6-2000-2006/remont/automatic-trans/#automatic-transmission-servicing-at-01j-multitronic-cvt) article.

O-RINGS, SEALS, GASKETS

Always replace O-rings, seals and gaskets.
After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
Thoroughly clean housing joint surfaces before assembling.
Lightly lubricate the outside surface and sealing lip of oil seals with ATF before installing.
Lightly lubricate O-rings with ATF before inserting to prevent them being trapped and damaged when assembling.
Use only ATF in the parts of the transmission where ATF is the specified lubricant; other lubricants will cause malfunctions in the hydraulics.
The open side of the oil seals faces toward the side with a fluid filling.
When replacing oil seals, always vary the point at which the sealing lips make contact (use insertion depth tolerances).
After installing a transmission, the following fluid levels must be checked and topped off if necessary: ATF in planetary gearbox, Gear oil in front final drive, and capacities and specifications. See «SERVICING - A/T (01J)»(/audi/a4/b6-2000-2006/remont/automatic-trans/#automatic-transmission-servicing-at-01j-multitronic-cvt) article.

NUTS, BOLTS

Loosen the bolts in reverse sequence to the specified tightening sequence.
Nuts and bolts which secure covers and housings should be tightened in stages according to the specified sequence and tightening method.
Nuts and bolts which secure covers and housings should be loosened and tightened diagonally in stages if no tightening sequence is specified.
The tightening torques stated apply to non-oiled nuts and bolts.
Replace self-locking nuts and bolts.
The threads of bolts which are secured by a locking fluid should be cleaned with a wire brush. Then apply AMV 185 101 A1 when inserting.
Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

LOCKING ELEMENTS

Do not overstretch circlips.
Always replace circlips which have been damaged or over-tensioned.
Circlips must be properly seated in the base of the groove.

BEARINGS

Install needle bearings with the lettering on the bearing (the side with thicker metal) facing toward the drift or other tool used for installing.
Lubricate bearings with gear oil or ATF, depending on installation location.
Do not interchange the outer or inner races of bearings of the same size.
Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.

SHIMS

Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain the exact shim thickness required.
Inspect for burrs and signs of damage. Install only shims which are in perfect condition.

GUIDED FAULT-FINDING

Before starting any repair work, always perform the guided fault-finding procedure using the VAS 5051.

RULES FOR CLEANLINESS

Thoroughly clean all connections and the surrounding area before disconnecting.
Place removed parts on a clean surface and cover over. Use sheeting and paper. Do not use fluffing cloths!
If repairs cannot be completed immediately and components are left open, cover the components carefully or install plugs as required.
Install only clean parts and do not remove replacement parts from their wrapping until just before installing.

SELECTOR SHAFT, CLEANING

Remove Transmission Control Module (TCM) -J217-. See TRANSMISSION CONTROL MODULE (J217) in SERVICING - A/T (01J) article.

Clean selector shaft detent (arrow). (Scheme 257)

Do not use fluffy materials for cleaning.
Remove metal parts or similar very carefully from contact surfaces of magnets.

Note. Make sure that spring -A- and roller -B- are properly secured. (Scheme 257)

Clean sensors -A-, -C- and -D- to remove metal particles and dirt if necessary. (Scheme 258)

Scheme 255

Re-install TCM -J217-. See TRANSMISSION CONTROL MODULE (J217) in SERVICING - A/T (01J) article.

VALVE BODY

Note. Valve body is also referred to as hydraulic control assembly.

Observe the rules for cleanliness when working on the automatic transmission. See «RULES FOR CLEANLINESS»(/audi/a4/b6-2000-2006/remont/automatic-trans/#automatic-transmission-overhaul-o1j-multitronic-cvt__rules-for-cleanliness) .
General repair instructions. See «REPAIR INSTRUCTIONS»(/audi/a4/b6-2000-2006/remont/automatic-trans/#automatic-transmission-overhaul-o1j-multitronic-cvt__repair-instructions) .
Always replace the hydraulic control assembly if it has collected dirt or if it is faulty.

Removal

Remove Transmission Control Module (TCM) -J217- . See TRANSMISSION CONTROL MODULE (J217) in SERVICING - A/T (01J) article.

Pull slide for selector lever position -C- downward and out of mounting drilling in hydraulic control assembly. (Scheme 257) Unhook spring -A- from selector shaft -D-.

Loosen bolts (arrows) and pull hydraulic control assembly back and out. (Scheme 259)

Scheme 256

Scheme 256: Removal

Installing

Install in reverse sequence; note the following points

Replace axial sealing elements -A- (4 elements) and -B-. (Scheme 260)

Scheme 257

Scheme 257: Installing

Note. Lightly lubricate axial sealing elements with ATF before installing. Axial sealing elements -A- must be installed into inserts with the smaller diameter facing the transmission.

Put on cover -C-. Note position of locating tab. (Scheme 260) Push selector shaft lever -2- completely to front until shifting cam -1- is almost vertical (with a slight inclination to the right).

Note. The locating tab at the rear of the cover must be inserted into the small drilling on the transmission surface.

Push control piston -B- on rear of hydraulic control assembly completely inward (to left) until it clips into securing spring -A-. see scheme 31

Scheme 258

Insert hydraulic control assembly into transmission. Align unit properly to fit without jamming.

Note. When installing the hydraulic control assembly, ensure that the cam (item -1- in illustration (Scheme 260) ) engages in the free groove (arrow) of control piston -B-.

Thread in bolts (arrows) hand-tight. Bolt (arrow -1-) is shorter than other two bolts. (Scheme 259)

Check that cover is mounted properly. Locating tab -B- must be inserted into drilling provided on transmission. (Scheme 259) Go to Checking Operation Of Control Piston -B.

Checking Operation Of Control Piston -B

Repeatedly turn selector shaft in both directions by moving either detent plate -C- or selector shaft lever.

Control piston -B- should travel in and out accordingly (double-headed arrow). see scheme 32

Scheme 259

If the control piston fails to move, the shifting cam is not engaged with the groove (arrow) of control piston -B- on the rear of the hydraulic control assembly. In this case take off the hydraulic control assembly again and re-install. see scheme 31

Tighten bolts (arrows) to 89 INCH lbs. (10 N.m). (Scheme 259) Go to Install Slide For Selector Lever Position -C.

Install Slide For Selector Lever Position -C

Push roller -B- with collar pointing downward onto slide for selector lever position -C-. see scheme 33 Hook spring -A- into selector shaft -D- and slide for selector lever position -C-. Push slide for selector lever position -C- into drilling in housing of hydraulic control assembly.

Scheme 260

Scheme 260: Install Slide For Selector Lever Position -C

Shift selector shaft lever -2- completely to front and back. (Scheme 260)

The detent plate (arrow) moves back and forward. As it moves, the roller -B- should be able to engage the individual notches one-by-one. At the same time, the slide for selector lever position -C- should move back and forward in steps matching the notches. see scheme 33

Roller -B- must be installed with the collar pointing downward, so that it cannot be pulled off upward.

Replace O-rings -A- on hydraulic control assembly before installing TCM -J217-. (Scheme 259)

Note. Lightly lubricate O-rings with ATF before inserting.

Clean selector shaft. See SELECTOR SHAFT, CLEANING .