5-speed Automatic Transmission 01v Front and All Wheel Drive - Internal Components, Servicing Audi A4 B6

General Repair Notes

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.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the article, are summarized here. They apply to this article.

Transmission

1. Rules of cleanliness for working on automatic transmissions --> «Rules of cleanliness for working on automatic transmissions»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing) .

Scheme 1029

1. On removed transmission, support torque converter against falling down with Bracket 30-211 A.
2. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
3. After repair work on the transmission, clean ATF lines and ATF cooler, replace ATF filter.
4. Check the following fluid levels after installing, top off if necessary. ATF in planetary gear --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) , axle oil for front final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) , axle oil in transfer case --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) . Install driveshaft --> «00 - GENERAL, TECHNICAL DATA»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Impurities in ATF area

If ATF area is very soiled caused by worn friction linings

1. Disassemble transmission completely and clean, replace ATF oil tubes.
2. Disassemble and check all clutches.
3. Replace torque converter (cannot be cleaned).
4. Replace valve body (cannot be cleaned).

1. Clean ATF lines and ATF cooler, replace ATF filter.

O-rings, gaskets, shaft seals and seals.

1. Always replace O-rings, gaskets, shaft seals and seals.
2. After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
3. The open side of the shaft seals point toward the fluid to be sealed in.
4. To install, thinly coat shaft seals along outer circumference and on sealing lip with ATF.

1. Lightly lubricate O-rings with ATF or Vaseline before installing, this prevents the rings from being pinched when inserting.
2. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
3. Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
4. Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals.

Bolts and nuts

1. Loosen bolts in reverse order of tightening.
2. Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
3. The tightening torques stated apply to unoiled bolts and nuts.
4. Replace self-locking bolts and nuts.

Locking elements

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

Scheme 1030

1. Replace spring pins. Installation position: Slit is longitudinal to direction of force - arrow -.

Bearings

1. Slightly grease mount with ATF before inserting.
2. Attach mount and adjustment shims only with Vaseline. Other lubricants cause malfunctions of the hydraulic transmission controls.

Oil tubes

1. Once removed, oil tubes must always be replaced.
2. If transmission is very dirty, oil tubes must be replaced.

Special tools

Special tools and equipment

Scheme 1031

Special tools, testers and auxiliary items required

1. Holding plate VW 309
2. Measuring bar VW 382/7 from Special socket measuring tools VW 382
3. Dial gauge holder VW 387
4. Thrust plate VW 401

1. Thrust plate VW 402
2. Punch VW 407

Scheme 1032

Special tools, testers and auxiliary items required

1. Punch VW 408 A
2. Punch VW 412
3. Thrust piece VW 454
4. Sleeve 30-21

1. Bracket 30-211 A
2. Sleeve 40-20

Scheme 1033

Special tools, testers and auxiliary items required

1. Seal installer 2080 A
2. Thrust piece 3118
3. Thrust piece 3295
4. Thrust piece 3301/4 from assembly tool 3301

1. Oil line installer 3381
2. Thrust piece 3403

Scheme 1034

Special tools, testers and auxiliary items required

1. Thrust piece 3404
2. Hook 3438
3. Attachment and holding rig 3457
4. Old oil collecting and extracting device V.A.G 1782

1. Vehicle diagnostic, testing, and information system VAS 5051 (VAS 5051 B version shown as example only)
2. Dial gauge VAS 6080

Scheme 1035

Special tools, testers and auxiliary items required

1. Digital depth gauge VAS 6087
2. Engine and Transmission Holder VAS 6095
3. Workshop crane VAS 6100
4. Extracting handle T10271

1. Installation bracket T10276
2. Installation bracket T10277

Scheme 1036

Special tools, testers and auxiliary items required

1. Mounting device T10282
2. Mounting device T10283
3. Adapter for torque converter T10284
4. Pre-tensioning tool T10285

1. Puller for ATF supply T10286
2. Lifting device T10287

Scheme 1037

Special tools, testers and auxiliary items required

1. Centering tool T10288
2. Installation bracket T10289
3. Assembly sleeve T10290
4. Plate T10291

1. Plate T10292
2. Plate T10293

Scheme 1038

Special tools, testers and auxiliary items required

1. Plate T10294
2. Plate T10295
3. 1 - Internal extractor Kukko 21/4
4. 3 - Separating tool 22 to 115 mm Kukko 17/2

1. 4 - Support Kukko 22/1
2. Heat gun
3. Safety glasses

Rules of cleanliness for working on automatic transmissions

1. Carefully clean all joints and adjacent areas before disconnecting.
2. Place removed parts on a clean surface and cover them. Use sheeting or paper. Use lint-free cloths only!
3. Carefully cover or plug unpacked components if repairs cannot be performed immediately.
4. Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.

Frequent damages

Note. Check DTC memory of Transmission Control Module (TCM) J217 before troubleshooting. Check also DTC memory of Engine Control Module (ECM), as DTCs of the Engine Control Module (ECM) can lead to transmission malfunctions. Check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING before troubleshooting.

Slipping problems in all gears

1. Possible damage

Scheme 1039

Coupling plate - arrows - on ATF pump wheel broken off

1. Causes

Scheme 1040

A - Torque converter not completely inserted during transmission or engine installation. Check installation dimension --> 32 - TORQUE CONVERTER .

Scheme 1041

B - Centering bushing for torque converter - arrow - not properly installed in crankshaft -->

1. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-mechanical-engine-codes-amb) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278881-S02386490842008020700000) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. «13 ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278883-S27934238612008020700000) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278885-S20771794552008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278884-S05161542512008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Scheme 1042

C - One or both alignment sleeves - A - for centering not installed on engine/transmission flange. Alignment sleeves or bores in transmission flange damaged.

Note. Disregard items - 1 to 9 -.

Scheme 1043

D - Incorrect installation position of drive plate for torque converter, drive plate secured to engine with incorrect shim - 1 - or shim - 1 - and washer - 2 - interchanged -->

1. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-mechanical-engine-codes-amb) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
2. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278881-S02386490842008020700000) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
3. «13 ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
4. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278883-S27934238612008020700000) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
5. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278885-S20771794552008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
6. «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278884-S05161542512008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

1. Required actions

1. Disassemble and check ATF pump, remove broken coupling plates.

Hard shifting procedures, individual gears not fully locked, shifting procedures too long

Note. Illustration shows the damage on a disassembled valve body. Valve body must not be disassembled in customer service. Possible damage

Scheme 1044

One of 3 rubber shock absorbers broken - arrow -.

1. Required actions

1. Check ATF level --> «Evaluating wear by evaluating ATF color and impurities»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing) .

ATF is OK

1. Replace valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .

ATF is not OK, damage was not repaired in a timely manner. In this case, clutch "G" is possibly damaged

1. Completely disassemble and clean transmission.
2. Clean ATF lines and ATF cooler.
3. Disassemble and check all clutches.
4. Replace valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .

Hard shifting, slipping in 4th and 5th gear

1. Possible damage

Scheme 1045

Plates - 3 - of clutch "E" burnt out.

1. Cause

Worn or faulty torque converter clutch

1. Required actions

1. Check torque converter clutch while driving --> «Torque converter clutch, checking»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__torque-converter-clutch-checking) .
2. Completely disassemble and clean transmission.
3. Clean ATF lines and ATF cooler.
4. Disassemble and check all clutches.

1. If there is heavy soiling --> «Evaluating wear by evaluating ATF color and impurities»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing), replace torque converter (cannot be cleaned).
2. Replace components - 2 to 5 - of clutch "E".
3. Replace overheated cylinder "E" - 1 - (blue color).
4. Replace ATF filter --> see scheme 118.

ATF leakage between engine and transmission

1. Possible damage

The ATF pump corroded resulting in increased wear and chafing on the torque converter hub, heavy ATF leakage.

1. Required actions

Scheme 1046

1. Make sure that no ATF escapes at oil leak inspection opening - arrow - after removing transmission. In this case, the final drive/transmission housing double shaft seal would be faulty.
2. Replace final drive/transmission housing double shaft seal if necessary --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Scheme 1047

1. Check brass sleeve - arrow - for signs of wear and seizing.

Scheme 1048

1. Check hub - arrow - of torque converter for wear and corrosion.

If corrosion is detected

1. Replace ATF pump and torque converter.
2. If there is heavy soiling --> «Evaluating wear by evaluating ATF color and impurities»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing) , disassemble and clean transmission.
3. Replace valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .

1. Check whether alignment sleeve - arrow - for torque converter is installed in crankshaft --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b6-2000-2006/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-mechanical-engine-codes-amb) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278881-S02386490842008020700000) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT «13 ENGINE - CRANKSHAFT, CYLINDER BLOCK»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278883-S27934238612008020700000) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278885-S20771794552008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-278884-S05161542512008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF .

1. Check whether both alignment sleeves - A - are inserted in cylinder block.
2. Check alignment sleeves for deformation and holes in transmission flange for damage.

Note. Disregard - 1 to 9 -.

Speed-dependent noises in driving operation

1. Possible damage

Scheme 1049

Faulty spur gear bearings or spur gears - 1 to 3 -.

1. Required action

1. Replace transmission.

Torque converter clutch, checking

Note. Check DTC memory of Transmission Control Module (TCM) J217 before troubleshooting. Check also DTC memory of Engine Control Module (ECM), as DTCs of the Engine Control Module (ECM) can lead to transmission malfunctions. Check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING before troubleshooting.

Scheme 1050

Torque converter clutch can only be checked when driving in On Board Diagnostics (OBD).

1. With ignition switched off, connect Vehicle Diagnosis, Testing and Information System VAS 5051 to Data Link Connector (DLC).
2. Start engine.

Scheme 1051

Display on VAS 5051

1. Tap Vehicle Self-Diagnosis button.

Scheme 1052

Display on VAS 5051

1. In selection - 1 - , click on function "02 - Transmission electronics".
2. Wait until the next indication appears on display.

Scheme 1053

Display on VAS 5051

1. From list - 1 - select function "08 - Reading measured value block".

Scheme 1054

Display on VAS 5051

1 - Enter display group, max. input value = 255

1. In button field - 2 - , tap 7 button for "display group 007" and confirm entry by tapping Q button.
2. Perform a road test.

Scheme 1055

Display on VAS 5051

1. Check indication in display fields - 3 - and - 4 -. Specified values

3 - TC closed

4 - 0 to 20/min

If indications do not resemble description, ratio of transmission RPM to engine speed with closed torque converter clutch does not match (implausibility).

1. Causes

1. Torque converter clutch circuit malfunctioning, worn.
2. Incorrect torque converter.
3. Automatic Transmission Pressure Regulating Valve 4 N218 mechanically malfunctioning.
4. Problems in ATF lines to Automatic Transmission Pressure Regulating Valve 4 N218.

1. Valve for torque converter pressure malfunctioning.
2. Torque converter clutch valve faulty.
3. Press <-- button to end function "08 - Read measured value block".
4. Select "06 - End output" function.

1. Switch off ignition and disconnect diagnostic connector.

Scheme 1056

In case of soiling of the ATF via shavings or during a major transmission overhaul, torque converter must be drained.

1. Extract ATF from torque converter with Used Oil Collection and Extraction Tool V.A.G 1782.

Torque converter, checking

1. Check hub - arrow - of torque converter for wear and corrosion.
2. Check whether balance plates are properly seated and threads are undamaged.

If signs of wear and corrosion on torque converter, loosened balance plates or damaged threads are detected

1. Replace torque converter.

Note. If the torque converter clutch is burnt or worn, sand-like material and residues can be found in the ATF filter.

Scheme 1057

1. If the bolts - arrow - for the attachment of the torque converter to the drive plate protrude only 2 mm, the torque converter can get dented and the torque converter clutch can be damaged. Therefore, only use original bolts.

Transmission, attaching assembly stand

Work procedure

1. Torque converter secured with Bracket 30-211 A or removed.

1. Attach holding plate VW 309 onto attachment and holding rig 3457.

Scheme 1058

1. Attach and secure Attachment and Holding Rig 3457 at mounts on transmission housing.

Note. Attachment and Holding Rig 3457 should only be installed by hand in transmission. If bolt is installed with pliers, transmission housing can be damaged.

1. Insert transmission into Engine and Transmission Holder VAS 6095 using Shop Crane -Load Cap=700-1200 kg VAS 6100.

Note. Vents for the transmission housing and final drive must be closed before turning a filled transmission with oil pan upward on the engine and transmission holder.

Planetary gear, disassembling and assembling

Note. General repair notes --> General Repair Notes . Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on automatic transmissions . Lubricate O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting. Attach mount and adjustment shims only with Vaseline.

1. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.

Planetary gear, component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part.

1 - Bolt, 10 Nm

2 - Sealing washer

1. Replace

3 - O-ring

1. Replace

4 - ATF supply

1. With ATF pump
2. Disassembling and assembling --> «Clutch "C" , disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__clutch-c-disassembling-and-assembling)

5 - Axial needle bearing

6 - Rectangular rings

1. Replace

7 - Rectangular ring

1. Replace

8 - O-rings

1. Replace

9 - Adjustment shim

1. Determine thickness --> (Scheme 1118)

10 - Tower "II"

1. Disassembling and assembling --> «Tower "II" , disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__tower-ii-disassembling-and-assembling)

11 - Thrust washer

12 - Axial needle bearing

13 - Thrust washer

14 - Intermediate shaft with inner plate carrier

15 - Angle washer

16 - Axial needle bearing

17 - Thrust washer

18 - Sun shaft

19 - Axial needle bearing

20 - Sun gear "I"

1. Magnetic, for transmission with hydraulic control "E17" , Transmission Input Speed (RPM) Sensor G182 is then an inductive sensor
2. Not magnetic, for transmission with hydraulic control "E18/2" , Transmission Input Speed (RPM) Sensor G182 is then a Hall sensor

21 - Planetary gear set "I" and "II"

22 - Angle washer

23 - Axial needle bearing

24 - Thrust washer

25 - Shaft with ring gear "I"

26 - Ribbed cup

27 - Thrust washer

28 - Axial needle bearing

29 - Angle washer

1. Height 2.5 mm incl. collar

30 - Circlip

31 - Fitting key

32 - Tower "I"

1. Disassembling and assembling --> «Tower "I" , disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__tower-i-disassembling-and-assembling)

33 - Angle washer

1. Height 5 mm incl. collar

34 - Axial needle bearing

35 - Angle washer

36 - Sun gear "III"

Disassembling

1. Transmission attached to assembly stand --> «Transmission, attaching assembly stand»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__transmission-attaching-assembly-stand) .

1. Remove torque converter.
2. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

Scheme 1059

1. Remove ATF drain plug - 1 - and allow ATF to drain.

Note. Observe disposal regulations. Rest of ATF remains in the ATF oil pan.

Automatic transmission 01V Front Wheel Drive

1. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

Scheme 1060

1. Loosen front final drive cover bolts in sequence - 14 to 1 - and then remove completely.
2. Allow escaping oil to drain into Used Oil Collecting and Extracting Device V.A.G 1782.

1. Lift off cover for front final drive.

1. Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.

1. Remove pinion gear together with intermediate pinion, while doing so pull drive pinion - 2 - slightly toward rear.
2. Remove drive pinion - 2 -.

Scheme 1061

1. Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
2. Remove coil spring - 3 - from pinion shaft.

Scheme 1062

Automatic transmission 01V All Wheel Drive

1. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
2. Remove locking bolt - A - and allow axle oil to drain from transfer case.

Scheme 1063

1. Loosen transfer case housing bolts - arrows - in a diagonal sequence and then remove them completely.

Scheme 1064

1. Remove Torsen differential - arrow - from input shaft.
2. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

Scheme 1065

1. Remove bolts - arrows - at intermediate flange for front final drive.
2. Allow escaping oil to drain into Used Oil Collecting and Extracting Device V.A.G 1782.

1. Lift off intermediate flange for front final drive.

Scheme 1066

1. Cover entire splines - arrow - on input shaft with insulating tape without wrinkling or overlapping to avoid damaging shaft seal in front final drive intermediate flange when removing drive pinion - 2 -.

1. Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.
2. Remove pinion gear together with intermediate pinion, while doing so pull drive pinion - 2 - slightly toward rear.
3. Remove drive pinion - 2 -.

Scheme 1067

1. Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
2. Remove coil spring - 3 - from pinion shaft.

Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive

Scheme 1068

1. Remove right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft using a pry bar.
2. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
3. Pull out right flange shaft.

Scheme 1069

1. Loosen final drive cover bolts in sequence - 12 to 1 - and then remove completely.

1. Remove final drive cover.

Scheme 1070

1. Carefully remove differential - arrow -.

Scheme 1071

1. Remove bolts - arrows - and remove baffle.

Scheme 1072

1. Completely cover splines - arrow - on left flange shaft with insulating tape without wrinkling or overlapping to avoid damaging final drive/transmission housing double shaft seal when removing flange shaft.

Scheme 1073

1. Remove left drive flange mounting bracket - arrows -.
2. Pull out left drive flange.

Note. When sliding off, left drive flange must be carefully guided by hand to prevent damage to the double seal in final drive/transmission housing.

Scheme 1074

1. Loosen ATF oil pan bolts - arrow - in a diagonal sequence and then remove them completely.
2. Remove ATF oil pan.

Note. Milky green cover in ATF oil pan means there is damage to the torque converter clutch.

Scheme 1075

1. Remove ATF screen bolts - arrows -.
2. Pull ATF filter off of valve body.

Scheme 1076

1. Remove circlip - arrow - for wiring harness/harness connector.
2. Remove wiring harness/harness connector by pressing inward.

Scheme 1077

1. Remove bolt - arrow - and remove Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

Scheme 1078

1. In a transmission with hydraulic control "E18/2" , disengage electrical connector to Transmission Input Speed (RPM) Sensor G182 at valve body - arrow - and disconnect connector.

Scheme 1079

1. Loosen valve body bolts - 17 to 1 - in sequence and remove them completely.

Scheme 1080

1. Carefully remove valve body from transmission.

Scheme 1081

1. Pull sealing sleeves - arrows - in inlet bores toward clutches "C" , "A" , "B" , "E" and toward torque converter clutch using extracting handle T10271.

Scheme 1082

1. Remove 3 securing rings - 1 -.
2. Remove coil springs - 2 -.
3. Pull out sealing sleeves - 3 - , using extracting handle T10271.
4. Rotate transmission on assembly stand.

1. ATF pump faces upward.

Scheme 1083

1. Loosen ATF pump bolts - 9 to 1 - in sequence and remove them completely.
2. Remove bolts with sealing washers.

Scheme 1084

1. Secure puller for ATF supply T10286 to stator shaft and pull ATF supply firmly upward.

If ATF pump cannot be loosened

Scheme 1085

1. On the bottom side of the transmission, place a screwdriver between sun gear "I" and ribbed cup and pry component above sun gear upward - arrow -.

Scheme 1086

1. Remove adjustment shim - 1 - and axial needle bearing - 2 -.

Scheme 1087

1. Lift tower "II" - 1 - out of transmission housing.

Scheme 1088

1. Twist tower "II" - 1 - and place together with input shaft in mounting device T10283.

Scheme 1089

1. Remove sun shaft - 1 - with intermediate shaft - 2 - with inner plate carrier.

Scheme 1090

1. Disassemble the following components

1. Sun shaft
2. Thrust washer
3. Axial needle bearing
4. Angle washer
5. Intermediate shaft with inner plate carrier
6. Thrust washer
7. Axial needle bearing
8. Thrust washer

Scheme 1091

1. Remove axial needle bearing - 1 -.

Scheme 1092

1. Remove sun gear "I" - 1 -.

Scheme 1093

1. Remove planetary gear set "I" and "II" - 1 -.

Scheme 1094

1. Remove angle washer - 3 - , axial needle bearing - 2 - and thrust washer - 1 -.

Scheme 1095

1. Remove shaft with ring gear "I" - 4 - , thrust washer - 3 - , axial needle bearing - 2 - and angle washer - 1 -.

Scheme 1096

1. Remove ribbed cup - 1 -.

Scheme 1097

1. Remove circlip - arrow - for tower "I".

Scheme 1098

1. Turn back knurled nut of lifting device T10287.
2. Insert lifting device into tower "I" until stop.
3. Tighten knurled nut of lifting device in clockwise direction.
4. Check lifting device in tower "I" for proper seating.

1. Lift tower "I" out of transmission housing by hand.

Scheme 1099

1. Place tower "I" in mounting device T10282.

Scheme 1100

1. Remove sun gear "III" - 1 - with lower angle washer - 2 - , axial needle bearing - 3 - and upper angle washer - 4 - from transmission housing.

Note. Upper angle washer - 4 - possibly adheres to underside of tower "I".

Assembling

1. Check lifting device in tower "I" for proper seating.

1. Lift tower "I" out of mounting device T10282 by hand and lay aside on workbench.

Scheme 1101

1. Attach the following components to input shaft of tower "I" - 5

4 - Upper angle washer - angled edge points up toward tower "I"

3 - Axial needle bearing

2 - Lower angle washer - angled edge points toward axial needle bearing

1 - Sun gear "III" - outer splines of sun gear must engage in splines of clutch "F"

Scheme 1102

Automatic transmission 01V Front Wheel Drive

1. Secure sun gear "III" on input shaft without play, using assembly sleeve T10290 , as depicted in illustration, thread stud bolt - 1 - into bore identified by "A" - arrow A - and hand-tighten.

Scheme 1103

Automatic transmission 01V All Wheel Drive

1. Secure sun gear "III" on input shaft without play, using assembly sleeve T10290 , as depicted in illustration, thread stud bolt - 1 - into bore identified by "B" - arrow B - and hand-tighten.

Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive

Scheme 1104

1. Check whether fitting keys - arrow - are inserted centrally on both sides of cylinder "D/G".

Scheme 1105

1. Bring tower "I" into installation position.

1. Oil bores - arrows - on cylinder "D/G" face toward underside of transmission and must align with openings in transmission housing.

1. Insert tower "I" completely into transmission housing.

1. Tower "I" must be inserted far enough that circlip groove is free.

1. Loosen knurled nut and remove lifting device T10287.

1. Carefully insert circlip - arrow - for tower "I" into transmission housing.

Scheme 1106

1. Loosen stud bolt and remove assembly sleeve T10290.

Note. Depicted in the illustration with Automatic Transmission 01V All Wheel Drive.

1. Insert ribbed cup - 1 -.

1. Attach angle washer - 1 - on tower "I".

1. Angled edge of angle washer faces down.

1. Insert axial needle bearing - 2 -.
2. Insert thrust washer - 3 -.
3. Insert shaft with ring gear "I" - 4 -.

1. Insert thrust washer - 1 - into ring gear "I".
2. Insert axial needle bearing - 2 -.
3. Place angled washer - 3 -.

1. Angled edge of angle washer faces down.

1. Insert planetary gear set "I" and "II" - 1 -.

1. Insert sun gear "I" - 1 - in planetary gear set "I" and "II".

Note. Magnetic sun gear for transmission with hydraulic control "E17" (Transmission Input Speed (RPM) Sensor G182 as inductive sensor). Non-magnetic sun gear for transmission with hydraulic control "E18/2" (Transmission Input Speed (RPM) Sensor G182 as Hall sensor).

1. Insert axial needle bearing - 1 -.

1. Assemble the following components as one unit

1. Sun shaft
2. Thrust washer
3. Axial needle bearing
4. Angle washer - angled edge points downward toward axial needle bearing
5. Intermediate shaft with inner plate carrier
6. Thrust washer
7. Axial needle bearing
8. Thrust washer

1. Insert sun shaft - 1 - together with intermediate shaft - 2 - with inner plate carrier.

1. Remove "tower II" - 1 - from mounting device T10283 and turn to installation position.

1. Insert tower "II" - 1 - into transmission housing by hand using turning motions.
2. Ensure sun gear coupling plate splines "I" engage in outer splines on cylinder "B" by turning input shaft and sun gear "I".

Scheme 1107

1. Check tower "II" for proper installation.
2. Measure distance between contact surface for adjustment shim on tower "II" and contact surface for ATF pump on transmission housing.

1. Dimension - a - = at least 6.0 mm.
2. Adjustment shim may not be installed.

Scheme 1108

1. Place previous adjustment shim - 1 - on plate carrier "C".

Scheme 1109

1. Replace 2 rectangular rings on input shaft.
2. Before inserting, thinly coat rectangular rings on input shaft with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in hydraulic transmission control.
3. Make sure that rectangular rings are fully seated all around in the input shaft groove.

Scheme 1110

1. Thinly coat back side of axial needle bearing - 2 - with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
2. Append axial needle bearing to ATF pump - 1 -.

1. Closed side of axial needle bearing faces toward ATF pump.

1. Replace rectangular rings - 3 - and - 4 - on stator shaft.
2. Before inserting, lightly coat rectangular ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
3. Make sure that rectangular rings are fully seated all around in stator shaft groove.

Scheme 1111

1. Engage ends of installed rectangular rings - arrows - , as depicted in illustration.

Scheme 1112

1. Replace O-ring - 1 - on ATF supply.
2. Thinly coat O-ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in hydraulic transmission control.

Scheme 1113

1. Align coated plates - 3 - of clutch "C" using centering tool T10288/1 , to do so let pins - 2 - and - 4 - engage in splines of all coated splines.
2. Align lining discs to ATF pump housing by inserting centering pins - 1 - and - 5 - into appropriate holes on ATF pump.

1. Centering pins fit only in one position.

1. Hold centering tool in this position and insert wedge T10288/2 from side between waved washer and piston "F" - arrow -.

1. Wedge must secure all plates in current position.

1. Remove centering tool T10288/1 , wedge T10288/2 remains inserted.

Scheme 1114

1. Align plate carrier for clutch "C" using centering tool T10288/3 , install guide pins T10288/4 into transmission housing.

1. Holes in centering tool and transmission housing only fit in one position.

1. Carefully remove centering tool T10288/3 upward, guide pins T10288/4 remain in transmission housing.

1. Plate carrier for clutch "C" may no longer be turned.

Scheme 1115

1. Attach puller for ATF supply T10286 at stator shaft.
2. Bring ATF supply to installation position.

1. Recess for flange shaft faces toward valve body side.

1. Attach ATF supply with corresponding bores onto guide pins T10288/4.
2. Carefully insert ATF supply into transmission housing and push forcefully.
3. Bring ATF supply to final installation position by alternately tightening two opposing attachment bolts each.

Scheme 1116

1. Remove wedge 10288/2 using hook 3438.
2. Remove Puller for ATF supply T10286.
3. Remove guide pins T10288/4.

1. Insert ATF pump bolts with new sealing washers into ATF pump housing.
2. Tighten ATF pump bolts - 1 to 9 - in sequence.

1. Tightening torque: 10 Nm.

Note. Check for correct ATF pump installation: You must be able to rotate the input shaft. Otherwise, the last clutch plate "C" may have been pinched during installation and bent. In this case, remove ATF pump again and check discs for damage.

Scheme 1117

1. Attach Dial gauge VAS 6080 with Dial gauge holder VW 387 to transmission flange.
2. Insert Dial gauge VAS 6080 with dial gauge extension onto input shaft of transmission, as depicted in illustration.
3. Set dial gauge to "0".
4. To protect against damage, cover input shaft with insulating tape.

1. Move input shaft up and down using pliers, while doing so avoid lateral movement.
2. Read input shaft axial clearance on dial gauge.

1. Specified value: 0.10 to 0.30 mm.

If specified value is not obtained

1. Remove ATF pump again.

Scheme 1118

1. Determine correct adjustment shim - 2 - on tower "II" item - 1 - according to the following table.

1. Measured axial clearance too small: Install respectively thinner shim.
2. Measured axial clearance too large: Install respectively thicker shim.

1. Reinstall ATF pump with new adjustment shim, new sealing washers and new O-ring. (Scheme 1111)
2. Check axial clearance of input shaft again --> (Scheme 1118).

If specified value is again not obtained

1. Repeat adjustment.

If specified value is obtained

1. Rotate transmission on assembly stand.

1. Valve body side points upward.

1. Press sealing sleeves - 3 - into transmission housing holes to stop.
2. Insert coil springs - 2 - and secure with circlips - 1 - by pressing circlips into hole down to shoulder.

Scheme 1119

1. Position valve body on transmission housing without force while inserting notched disc pins - 1 - into selector slide groove - 2 -.
2. Position valve body bolts.

Note. Note different length of bolts.

1. Bolt - 6 - is only present on transmissions with hydraulic control "E17".
2. On a transmission with hydraulic control "E18/2" , ensure electrical wire to Transmission Input Speed (RPM) Sensor G182 is not pinched between transmission housing and valve body.

1. Tighten valve body bolts in 2 stages as follows

1. Replace O-rings for wiring harness/harness connector.

Scheme 1120

1. Connect wiring harness connector - arrow - to transmission housing.

1. Installation position: Retainers - 1 - and - 2 - at collar are horizontal, leveled side - arrow - of connector must be parallel to ATF oil pan sealing surface.

1. Position wiring harness connector securing clip - arrow - and ensure it locks securely.

1. Tighten bolt - arrow - for Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

1. Tightening torque: 10 Nm.

1. With a transmission with hydraulic control "E18/2" , connect electrical connector to Transmission Input Speed (RPM) Sensor G182.
2. Clip electrical harness connector into valve body mount - arrow -.
3. Replace ATF filter.

1. Position ATF filter on valve body and tighten - arrows -.

1. Tightening torque: 5 Nm.

Note. Clean magnets (6x) in ATF oil pan. Ensure full surface contact of the magnets in the ATF oil pan.

1. Install ATF oil pan - arrow - with new seal.
2. Tighten bolts for ATF oil pan in diagonal sequence in stages.

1. Tightening torque: 10 Nm.

Scheme 1121

1. If necessary, replace flange seal for left flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Replace O-ring - arrow B - in mounting bracket for left flange shaft.

Note. Disregard - arrow A -.

1. Replace final drive/transmission housing double shaft seal if necessary --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Completely cover splines - arrow - on left flange shaft with insulating tape without wrinkling or overlapping to avoid damaging final drive/transmission housing double shaft seal when installing flange shaft.
2. Insert left flange shaft into transmission.

Note. When sliding on, left drive flange must be carefully guided by hand to prevent damage to the double seal in final drive/transmission housing.

1. Tighten left flange shaft mounting bracket bolts - arrows -.

1. Tightening torque: 23 Nm.

1. Clean baffle and tighten it to final drive cover - arrows -.

1. Tightening torque: 10 Nm.

Scheme 1122

1. Replace O-ring - arrow - in final drive cover.
2. If necessary, replace flange seal for right flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Carefully install differential - arrow -.

1. Position final drive cover on transmission housing.
2. Tighten final drive cover bolts in 2 stages as follows

1. Tighten right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft using a pry bar.

1. Tightening torque: 23 Nm.

Automatic transmission 01V Front Wheel Drive

1. Attach coil spring - 3 - onto pinion shaft.
2. Attach axial needle bearing - 2 - and adjustment shim - 1 - onto input shaft.

1. Angled edge of axial needle bearing points toward adjustment shim.

1. Attach drive pinion - 2 - onto input shaft until stop.

1. Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 - , as marked when removed, to do so pull back drive pinion - 2 - from input shaft approx. 20 mm.

1. Check whether alignment sleeve - A - is inserted in front final drive cover.
2. Install new gasket.

Note. Apply thin coat of axle oil on sealing surface before installing gasket to avoid slipping of the gasket.

1. Tighten front final drive cover bolts in 2 stages as follows

Scheme 1123

Automatic transmission 01V All Wheel Drive

1. Completely cover splines on input shaft - arrow A - with insulating tape without creasing or overlapping the tape to prevent damage to gasket when sliding on drive pinion.

Note. Disregard - arrow B -.

1. Attach coil spring - 3 - onto pinion shaft.
2. Attach axial needle bearing - 2 - and adjustment shim - 1 - onto input shaft.

1. Angled edge of axial needle bearing points toward adjustment shim.

1. Replace shaft seal in drive pinion if necessary --> «Shaft seal in drive pinion, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__shaft-seal-in-drive-pinion-replacing) .

1. Attach drive pinion - 2 - onto input shaft until stop.

1. Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 - , as marked when removed, to do so pull back drive pinion - 2 - from input shaft approx. 20 mm.
2. If necessary, replace shaft seal for output flange/drive shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Scheme 1124

1. Check whether alignment sleeve - A - is inserted in intermediate flange for front final drive.
2. Install new gasket.

Note. Apply thin coat of axle oil on sealing surface before installing gasket to avoid slipping of the gasket.

1. Carefully place intermediate flange for front final drive.

1. Tighten front final drive intermediate flange bolts in 2 stages as follows

1. Check whether alignment sleeves - A - are inserted in front final drive intermediate flange.
2. Install new gasket.

Note. Apply thin coat of axle oil on sealing surface before installing gasket to avoid slipping of the gasket.

1. Slide cleaned solenoid in cast-on holding pocket - B - in front final drive intermediate flange.
2. Add 200 ml axle oil to Torsen differential.

1. Attach Torsen differential - arrow - onto input shaft.

1. Attach transfer case housing with installed spur gears and driveshaft input flange to transmission.
2. Tighten transfer case housing bolts in 2 stages as follows

Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive

1. Remove transmission from assembly stand.

1. Insert torque converter and secure against falling down with Bracket 30-211 A.
2. Check installation dimension of torque converter --> «32 - TORQUE CONVERTER»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Fill ATF and check ATF level --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Fill axle oil in front final drive and check oil level --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
3. Top off axle oil in transfer case and check oil level --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Torque specifications

Tower "I" , disassembling and assembling

Note. General repair notes --> General Repair Notes . Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on automatic transmissions . Lubricate O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting. Attach mount and adjustment shims only with Vaseline.

1. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.

Scheme 1125

1 - Clutch "D/G" with freewheel

2 - Clutch "F"

3 - Angle washer

4 - Axial needle bearing

5 - Thrust washer

6 - Planetary drive "III"

Tower "I" , disassembling

1. Remove lifting device T10287 from tower "I".

Scheme 1126

1. Remove clutch "D/G" - 2 - from clutch "F" - 1 -.

Scheme 1127

1. Remove clutch "F" - 5 - from planetary gear "III" - 1 -.

Note. Thrust washer - 2 - , axial needle bearing - 3 - and angle washer - 4 - remain on planetary drive "III".

Clutch "F" , component overview

Note. Clutch "F" is depicted in installed position. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check clutch components "F" for wear and damage --> Clutch "F" .

Scheme 1128

1 - Cylinder "F"

2 - O-ring

1. Replace

3 - Piston "F"

4 - O-ring

1. Replace

5 - Thrust piece

6 - Plate spring

7 - Split retaining ring

8 - Waved washer

9 - Outer plate

10 - Coated plate

11 - Circlip

Scheme 1129

Disassembling

1. Rotate clutch - F -.
2. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "F".

Scheme 1130

1. Press plate spring down under shop press using installation bracket T10289.
2. Remove split retaining ring - 1 -.
3. Release shop press.
4. Remove thrust piece and plate spring.

1. Position cylinder "F" on clutch "D/G" with freewheel.

Scheme 1131

1. Carefully press piston "F" with compressed air out of cylinder "F" as shown in illustration.

Assembling

Scheme 1132

1. Replace O-rings - 2 - and - 4 - for piston "F" - 3 -.
2. Press piston "F" - 3 - into cylinder "F" - 1 - as far as stop.
3. Place thrust piece - 5 -.
4. Position plate spring - 6 -.

7 - Split retaining ring

1. Press plate spring down under shop press using installation bracket T10289.
2. Install split retaining ring - 1 -.

1. Bent inner side at right angle of retaining ring faces downward.

1. Release shop press.

Scheme 1133

1. Insert waved washer - 2 - into cylinder "F" - 1 -.
2. Install outer plate - 3 - and coated plate - 4 - alternately.

Note. Ensure rounded edges of last outer clutch disc faces toward lining disc - 4 - and not toward circlip - 5 -. This improves circlip contact surface.

1. Insert circlip - 5 -.

Adjust clutch "F"

Scheme 1134

1. Place clutch "F" on pre-tensioning tool T10285.
2. Place plate T10292 on outer clutch disc "F".

1. Plate must not touch circlip all around.

1. Insert pressure unit T10285/1 with centering pin into bore of plate.
2. Align clutch "F" on plate of pre-tensioning tool.

1. The pressure unit must be centrally positioned under spindle thrust piece.

1. Turn spindle of pre-tensioning tool downward.

1. The markings at inspection hole of pressure unit must align - arrow -.

1. Apply Digital depth gauge VAS 6087 at upper edge of cylinder "F" , as depicted in illustration.
2. Apply measuring tongue on outer plate and note measuring value.
3. Mark contact point on cylinder "F".
4. Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

1. Average over 3 measured values under load.
2. Release spindle and remove plate.

Scheme 1135

1. Reach with both hands into clutch "F" and pull plate pack upward until stop.
2. When disc pack is pulled up, measure distance between upper edge of cylinder "F" and outer disc (2nd technician required) at one of the marked points.
3. Repeat measurement at 2 other marked points of outer plate.
4. Average over 3 measured values when plate pack is pulled up.

1. Determine air gap on basis of the following calculus

1. Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "F" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "F" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained

1. Determine new circlip - 1 - according to the following table.

Note. Disregard - 2 -. Air gap too small: Install respectively thinner circlip. Air gap too large: Install respectively thicker circlip.

1. Check air gap of circlip again after inserting.

Clutch "D/G" with freewheel, component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check components of freewheel, clutch "D" or clutch "G" for wear and damage --> Clutch "D/G" with freewheel .

Scheme 1136

1 - Freewheel inner race

2 - O-rings

1. Replace

3 - Rectangular rings

1. Replace

4 - Freewheel with freewheel housing

5 - Circlip

6 - Thick outer plates

7 - Coated plates

8 - Outer plates

9 - Waved washer

10 - Holding plate

11 - Plate spring

12 - O-ring

1. Replace

13 - Piston "D"

14 - O-ring

1. Replace

15 - Cylinder "D/G"

16 - O-ring

1. Replace

17 - Piston "G"

18 - O-ring

1. Replace

19 - Plate spring

20 - Thrust washer

21 - Circlip

22 - Waved washer

23 - Outer plates

24 - Coated plates

25 - Thick outer plate

26 - Circlip

Clutch "D/G" with freewheel, disassembling and assembling

Disassembling

1. Clutch "D" faces upward.

Scheme 1137

1. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".
2. Twist cylinder "D/G".

1. Clutch "G" faces upward (plate spring is visible).

Scheme 1138

1. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G".

Scheme 1139

1. Place cylinder "D/G" on thrust piece 3301/4 under shop press.
2. Press plate spring down under shop press using installation bracket T10289.
3. Remove circlip - 1 - , thrust washer and plate spring.
4. Release shop press.

Scheme 1140

1. Carefully press piston "G" out of cylinder "D/G" with compressed air.

Scheme 1141

1. Press freewheel inner race - 2 - out of cylinder "D/G" - 1 - - arrow - , loosen with light taps using a plastic hammer if necessary.
2. Remove cylinder "D/G" from freewheel.
3. Twist cylinder "D/G".

1. Cylinder "D" faces upward.

Scheme 1142

1. Carefully press piston "D" out of cylinder "D/G" with compressed air.

Scheme 1143

1. Disassemble freewheel

6 - Plate spring

5 - Holding plate

4 - Freewheel with freewheel housing

3 - Rectangular rings

2 - O-rings

1 - Freewheel inner race

Assembling

Scheme 1144

1. Replace O-rings - 2 - and - 4 - for piston "D" - 3 -.
2. Press piston "D" - 3 - into cylinder "D/G" - 1 - as far as stop.

Scheme 1145

1. Insert waved washer - 2 - into cylinder "D/G" - 1 -.
2. Install outer plate - 3 - and coated plate - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Adjust clutch "D" air gap

Scheme 1146

1. Place clutch "D/G" on pre-tensioning tool T10285.

1. Clutch "D" faces upward.

1. Place plate T10293 on outer clutch disc "D".

1. Plate must not touch circlip all around.

1. Insert pressure unit T10285/1 with centering pin into bore of plate.
2. Align clutch "D/G" on plate of pre-tensioning tool.

1. The pressure unit must be centrally positioned under spindle thrust piece.

1. Turn spindle of pre-tensioning tool downward.

1. The markings at inspection hole of the pressure unit must align - arrow -.

Scheme 1147

1. Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G" , as depicted in illustration.
2. Apply measuring tongue on outer plate and note measuring value.
3. Mark contact point on cylinder "D/G".
4. Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

1. Average over 3 measured values under load.
2. Release spindle and remove plate.
3. Reach with both hands into clutch "D" and pull plate pack upward until stop.
4. When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd technician required) at one of marked points.

1. Repeat measurement at 2 other marked points of outer plate.
2. Average over 3 measured values when plate pack is pulled up.
3. Determine air gap on basis of the following calculations

1. Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "D" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "D" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained

1. Determine new circlip - 1 - according to the following table.

Note. Disregard - 2 -. Air gap too small: Install respectively thinner circlip. Air gap too large: Install respectively thicker circlip.

1. Check air gap of circlip again after inserting.

1. After having determined correct circlip, remove circlip - 1 - and remove plate pack - 2 - from cylinder "D/G" again.

1. Replace O-rings - 2 - and rectangular rings - 3 - on freewheel inner race - 1 -.

4 - Freewheel with freewheel housing

5 - Holding plate

6 - Plate spring

1. Before inserting, thinly coat O-rings and rectangular rings with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
2. Make sure that rectangular rings are fully seated all around in freewheel inner race grooves.

Scheme 1148

1. Insert freewheel inner race - 2 - with freewheel housing until stop into freewheel - 1 - using turning motions in clockwise direction - arrows -.

Scheme 1149

1. Lay cylinder "D/G" - 1 - on 2 wood blocks in height of approx. 40 mm.

1. Cylinder "D" faces upward.

1. Insert dished washer - 2 - and holding plate - 3 - into cylinder "D/G".

1. Tabs on holding plate face cylinder "D/G".

1. Grasp freewheel - 4 - so that the freewheel inner race can no longer slip out and press inner race splines into splines of cylinder "D/G".

Scheme 1150

1. Twist cylinder "D/G" - 1 - , while doing so secure freewheel inner race against slipping out.

1. Cylinder "G" faces upward.

1. Place cylinder "D/G" on thrust piece 3301/4.
2. Replace O-rings - 2 - and - 4 - for piston "G" - 3 -.
3. Press piston "G" - 3 - into cylinder "D/G" until stop.
4. Place dished washer - 5 - and thrust washer - 6 -.

1. Teeth of thrust washer must engage into splines of freewheel inner race.

7 - Circlip

1. Place cylinder "D/G" on thrust piece 3301/4 under shop press.
2. Press plate spring down under shop press using installation bracket T10289.
3. Push thrust washer fully downward and insert circlip - 1 -.
4. Make sure that circlip is seated evenly all around in groove of freewheel inner race, if necessary, press circlip into groove all around using screwdriver.

1. Release shop press.
2. Press plate spring down again to check if freewheel is inserted correctly.

1. Thrust washer - 6 - --> in previous illustration "A37-10345" must be able to move.

Scheme 1151

1. Insert waved washer - 2 - into cylinder "D/G" - 1 -.
2. Install outer plate - 3 - and coated plate - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Adjust clutch "G" air gap

1. Clutch "G" faces upward.

Scheme 1152

1. Place clutch "D/G" on pre-tensioning tool T10285.
2. Place plate T10292 on outer clutch disc "G".

1. Plate must not touch circlip all around.

1. Insert pressure unit T10285/1 with centering pin into bore of plate.
2. Align clutch "D/G" on plate of pre-tensioning tool.

1. The pressure unit must be centrally positioned under spindle thrust piece.

1. Turn spindle of pre-tensioning tool downward.

1. The markings at inspection hole of the pressure unit must align - arrow -.

1. Apply Digital depth gauge VAS 6087 at upper edge of cylinder "D/G" , as depicted in illustration.
2. Apply measuring tongue on outer plate and note measuring value.
3. Mark contact point on cylinder "D/G".
4. Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

1. Average over 3 measured values under load.
2. Release spindle and remove plate.

Scheme 1153

1. Reach with both hands into clutch "G" and pull plate pack upward until stop.
2. When disc pack is pulled up, measure distance between upper edge of cylinder "D/G" and outer disc (2nd technician required) at one of the marked points.
3. Repeat measurement at 2 other marked points of outer plate.
4. Average over 3 measured values when plate pack is pulled up.

1. Determine air gap on the basis of the following calculations

1. Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "G" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "G" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained

1. Determine new circlip - 1 - according to the following table.

Note. Disregard - 2 -. Air gap too small: Install respectively thinner circlip. Air gap too large: Install respectively thicker circlip.

1. Twist clutch "D/G".

1. Clutch "D" faces upward.

1. Install plates for clutch "D" with newly determined circlip as follows

1. Insert waved washer - 2 - into cylinder "D/G" - 1 -.
2. Install outer plate - 3 - and coated plate - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Planetary drive "III" , component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check components of planetary gear for wear and damage --> Planetary drive "III" .

Scheme 1154

1 - Circlip

2 - Shaft

3 - Ring gear "III"

4 - Angle washer

5 - Axial needle bearing

6 - Thrust washer

7 - Planetary carrier "III"

Planetary drive "III" , disassembling and assembling

Disassembling

Scheme 1155

1. Remove ring gear "III" with shaft - 5 - from planetary carrier "III" - 1 -.
2. Remove angle washer - 4 - , axial needle bearing - 3 - and thrust washer - 2 -.

Assembling

1. Attach the following components onto shaft of planetary carrier "III" - 1

2 - Thrust washer

3 - Axial needle bearing

4 - Angle washer - angled edge points toward axial needle bearing

1. Position ring gear "III" with shaft - 5 - on planetary carrier "III" - 1 -.

Tower "I" , assembling

1. Place planetary drive "III" - 1 - in mounting device T10282.
2. Lay thrust washer - 2 - , axial needle bearing - 3 - and angle washer - 4 - on planetary drive "III" - item 1 -.

1. Angled edge of angle washer faces planetary drive "III".

1. Attach clutch "F" "item 5" onto disc carrier of planetary gear - III - - 1 - , using short lifting/turning motions.

1. All clutch discs "F" must engage one after another in planetary drive disc carrier "III".

1. Check whether all plates are engaged, to do so lift clutch "F" a few millimeters and let fall.

1. If this produces a metallic sound, all plates are engaged.
2. If only a muted sound is heard, not all plates are engaged.

1. Place clutch "D/G" - 2 - onto plate carrier on clutch "F" - 1 - , using short lifting/turning motions.

1. All clutch discs "G" must engage in sequence in plate carrier of clutch "F".

1. Check whether all plates are engaged, to do so lift clutch "D/G" a few millimeters and let fall.

1. If this produces a metallic sound, all plates are engaged.
2. If only a muted sound is heard, not all plates are engaged.

Install lifting device T10287 as follows

1. Turn back knurled nut of lifting device.
2. Insert lifting device into tower "I" until stop.
3. Tighten knurled nut of lifting device in clockwise direction.
4. Check lifting device in tower "I" for proper seating.

Tower "II" , disassembling and assembling

Note. General repair notes --> General Repair Notes . Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on automatic transmissions . Lubricate O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting. Attach mount and adjustment shims only with Vaseline.

1. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.

Scheme 1156

1 - Clutch "E"

2 - O-ring

1. Replace

3 - Clutch "A"

4 - Circlip

5 - Axial needle bearing

6 - Clutch "B"

7 - Adjustment shim

1. Determine thickness --> (Scheme 1118)

8 - Rectangular rings

1. Replace

Tower "II" , disassembling

1. If not carried out yet, remove adjustment shim - 2 - from clutch "B" - 1 -.

Scheme 1157

1. Remove clutch "B" - 3 - and axial needle bearing - 2 - from clutch "A" - 1 -.

Scheme 1158

1. Remove circlip - 2 - from input shaft - 1 -.

Scheme 1159

1. Place clutch "A" - 1 - with outer edges on 2 wood blocks, approx. 40 mm high.
2. Tap on input shaft - 2 - with clutch "E" using plastic hammer.
3. Remove clutch "A" from clutch "E".

Clutch "B" , component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check components of clutch "B" for wear and damage --> Clutch "B" .

Scheme 1160

1 - Adjustment shim

2 - Cylinder "B"

3 - O-ring

1. Replace

4 - Piston "B"

5 - O-ring

1. Replace

6 - Plate spring

7 - Split retaining ring

1. Bent side at right angle faces dished washer

8 - Waved washer

9 - Outer plate

10 - Coated plate

11 - Thick outer plate

12 - Circlip

1. Determining thickness «Available circlips - thickness in mm»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Clutch "B" , disassembling and assembling

Disassembling

1. Rotate clutch "B".

Scheme 1161

1. Remove circlip - 1 - and remove disc pack - 2 - from cylinder "B".

Scheme 1162

1. Press plate spring down under shop press using installation bracket T10289.
2. Remove split retaining ring - 1 -.

Scheme 1163

1. Remove dished washer - 5 -.
2. Release shop press.

Scheme 1164

1. Carefully press piston "B" out of cylinder "B" with compressed air, to do so plug free oil bore using finger.

Assembling

1. Replace O-rings - 2 - and - 4 - for piston "B" - 3 -.
2. Press piston "B" - 3 - into cylinder "B" - 1 - as far as stop.
3. Position plate spring - 5 -.

6 - Split retaining ring

1. Press plate spring down under shop press using installation bracket T10289.
2. Install split retaining ring - 1 -.
3. Release shop press.

Scheme 1165

1. Insert waved washer - 2 - into cylinder "B" - 1 -.
2. Install outer plate - 3 - and coated plate - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Adjust clutch "B" air gap

Scheme 1166

1. Place clutch "B" on pre-tensioning tool T10285.
2. Place plate T10294 on outer clutch disc "B".

1. Plate must not touch circlip all around.

1. Insert pressure unit T10285/1 with centering pin into bore of plate.
2. Align clutch "B" on plate of pre-tensioning tool.

1. The pressure unit must be centrally positioned under spindle thrust piece.

1. Turn spindle of pre-tensioning tool downward.

1. The markings at the inspection hole of the pressure unit must align - arrow -.

1. Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
2. Apply measuring bar at upper edge of cylinder "B" , as depicted in illustration.
3. Check whether measuring bar makes proper contact at edge of cylinder "B".
4. Position measuring tip on outer plate and note measuring value.

1. Mark exact contact point on cylinder "B".
2. Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.
3. Average over 3 measured values under load.
4. Release spindle and remove plate.

1. Reach with both hands into clutch "B" and pull plate pack upward until stop.
2. When disc pack is pulled up, measure exact distance between upper edge of cylinder "B" and outer disc (2nd technician required) at one of the marked points.
3. Repeat measurement at 2 other marked points of outer plate.
4. Average over 3 measured values when plate pack is pulled up.

1. Determine air gap on the basis of the following calculations

1. Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "B" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "B" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained

1. Determine new circlip - 1 - according to the following table.

Note. Disregard - 2 -. Air gap too small: Install respectively thinner circlip. Air gap too large: Install respectively thicker circlip.

Available circlips - thickness in mm

1. Check air gap of circlip again after inserting.

Clutch "A" , component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check clutch components "A" for wear and damage --> Clutch "A" .

Scheme 1167

1 - Circlip

1. Replace
2. Do not over-stretch circlip when installing.

2 - Adjustment shim

1. Determining thickness --> (Scheme 1118)

3 - O-ring

1. Replace

4 - Ring

5 - Cylinder "A"

6 - O-ring

1. Replace

7 - Green O-ring

1. Replace

8 - Piston "A"

9 - O-ring

1. Replace

10 - Plate spring

11 - Split retaining ring

1. Bent side at right angle faces dished washer

12 - Waved washer

1. Equipment depends on version

13 - Outer plate

14 - Coated plate

15 - Thick outer plate

16 - Circlip

1. Determining thickness --> «Available circlips - thickness in mm»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Clutch "A" , disassembling and assembling

Disassembling

1. Rotate clutch "A".

Scheme 1168

1. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "A".

Scheme 1169

1. Press plate spring down under shop press using installation bracket T10276.
2. Remove split retaining ring - 1 -.
3. Release shop press.
4. Remove dished washer.

Scheme 1170

1. Press ring - 2 - with O-ring - 3 - out of cylinder "A" - 1 -.

Scheme 1171

1. Carefully press piston "A" out of cylinder "A" with compressed air, to do so plug two other oil bores using fingers.

Assembling

Scheme 1172

1. Replace O-rings - 2 - (green), - 3 - (black) and - 5 - (black) for piston "A" - 4 -.
2. Press piston "A" - 4 - into cylinder "A" - 1 - as far as stop.
3. Position plate spring - 6 -.

7 - Split retaining ring

1. Press plate spring down under shop press using installation bracket T10276.
2. Install split retaining ring - 1 -.

1. Bent inner side at right angle of retaining ring faces downward.

1. Release shop press.

Scheme 1173

1. Insert waved washer - 2 - into cylinder "A" - 1 -.
2. Install outer plate - 3 - and coated plate - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Scheme 1174

Adjust clutch "A" air gap

1. Place clutch "A" on pre-tensioning tool T10285.
2. Place plate T10293 on outer clutch disc "A".

1. Plate must not touch circlip all around.

1. Insert pressure unit T10285/1 with centering pin into bore of plate.
2. Align clutch "A" on plate of pre-tensioning tool.

1. The pressure unit must be centrally positioned under spindle thrust piece.

1. Turn spindle of pre-tensioning tool downward.

1. The markings at the inspection hole of the pressure unit must align - arrow -.

1. Apply Digital depth gauge VAS 6087 at upper edge of cylinder "A" , as depicted in illustration.
2. Apply measuring tongue on outer plate and note measuring value.
3. Mark contact point on cylinder "A".
4. Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

1. Average over 3 measured values under load.
2. Release spindle and remove plate.

Scheme 1175

1. Reach with both hands into clutch "A" and pull plate pack upward until stop.
2. When disc pack is pulled up, measure distance between upper edge of cylinder "A" and outer disc (2nd technician required) at one of the marked points.
3. Repeat measurement at 2 other marked points of outer plate.
4. Average over 3 measured values when pate pack is pulled up.

1. Determine air gap on basis of the following calculations

1. Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "A" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "A" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained

1. Determine new circlip - 1 - according to the following table.

Note. Disregard - 2 -. Air gap too small: Install respectively thinner circlip. Air gap too large: Install respectively thicker circlip.

Available circlips - thickness in mm

1. Check air gap of circlip again after inserting.

1. Replace O-ring - 3 - on ring - 2 -.
2. Press ring into cylinder "A" - 1 - until stop.

Clutch "E" , component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check components of clutch "E" for wear and damage --> Clutch "E" .

Scheme 1176

1 - Rectangular rings

1. Replace

2 - O-ring

1. Replace

3 - Cylinder "E"

4 - O-ring

1. Replace

5 - Piston "E"

6 - O-ring

1. Replace

7 - Plate spring

8 - O-ring

1. Replace

9 - Diaphragm plate

10 - Circlip

1. Replace
2. Do not over-stretch circlip when installing.

11 - Waved washer

12 - Outer plates

13 - Coated plates

14 - Thick outer plate

15 - Circlip

1. Determining thickness --> «Available circlips - thickness in mm»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Clutch "E" , disassembling and assembling

Disassembling

Scheme 1177

1. Place clutch "E" - 1 - in mounting device T10283.

Scheme 1178

1. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "E".

Scheme 1179

1. Press diaphragm plate down under shop press using installation bracket T10276.
2. Remove circlip - 1 -.
3. Release shop press.

Scheme 1180

1. Remove diaphragm plate - 7 -.
2. Remove dished washer - 5 -.
3. Twist cylinder "E".

Scheme 1181

1. Carefully press piston "E" out of cylinder "E" with compressed air.

Assembling

1. Replace O-rings - 2 - and - 4 - for piston "E" - 3 -.
2. Press piston "E" - 3 - into cylinder "E" - 1 - as far as stop.
3. Insert dished washer - 5 -.
4. Replace O-ring - 6 - on diaphragm plate - 7 -.

1. Insert diaphragm plate - 7 - into cylinder "E" - 1 -.

8 - Circlip

1. Press diaphragm plate down under shop press using installation bracket T10276.
2. Insert new circlip - 1 -.

1. Release shop press.

1. Insert waved washer - 2 - into cylinder "E" - 1 -.
2. Install outer plates - 3 - and coated plates - 4 - alternately.
3. Install thick outer plates - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Scheme 1182

Adjust clutch "E" air gap

1. Secure pre-tensioning tool T10285 with wide base in vise.
2. Install clutch "E" in pre-tensioning tool.

1. Input shaft projects through bore in base plate.

1. Place plate T10291 on outer clutch disc "E".

1. Plate must not touch circlip all around.

1. Insert pressure unit T10285/1 with centering pin into bore of plate.
2. Align clutch "E" on plate of pre-tensioning tool.

1. The pressure unit must be centrally positioned under spindle thrust piece.

1. Turn spindle of pre-tensioning tool downward.

1. The markings at the inspection hole of the pressure unit must align - arrow -.

1. Insert dial gauge VAS 6080 into measuring bar VW 382/7 and tighten knurled nut.
2. Apply measuring bar at upper edge of cylinder "E" , as depicted in illustration.
3. Check whether measuring bar makes proper contact at edge of cylinder "E".
4. Position measuring tip on outer plate and note measuring value.

1. Mark exact contact point on cylinder "E".
2. Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.
3. Average over 3 measured values under load.
4. Release spindle and remove plate.

Scheme 1183

1. Reach with both hands into clutch "E" and pull plate pack upward until stop.
2. When disc pack is pulled up, measure distance between upper edge of cylinder "E" and outer disc (2nd technician required) at one of the marked points.
3. Repeat measurement at 2 other marked points of outer plate.
4. Average over 3 measured values when plate pack is pulled up.

1. Determine air gap on the basis of the following calculations

1. Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "E" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "E" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained

1. Determine new circlip - 1 - according to the following table.

Note. Disregard - 2 -. Air gap too small: Install respectively thinner circlip. Air gap too large: Install respectively thicker circlip.

Available circlips - thickness in mm

1. Check air gap of circlip again after inserting.

Scheme 1184

1. Replace rectangular rings - 3 - and O-ring - 2 - on input shaft at clutch "E" - 1 -.
2. Before inserting, thinly coat rectangular rings - 3 - and O-ring - 2 - with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
3. Make sure that rectangular rings - 3 - are fully seated all around in the input shaft groove.

Scheme 1185

1. Press clutch "A" - 2 - onto clutch "E" - 1 - until stop.

1. Install circlip - 2 - on input shaft - 1 -.

1. Place axial needle bearing - 2 - onto clutch "A" - 1 -.
2. Attach clutch "B" - 3 - onto disc carrier of clutch "A" , using short lifting/turning motions.

1. All clutch discs "B" must engage in sequence in plate carrier of clutch "A".

1. Check whether all plates are engaged, to do so lift clutch "B" a few millimeters and let fall.

1. If this produces a metallic sound, all plates are engaged.
2. If only a muted sound is heard, not all plates are engaged.

1. Place adjustment shim - 2 - onto clutch "B" - 1 -.

Clutch "C" , disassembling and assembling

Note. General repair notes --> General Repair Notes . Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on automatic transmissions . Lubricate O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting. Attach mount and adjustment shims only with Vaseline.

1. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.

Clutch "C" , component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check components of clutch "C" for wear and damage --> Clutch "C" .

Scheme 1186

1 - ATF pump

1. Disassembling --> «ATF pump, component overview»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__atf-pump-component-overview)

2 - O-ring

1. Replace

3 - Piston "C"

4 - O-ring

1. Replace

5 - Plate spring

6 - Split retaining ring

7 - Waved washer

8 - Outer plates

9 - Coated plates

10 - Thick outer plate

11 - Circlip

1. Determining thickness --> «Available circlips - thickness in mm»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Disassembling

1. Twist ATF pump.

Scheme 1187

1. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "C".

Scheme 1188

1. Press plate spring down under shop press using installation bracket T10289.
2. Remove split retaining ring - 1 -.
3. Release shop press.

Scheme 1189

1. Remove dished washer - 5 -.

Scheme 1190

1. Carefully press piston "C" out of ATF pump with compressed air.

Assembling

1. Replace O-rings - 2 - and - 4 - for piston "C" - 3 -.
2. Press piston "C" - 3 - into ATF pump - 1 - until stop.
3. Position plate spring - 5 -.

6 - Split retaining ring

1. Press plate spring down under shop press using installation bracket T10289.
2. Install split retaining ring - 1 -.

1. Bent inner side at right angle of retaining ring faces downward.

1. Release shop press.

Scheme 1191

1. Insert waved washer - 2 - into cylinder "B" - 1 -.
2. Install outer plates - 3 - and coated plates - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Adjust clutch "C" air gap

Scheme 1192

1. Secure pre-tensioning tool T10285 with wide base in vise.
2. Place ATF pump on pre-tensioning tool.

1. Stator shaft projects through bore in base plate.

1. Place plate T10295 on outer clutch disc "C".

1. Plate must not touch circlip all around.

1. Insert pressure unit T10285/1 with centering pin into bore of plate.
2. Align ATF pump on plate of pre-tensioning tool.

1. The pressure unit must be centrally positioned under spindle thrust piece.

1. Turn spindle of pre-tensioning tool downward.

1. The markings at inspection hole of the pressure unit must align - arrow -.

1. Apply Digital depth gauge VAS 6087 at upper edge of outer plate carrier "C" , as depicted in illustration.
2. Apply measuring tongue on outer plate and note measuring value.
3. Mark contact point on outer plate carrier "C".
4. Repeat measurement at 2 other points of outer plate, 120° offset each, and mark contact points.

1. Average over 3 measured values under load.
2. Release spindle and remove plate.

Scheme 1193

1. Reach with both hands into clutch "C" and pull plate pack upward until stop.
2. When disc pack is pulled up, measure distance between upper edge of outer disc carrier "C" and outer disc (2nd technician required) at one of the marked points.
3. Repeat measurement at 2 other marked points of outer plate.
4. Average over 3 measured values when plate pack is pulled up.

1. Determine air gap on the basis of the following calculations

1. Subtract average of measured values when plate pack is pulled up from average of measured values under load.

Clutch "C" air gap - Automatic Transmission 01V Front Wheel Drive

Clutch "C" air gap - Automatic Transmission 01V All Wheel Drive

If specified value is not obtained

1. Determine new circlip - 1 - according to the following table.

Note. Disregard - 2 -. Air gap too small: Install respectively thinner circlip. Air gap too large: Install respectively thicker circlip.

Available circlips - thickness in mm

1. Check air gap of circlip again after inserting.

ATF pump, disassembling and assembling

Note. General repair notes --> General Repair Notes . Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on automatic transmissions . Lubricate O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting. Attach mount and adjustment shims only with Vaseline.

1. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.

ATF pump, component overview

Note. Some of the depicted components are part of component groups and are not available separately as replacement part . Before assembling, check components of ATF pump for wear and damage --> ATF supply . Before assembling, check components of clutch "C" for wear and damage --> Clutch "C" .

Scheme 1194

1 - Shaft seal

1. Replace

2 - Locking washer

3 - O-ring

1. Replace

4 - ATF pump housing

5 - Ring gear

6 - ATF pump wheel

7 - Positioning sleeve

8 - Intermediate panel

9 - O-ring

1. Replace

10 - ATF pump housing

11 - Outer lamella carrier "C"

12 - Recessed bolt

1. Tightening sequence Tighten ATF pump screws as follows: under «ATF supply housing with stator shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__atf-supply-housing-with-stator-shaft)

13 - Bolt

1. Tightening sequence Tighten ATF pump screws as follows: under «ATF supply housing with stator shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__atf-supply-housing-with-stator-shaft)

14 - Stator shaft

1. Removing and installing --> «Stator shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__stator-shaft-removing-and-installing)

15 - Recessed bolt

1. Tightening sequence Tighten ATF pump screws as follows: under «ATF supply housing with stator shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__atf-supply-housing-with-stator-shaft)

16 - Rectangular rings

1. Replace

17 - Rectangular ring

1. Replace

18 - Axial needle bearing

ATF pump (with assembled transmission), completely removing and installing

Removing

1. Transmission attached to assembly stand --> «Transmission, attaching assembly stand»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__transmission-attaching-assembly-stand) .

1. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

1. Remove ATF drain plug - 1 - and allow ATF to drain.

Note. Observe disposal regulations. Rest of ATF remains in the ATF oil pan.

1. Remove torque converter.

1. Remove right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft using a pry bar.
2. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
3. Pull out right flange shaft.

1. Loosen final drive cover bolts in sequence - 12 to 1 - and then remove completely.

1. Remove final drive cover.

1. Carefully remove differential - arrow -.

1. Completely cover splines - arrow - on left flange shaft with insulating tape without wrinkling or overlapping to avoid damaging final drive/transmission housing double shaft seal when removing left flange shaft.

1. Remove left drive flange mounting bracket - arrows -.
2. Pull out left drive flange.

Note. When sliding off, left drive flange must be carefully guided by hand to prevent damage to the double seal in final drive/transmission housing.

1. Loosen ATF oil pan bolts - arrow - in a diagonal sequence and then remove them completely.
2. Remove ATF oil pan.

1. Remove ATF screen bolts - arrows -.
2. Pull ATF filter off of valve body.

1. Remove circlip - arrow - for wiring harness/harness connector.
2. Remove wiring harness/harness connector by pressing inward.

1. Remove bolt - arrow - and remove Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

1. In a transmission with hydraulic control "E18/2" , disengage electrical connector to Transmission Input Speed (RPM) Sensor G182 at valve body - arrow - and disconnect connector.

1. Loosen valve body bolts - 17 to 1 - in sequence and remove them completely.

1. Carefully remove valve body from transmission.

1. Pull sealing sleeves - arrows - in inlet bores toward clutches "C" , "A" , "B" , "E" and toward torque converter clutch using extracting handle T10271.

1. Remove 3 securing rings - 1 -.
2. Remove coil springs - 2 -.
3. Pull out sealing sleeves - 3 - , using extracting handle T10271.
4. Rotate transmission on assembly stand.

1. ATF pump faces upward.

1. Loosen ATF pump bolts in - 9 to 1 - sequence and remove them completely.
2. Remove bolts with sealing washers.

1. Secure puller for ATF supply T10286 to stator shaft and pull ATF supply firmly upward.

If ATF pump cannot be loosened

1. On the bottom side of the transmission, place a screwdriver between sun gear "I" and ribbed cup and pry component above sun gear upward - arrow -.

Installing

1. Check if tower "II" is still inserted correctly.
2. Measure distance between contact surface for adjustment shim on tower "II" and contact surface for ATF pump on transmission housing.

1. Dimension - a - = at least 6.0 mm.
2. Adjustment shim may not be installed.

If dimension - a - is exceeded, the tower "II" would be pulled out of disc contact during removal.

1. Remove tower "II" and then reinstall Lift tower under «Planetary gear, disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing) .

1. Place previous adjustment shim - 1 - on plate carrier "C".

1. Replace 2 rectangular rings on input shaft.
2. Before inserting, thinly coat rectangular rings on input shaft with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
3. Make sure that rectangular rings are fully seated all around in the input shaft groove.

1. Thinly coat back side of axial needle bearing - 2 - with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
2. Append axial needle bearing to ATF pump - 1 -.

1. Closed side of axial needle bearing faces toward ATF pump.

1. Replace rectangular rings - 3 - and - 4 - on stator shaft.
2. Before inserting, lightly coat rectangular ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
3. Make sure that rectangular rings are fully seated all around in the stator shaft groove.

1. Engage ends of installed rectangular rings - arrows - , as depicted in illustration.

1. Replace O-ring - 1 - on ATF supply.
2. Thinly coat O-ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.

1. Align coated plates - 3 - of clutch "C" using centering tool T10288/1 , to do so let pins - 2 - and - 4 - engage in splines of all coated plate.
2. Align lining discs to ATF pump housing by inserting centering pins - 1 - and - 5 - into appropriate holes on ATF pump.

1. Centering pins fit only in one position.

1. Hold centering tool in this position and insert wedge T10288/2 from side between waved washer and piston "F" - arrow -.

1. Wedge must secure all plates in current position.

1. Remove centering tool T10288/1 , wedge T10288/2 remains inserted.

1. Align plate carrier for clutch "C" using centering tool T10288/3 , install guide pins T10288/4 into transmission housing.

1. Bores of centering tool and transmission housing only fit in one position.

1. Carefully remove centering tool T10288/3 upward, guide pins T10288/4 remain in transmission housing.

1. Plate carrier for clutch "C" may no longer be turned.

1. Attach puller for ATF supply T10286 at stator shaft.
2. Bring ATF supply to installation position.

1. Recess for flange shaft faces toward valve body side.

1. Attach ATF supply with corresponding bores onto guide pins T10288/4.
2. Carefully insert ATF supply into transmission housing and push forcefully.
3. Bring ATF supply to final installation position by alternately tightening two opposing attachment bolts each.

1. Remove wedge 10288/2 using hook 3438.
2. Remove Puller for ATF supply T10286.
3. Remove guide pins T10288/4.

1. Insert ATF pump bolts with new sealing washers into ATF pump housing.
2. Tighten ATF pump bolts - 1 to 9 - in sequence.

1. Tightening torque: 10 Nm.

Note. Check for correct ATF pump installation: You must be able to rotate the input shaft. Otherwise, the last clutch plate "C" may have been pinched during installation and bent. In this case, remove ATF pump again and check discs for damage.

1. Attach Dial gauge VAS 6080 with Dial gauge holder VW 387 to transmission flange.
2. Insert Dial gauge VAS 6080 with dial gauge extension onto input shaft of transmission, as depicted in illustration.
3. Set dial gauge to "0".
4. To protect against damage, cover input shaft with insulating tape.

1. Move input shaft up and down using pliers, while doing so avoid lateral movement.
2. Read input shaft axial clearance on dial gauge.

1. Specified value: 0.10 to 0.30 mm.

If specified value is not obtained

1. Remove ATF pump again.

1. Determine correct adjustment shim - 2 - on tower "II" item - 1 - according to the following table.

1. Measured axial clearance too small: Install respectively thinner shim.
2. Measured axial clearance too large: Install respectively thicker shim.

1. Reinstall ATF pump with new adjustment shim, new sealing washers and new O-ring. (Scheme 1111)
2. Check axial clearance of input shaft again --> (Scheme 1118).

If specified value is again not obtained

1. Repeat adjustment.

If specified value is obtained

1. Rotate transmission on assembly stand.

1. Valve body side points upward.

1. Press sealing sleeves - 3 - into transmission housing holes to stop.
2. Insert coil springs - 2 - and secure with circlips - 1 - by pressing circlips into hole down to shoulder.

1. Position valve body on transmission housing without force while inserting notched disc pins - 1 - into selector slide groove - 2 -.
2. Position valve body bolts.

Note. Note different length of bolts.

1. Bolt - 6 - is only present on transmissions with hydraulic control "E17".
2. On a transmission with hydraulic control "E18/2" , ensure electrical wire to Transmission Input Speed (RPM) Sensor G182 is not pinched between transmission housing and valve body.

1. Tighten valve body bolts in 2 stages as follows

1. Replace O-rings for wiring harness/harness connector.
2. Connect wiring harness connector - arrow - to transmission housing.

1. Installation position: Retainers - 1 - and - 2 - at collar are horizontal, leveled side - arrow - of connector must be parallel to ATF oil pan sealing surface.

1. Position wiring harness connector securing clip - arrow - and ensure it locks securely.

1. Tighten bolt - arrow - for Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

1. Tightening torque: 10 Nm.

1. With a transmission with hydraulic control "E18/2" , connect electrical connector to Transmission Input Speed (RPM) Sensor G182.
2. Clip electrical harness connector into valve body mount - arrow -.
3. Replace ATF filter.

1. Position ATF filter on valve body and tighten - arrows -.

1. Tightening torque: 5 Nm.

Note. Clean magnets (6x) in ATF oil pan. Ensure full surface contact of the magnets in the ATF oil pan.

1. Install ATF oil pan - arrow - with new seal.
2. Tighten bolts for ATF oil pan in diagonal sequence in stages.

1. Tightening torque: 10 Nm.

1. If necessary, replace flange seal for left flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Replace O-ring - arrow B - in mounting bracket for left flange shaft.

Note. Disregard - arrow A -.

1. Replace final drive/transmission housing double shaft seal if necessary --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Completely cover splines - arrow - on left flange shaft with insulating tape without wrinkling or overlapping to avoid damaging final drive/transmission housing double shaft seal when installing flange shaft.
2. Insert left flange shaft into transmission.

Note. When sliding on, left drive flange must be carefully guided by hand to prevent damage to the double seal in final drive/transmission housing.

1. Tighten left flange shaft mounting bracket bolts - arrows -.

1. Tightening torque: 23 Nm.

1. Replace O-ring - arrow - in final drive cover.
2. If necessary, replace flange seal for right flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Carefully install differential - arrow -.

1. Position final drive cover on transmission housing.
2. Tighten final drive cover bolts in 2 stages as follows

1. Tighten right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft using a pry bar.

1. Tightening torque: 23 Nm.

1. Remove transmission from assembly stand.

1. Insert torque converter and secure against falling down with Bracket 30-211 A.
2. Check installation dimension of torque converter --> «32 - TORQUE CONVERTER»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
3. Fill ATF and check ATF level --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
4. Fill axle oil in front final drive and check oil level --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Top off axle oil in transfer case and check oil level --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Torque specifications

ATF pump and ATF supply housing, removing and installing

Removing

1. ATF supply removed.

1. Twist ATF pump.

1. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "C".

1. Press plate spring down under shop press using installation bracket T10289.
2. Remove split retaining ring - 1 -.
3. Release shop press.

1. Remove dished washer - 5 -.

1. Carefully press piston "C" out of ATF pump with compressed air.

Scheme 1195

1. Remove bolts - 3 to 10 -.
2. Remove bolts - 1 - and - 2 - approx. 5 rotations.

Scheme 1196

1. Attach TORX socket with extension - 1 - onto head bolt, as depicted in illustration.
2. Loosen ATF pump by lightly tapping on two bolts alternately using a plastic hammer - arrow -.
3. Remove remaining 2 bolts.
4. Remove ATF supply housing.

Scheme 1197

1. Remove intermediate plate - 5 - and positioning sleeve - 6 -.
2. Remove ATF pump wheels - 3 - and - 4 - from ATF pump housing - 2 -.

1 - O-ring

Installing

1. Replace O-ring - 1 - on ATF pump housing.
2. Install ATF pump wheels - 3 - and - 4 - in ATF pump housing - 2 -.

1. Markings (points) on ATF pump wheels point toward intermediate panel - 5 -.

1. Place intermediate panel and insert positioning sleeve - 6 -.

1. Positioning sleeve engages in rectangular bore on intermediate panel.

Scheme 1198

1. Turn in guide pins T10288/4 in 2 bores of ATF pump housing that are opposite to each other.
2. Attach ATF pump housing onto ATF pump.

1. Tighten ATF pump bolts in 2 stages as follows

1. Replace O-rings - 2 - and - 4 - for piston "C" - 3 -.
2. Press piston "C" - 3 - into ATF pump - 1 - until stop.
3. Position plate spring - 5 -.

6 - Split retaining ring

1. Press plate spring down under shop press using installation bracket T10289.
2. Install split retaining ring - 1 -.

1. Bent inner side at right angle of retaining ring faces downward.

1. Release shop press.

1. Insert waved washer - 2 - into cylinder "C" - 1 -.
2. Install outer plates - 3 - and coated plates - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Note. If plate pack of clutch "C" was replaced, air gap must be adjusted again Adjust clutch under Clutch "C" , disassembling and assembling .

ATF supply housing with stator shaft, removing and installing

Removing

1. ATF supply removed.

1. Twist ATF pump.

1. Remove circlip - 1 - and remove plate pack - 2 - from cylinder "C".

1. Press plate spring down under shop press using installation bracket T10289.
2. Remove split retaining ring - 1 -.
3. Release shop press.

1. Remove dished washer - 5 -.

1. Carefully press piston "C" out of ATF pump with compressed air.

Scheme 1199

1. Remove bolts - 1 to 3 -.

Scheme 1200

1. Remove outer plate carrier "C" - 2 - from ATF pump housing - 1 -.

1. Remove bolts - 6 to 13 -.
2. Remove bolts - 4 - and - 5 - approx. 5 rotations.

Scheme 1201

1. Attach TORX socket with extension - 1 - onto head bolt, as depicted in illustration.
2. Loosen ATF pump by lightly tapping on two bolts alternately using a plastic hammer - arrow -.
3. Remove remaining 2 bolts.
4. Remove ATF supply housing.

1. Remove intermediate plate - 5 - and positioning sleeve - 6 -.
2. Remove ATF pump wheels - 3 - and - 4 - from ATF pump housing - 2 -.

1 - O-ring

Installing

1. Replace O-ring - 1 - on ATF pump housing.
2. Install ATF pump wheels - 3 - and - 4 - in ATF pump housing - 2 -.

1. Markings (points) on ATF pump wheels point toward intermediate panel - 5 -.

1. Place intermediate panel and insert positioning sleeve - 6 -.

1. Positioning sleeve engages in rectangular bore on intermediate panel.

1. Turn in guide pins T10288/4 in 2 bores of ATF pump housing that are opposite to each other.

1. Attach ATF pump housing onto ATF pump.
2. Tighten ATF pump screws as follows

1. Hand-tighten outer disc carrier "C" - 2 - to ATF supply housing - 1 -.

1. Outer disc carrier "C" must be able to slide onto ATF supply housing.

1. Replace O-rings - 2 - and - 4 - for piston "C" - 3 -.
2. Press piston "C" - 3 - into ATF pump - 1 - until stop.

5 - Plate spring

6 - Split retaining ring

1. Tighten outer disc carrier bolts "C" and ATF pump with inserted piston "C" in 2 additional stages as follows

1. Position plate spring.
2. Press plate spring down under shop press using installation bracket T10289.
3. Install split retaining ring - 1 -.

1. Bent inner side at right angle of retaining ring faces downward.

1. Release shop press.

1. Insert waved washer - 2 - into cylinder "C" - 1 -.
2. Install outer plates - 3 - and coated plates - 4 - alternately.
3. Install thick outer plate - 5 -.

Note. Ensure rounded edges of thick outer clutch disc faces toward lining disc - 4 - and not toward circlip - 6 -. This improves circlip contact surface.

1. Insert circlip - 6 -.

Note. If plate pack of clutch "C" was replaced, air gap must be adjusted again Adjust clutch under Clutch "C" , disassembling and assembling .

Stator shaft, removing and installing

Removing

1. ATF pump removed from ATF supply housing --> «ATF pump and ATF supply housing, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__atf-pump-and-atf-supply-housing) .

Scheme 1202

1. Remove bolts - arrows -.

Scheme 1203

1. Warm ATF supply housing area around stator shaft to approx. 70° C with a hot air gun.
2. Press stator shaft under shop press with a suitable drift - 1 -.

Installing

Scheme 1204

1. Install guide pin M6 T10288/4 and position stator shaft.
2. Warm ATF supply housing area around stator shaft to approx. 70° C with a hot air gun.
3. Press stator shaft in under shop press using a suitable drift.

1. Tighten bolts - arrows -.

1. Tightening torque: 10 Nm.

ATF pump shaft seal, replacing

Work procedure

1. ATF pump removed from ATF supply housing --> «ATF pump and ATF supply housing, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__atf-pump-and-atf-supply-housing) .

Note. Attach screwdriver only at shaft seal but not at locking washer lying underneath.

Scheme 1205

1. Pry off shaft seal using screwdriver - arrow -.
2. Check locking washer lying underneath for damage.

Scheme 1206

1. Drive in new shaft seal to stop using thrust piece 3295.

Installed transmission, servicing

Note. General repair notes --> General Repair Notes . Observe the rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on automatic transmissions .

Valve body, removing and installing

Removing

1. Remove ATF oil pan --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Remove ATF filter bolts - arrows -.
2. Pull ATF filter off of valve body.

1. Remove circlip - arrow - for wiring harness/harness connector.
2. Remove wiring harness/harness connector by pressing inward.

1. Remove bolt - arrow - and remove Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

1. In a transmission with hydraulic control "E18/2" , disengage electrical connector to Transmission Input Speed (RPM) Sensor G182 at valve body - arrow - and disconnect connector.

1. Loosen valve body bolts - 17 to 1 - in sequence and remove them completely.

1. Remove valve body from transmission while guiding wiring connector back.

Installing

Install in reverse order of removal, note the following

Note. Replace dirty or faulty valve body.

1. Position valve body on transmission housing without force while inserting notched disc pins - 1 - into selector slide groove - 2 -.
2. Position valve body bolts.

Note. Note different length of bolts.

1. Bolt - 6 - is only present on transmissions with hydraulic control "E17".
2. On a transmission with hydraulic control "E18/2" , ensure electrical wire to Transmission Input Speed (RPM) Sensor G182 is not pinched between transmission housing and valve body.

1. Tighten valve body bolts in 2 stages as follows

1. Replace O-rings for wiring harness/harness connector.

1. Connect wiring harness connector - arrow - to transmission housing.

1. Installation position: Retainers - 1 - and - 2 - at collar are horizontal, leveled side - arrow - of connector must be parallel to ATF oil pan sealing surface.

1. Position wiring harness connector securing clip - arrow - and ensure it locks securely.

1. Tighten bolt - arrow - for Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

1. Tightening torque: 10 Nm.

1. With a transmission with hydraulic control "E18/2" , connect electrical connector to Transmission Input Speed (RPM) Sensor G182.
2. Clip electrical harness connector into valve body mount - arrow -.

1. Position ATF filter on valve body and tighten - arrows -.

1. Tightening torque: 5 Nm.

1. Install ATF oil pan --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Fill ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Torque specification

Inner oil line, removing and installing

Note. Faulty O-rings on inner oil line allow ATF to leak into the final drive. This will lead to overfilling and oil will drip from the final drive breather hole.

Removing

1. Remove valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .

Scheme 1207

1. Press inner oil line evenly off of transmission housing with a screwdriver.

Note. Inner oil line cannot be removed without causing damage.

Installing

Install in reverse order of removal, note the following

Note. Replace O-rings. Oil line may be installed with Oil Line Installer 3381. Otherwise the risk exists that the oil line may leak by bending.

Scheme 1208

1. Insert oil line in Oil Line Installer 3381.
2. Using light blows with a plastic hammer, drive oil line on Oil Line Installer 3381 into transmission housing as far as stop on tool.

1. Open side of oil line installer 3381 faces toward outer wall of transmission.
2. Do not distort oil line. Drive both line ends in equally.

1. Install valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .
2. Fill ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
3. Check oil level in front final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195 , removing and installing

Removing

1. Drain ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Remove ATF oil pan --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Scheme 1209

1. Disconnect electrical connector - arrow - at Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

Scheme 1210

1. Remove bolt and remove Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195 - 2 - with spacer sleeve - 1 -.

Installing

Installation in reverse order of removal, note the following

1. Position Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195 - 2 - with spacer sleeve - 1 - on transmission and tighten bolt.

1. Spacer sleeve height: 8 mm.

1. Install ATF oil pan --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Fill ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Torque specification

Transmission Input Speed (RPM) Sensor G182 (transmission with hydraulic control "E17"), removing and installing

Note. On a transmission with hydraulic control "E17" , Transmission Input Speed (RPM) Sensor G182 is an inductive sensor (secured on underside of valve body). The allocation of the hydraulic control can be found in Technical Data --> 00 - GENERAL, TECHNICAL DATA .

Removing

1. Remove valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .
2. Rotate valve body.

Scheme 1211

1. Disconnect electrical harness connector at Transmission Input Speed (RPM) Sensor G182 - 1 -.

Note. Ignore - arrows - and item - 2 -.

Scheme 1212

1. Remove bolts and remove Transmission Input Speed (RPM) Sensor G182 - 1 -.

Note. Disregard - 2 -.

Installing

Installation is in reverse order or removal, note the following

1. Position Transmission Input Speed (RPM) Sensor G182 - 1 - with spacer sleeves - 2 - on valve body and tighten bolts.

1. Spacer sleeve height: 20 mm.
2. Installation position: Transmission Input Speed (RPM) Sensor G182 contacts face toward center of valve body.

1. Install valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .
2. Fill ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Torque specification

Transmission Input Speed (RPM) Sensor G182 (transmission with hydraulic control "E18/2"), removing and installing

Note. On a transmission with hydraulic control "E18/2" , Transmission Input Speed (RPM) Sensor G182 is a Hall sensor (secured behind valve body on transmission housing). The allocation of the hydraulic control can be found in Technical Data --> 00 - GENERAL, TECHNICAL DATA .

Removing

1. Remove valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .

Scheme 1213

1. Remove bolt - B -.
2. Remove Transmission Input Speed (RPM) Sensor G182 - A - from transmission.

Installing

Installation is in reverse order of removal, note the following

1. Electrical connector - C - for Transmission Input Speed (RPM) Sensor G182 is clipped into valve body mount after installing valve body.
2. Install valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .
3. Fill ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Torque specification

Wiring harness in transmission, removing and installing

Removing

1. Remove valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .

Scheme 1214

1. Pry retaining tabs on electrical connectors on solenoid valves out with a small screwdriver and disconnect electrical connectors - A - one after the other.
2. Disengage wiring harness at valve body side retaining tabs - B -.

1. Disconnect electrical connector - arrow - at Transmission Vehicle Speed Sensor (VSS) G38/Transmission Output Speed (RPM) Sensor G195.

Note. Shown with valve body installed in illustration.

1. Rotate valve body.

Transmission with hydraulic control "E17"

1. Disconnect electrical harness connector at Transmission Input Speed (RPM) Sensor G182 - 1 -.
2. Remove retaining clip - arrow A - and unclip wiring harness from retaining clip - arrow B -.
3. Disconnect electrical connector - 2 - at Solenoid Valve 4 N91.

Transmission with hydraulic control "E18/2"

Scheme 1215

1. Disconnect electrical harness connector at Transmission Input Speed (RPM) Sensor G182 - 1 -.
2. Remove retaining clip - arrow A - and unclip wiring harness from retaining clip - arrow B -.

Installing

Installation is in reverse order of removal, note the following

1. Connect wiring harness electrical connectors to corresponding solenoid valves and sensors.
2. Clip wiring harness into intended retaining clips. If deviated, the wiring harness could be pinched when installing the valve body.
3. Install valve body --> «Valve body, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__valve-body-removing-and-installing) .
4. Fill ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

ATF color

1. Yellow color: New ATF.
2. Brown color: Used ATF (from approx. 60,000 km).
3. Black, ATF smells burned: Malfunction in transmission, e.g. torque converter clutch overheated, clutch lining burned.

Shavings in ATF

1. Metal shavings smaller than 0.1 mm diameter up to a maximum of 1 cm 3 at solenoid in ATF oil pan or in ATF are normal.
2. Metal shavings larger than 2.0 mm diameter at solenoid in ATF oil pan or in ATF indicate a mechanical malfunction or strong wear in transmission.

Measures for contaminated ATF area

If ATF area is heavily soiled (ATF black or shavings Shavings in ATF )

1. Completely disassemble and clean transmission.
2. Flush ATF oil passages and blow through with pressurized air.
3. Disassemble and check all clutches.
4. Replace torque converter (cannot be cleaned).

1. Replace valve body (cannot be cleaned).
2. Replace ATF filter.
3. Clean ATF lines and ATF cooler.

Clutch "F"

1 - Cylinder "F"

1. Check for scoring from lining discs on inner circumference --> «Check cylinder "F" inner circumference for scoring from lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
2. Check for scoring from lining discs on outer circumference --> «Check cylinder "F" outer circumference for scoring from lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
3. Checking splines
4. Checking needle bearing and metal sleeve for wear --> «Checking needle bearing and metal sleeve in cylinder "F" for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

3 - Piston "F"

1. Checking for wear

6 - Plate spring

1. Replace in case of signs of wear or if dished washer tips are bent
2. Replace broken plate spring

7 - Split retaining ring

1. Replace if deformed

10 - Outer plates

1. Checking for wear «Checking coated and outer plate for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

11 - Coated plate

1. Checking for wear «Checking coated and outer plate for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Scheme 1216

1. Check cylinder "F" at inner circumference for signs of wear caused by coated plates.

1. Coated plates must not get caught in scoring - arrows -.

If scoring - arrows - caused by coated plates are greater than 0.5 mm

1. Replace cylinder "F" and clutch freewheel inner race "D/G"

Scheme 1217

1. Check cylinder "F" at outer circumference for signs of wear caused by coated plates.

1. Coated plates must not get caught in scoring - arrows -.

If scoring - arrows - caused by coated plates are greater than 0.5 mm

1. Replace cylinder "F".

Note. This damage is always caused by a malfunctioning valve body.

Scheme 1218

1. Perform a visual check of needle bearing - arrow 1 -.

1. Needle bearing must be like new.

1. Replace cylinder "F" if necessary.
2. Check contact surface of metal sleeve for wear - arrow 2 - in cylinder "F".

1. Contact surface must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace cylinder "F".

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface. Contact surface must now be like new.

If scores cannot be removed in this manner

1. Replace cylinder "F".

Scheme 1219

Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows

A - Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and coated plate OK, can be reused.

B - Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.

C - Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates overheated and worn, must be replaced.

Clutch "D/G" with freewheel

1 - Freewheel inner race

1. Checking rotating and locking direction of freewheel «Checking rotating and locking direction of freewheel»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-rotating-and-locking-direction-of)
2. Checking brass sleeves for wear «Checking upper and lower brass sleeves in freewheel inner race for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
3. Checking splines

3 - Rectangular rings

1. Checking for wear «Checking rectangular rings for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-rectangular-rings-for-wear)

4 - Freewheel with freewheel housing

1. Checking rotating and locking direction of freewheel «Checking rotating and locking direction of freewheel»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-rotating-and-locking-direction-of)

7 - Coated plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-coated-and-outer-plates-for)

8 - Outer plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-coated-and-outer-plates-for)

11 - Plate spring

1. Replace in case of signs of wear or if dished washer tips are bent
2. Check for cracks

13 - Piston "D"

1. Check for cracks
2. Perform sound test by striking with a screwdriver: Clear sound - pistons OK, thudding sound - cracks in pistons

15 - Cylinder "D/G"

1. Check for scoring from lining discs on inner and outer circumference --> «Check cylinder "D/G" for scoring from lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
2. Checking splines
3. Checking for cracks in area of groove for circlip

19 - Plate spring

1. Replace in case of signs of wear or if dished washer tips are bent

23 - Coated plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-coated-and-outer-plates-for)

24 - Outer plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-coated-and-outer-plates-for)

Checking rotating and locking direction of freewheel

1. Freewheel inner race - 2 - must be able to turn in a clockwise direction and must lock in a counter-clockwise direction when turned.

If there is no locking effect

1. Replace freewheel with freewheel housing - 1 -.

Scheme 1220

1. Check contact surfaces of brass sleeves - arrows - at inside of freewheel inner race for wear.

1. Contact surfaces must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace freewheel inner race.

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surfaces.

1. Contact surfaces must now be like new.

If scores cannot be removed in this manner

1. Replace freewheel inner race.

Scheme 1221

Note. Always replace rectangular rings. However, conclusions can be drawn from the signs of wear of the rectangular rings regarding the quality of contact surface for rectangular rings. Evaluating the rectangular rings for wear is therefore essential.

If rectangular rings show strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is normal)

1. Replace freewheel inner race.

If rectangular rings show strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure thickness of new rectangular ring)

1. Replace cylinder "F".

Checking coated and outer plates for wear

Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows

A - Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and coated plates OK, can be reused.

B - Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.

C - Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates overheated and worn, must be replaced.

Scheme 1222

1. Check cylinder "D/G" at inner and outer circumference for signs of wear caused by lining discs.

1. Coated plates must not get caught in scoring.

If scoring - arrows - caused by coated plates are greater than 0.5 mm

1. Replace cylinder "D/G".

Planetary drive "III"

2 - Shaft

1. Checking contact surface and brass sleeve of shaft for wear «Checking contact surface and brass sleeve of shaft for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
2. Checking splines

3 - Ring gear "III"

1. Checking splines of planetary drive, replace planetary drive if splines are damaged

4 - Angle washer

5 - Axial needle bearing

6 - Thrust washer

7 - Planetary carrier "III"

1. Checking contact surfaces of shaft for wear --> «Checking contact surfaces of shaft planetary carrier "III" for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
2. Checking splines of planetary drive, replace planetary drive if splines are damaged
3. Checking axial and radial play of planetary gears «Checking axial and radial play of planetary gears»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Scheme 1223

1. Check contact surfaces of brass sleeve - arrow 2 - at inside of shaft and contact surface at outer circumference - arrow 1 - for wear.

1. Contact surfaces must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace shaft.

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface.

1. Contact surfaces must now be like new.

If scores cannot be removed in this manner

1. Replace shaft.

Scheme 1224

1. Check contact surfaces - arrows - of shaft for wear.

1. Contact surfaces must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace planetary drive.

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface.

1. Contact surfaces must now be like new.

If scores cannot be removed in this manner

1. Replace planetary drive.

Scheme 1225

1. Check axial play of planetary gears - arrow A -.

1. Axial play wear limit: 0.4 mm.

1. Check planetary gears for radial play - arrow B -.

1. Planetary gears must not show radial play.

1. Check planetary gear axles.

1. Axle peening must be intact.
2. Area around axles must not be blue.

1. Replace planetary carrier "III" if necessary.

Clutch "B"

2 - Cylinder "B"

1. Checking contact surface for rectangular rings for wear --> «Checking contact surface for rectangular rings in cylinder "B" for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

4 - Piston "B"

1. Checking freedom of movement of valve ball --> «Checking freedom of movement of valve ball in piston "B"»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

6 - Plate spring

1. Replace in case of signs of wear or if dished washer tips are bent

7 - Split retaining ring

1. Replace if deformed

8 - Waved washer

9 - Outer plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

10 - Coated plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Scheme 1226

1. Check contact surface - arrow - in cylinder "B" for wear.

1. Contact surface must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace cylinder "B".
2. Check rectangular rings.

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface.

1. Contact surface must now be like new.

If scores cannot be removed in this manner

1. Replace cylinder "B".

Scheme 1227

1. Lightly coat bore for valve ball - arrow - at front side with oil.

1. Charge valve ball from rear with compressed air.

1. Only little ball stroke (hardly visible).
2. Ball is not spring-loaded (moves back slowly).

If valve ball is stuck

1. Loosen ball with a nail or tip of a ball point pen.

If valve ball is still stuck or leaks

1. Replace piston "B".

Note. A valve ball that does not seal properly or is stuck will cause slipping in reverse gear.

Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows

A - Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and coated plates OK, can be reused.

B - Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.

C - Tarnish blue/brown at outer and/or inner area of outer plates: Outer and coated plates overheated and worn, must be replaced.

Clutch "A"

5 - Cylinder "A"

1. Check for scoring from lining discs on inner circumference --> «Check cylinder "A" inner circumference for scoring from lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__check-cylinder-a-inner-circumference-for)
2. Check for scoring from lining discs on outer circumference --> «Check cylinder "A" outer circumference for scoring from lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__check-cylinder-a-outer-circumference-for)
3. Checking contact surface for rectangular ring in cylinder "A" for wear --> «Checking contact surface for rectangular ring in cylinder "A" for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-contact-surface-for-rectangular-ring)
4. Checking splines

10 - Plate spring

1. Replace in case of signs of wear or if dished washer tips are bent

11 - Split retaining ring

1. Replace if deformed

12 - Outer plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

13 - Coated plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Check cylinder "A" inner circumference for scoring from lining discs

1. Check cylinder "A" at inner circumference for signs of wear caused by coated plates.

1. Coated plates must not get caught in scoring - arrows -.

If scoring - arrows - caused by coated plates are greater than 0.5 mm

1. Replace cylinder "A".

Check cylinder "A" outer circumference for scoring from lining discs

1. Check cylinder "A" at outer circumference for signs of wear caused by coated plates.

1. Coated plates must not get caught in scoring - arrows -.

If scoring - arrows - caused by coated plates are greater than 0.5 mm

1. Replace cylinder "A".

Checking contact surface for rectangular ring in cylinder "A" for wear

1. Check contact surface - arrow - in cylinder "A" for wear.

1. Contact surface must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace cylinder "A".
2. Check rectangular rings.

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface.

1. Contact surface must now be like new.

If scores cannot be removed in this manner

1. Replace cylinder "A".

Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows

A - Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and coated plates OK, can be reused.

B - Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.

C - Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates seated and worn, must be replaced.

Clutch "E"

1 - Rectangular rings

1. Checking for wear «Checking rectangular rings for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

3 - Cylinder "E"

1. Checking contact surfaces of shaft and brass sleeve for wear --> «Checking contact surfaces of shaft cylinder "E" and brass sleeve for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
2. Checking welding seam between shaft and cylinder «Checking welding seam between shaft and cylinder»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
3. Checking splines

7 - Plate spring

1. Replace in case of signs of wear or if dished washer tips are bent

12 - Outer plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

13 - Coated plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Checking rectangular rings for wear

Note. Always replace rectangular rings. However, conclusions can be drawn from the signs of wear of the rectangular rings regarding the quality of contact surface for rectangular rings. Evaluating the rectangular rings for wear is therefore essential.

If rectangular rings show strong axial wear - arrow 1 - (slight wear of outer edges is normal)

1. Replace cylinder "E".

If rectangular rings show strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure thickness of new rectangular ring)

1. Replace stator shaft.

Note. If rectangular rings are worn, converter clutch is possibly worn out because contact pressure is too low.

Scheme 1228

1. Check contact surfaces of brass sleeve - arrow 2 - at inside of shaft and contact surfaces at outer circumference - arrows 1 - for wear.

1. Contact surfaces must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace cylinder "E".

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface.

1. Contact surfaces must now be like new.

If scores cannot be removed in this manner

1. Replace cylinder "E".

Scheme 1229

1. Check seal of welding seam between shaft and cylinder "E" , place shaft under friction press with plastic piece - 1 - in between and charge shaft with very little force.

If shaft is loose or a crack is visible in the area marked with - arrows

1. Replace cylinder "E".

Note. If cylinder "E" is not properly sealed, there will be shifting from 4th to 5th gear.

Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows

A - Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and coated plates OK, can be reused.

B - Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.

C - Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates overheated and worn, must be replaced.

Clutch "C"

1 - ATF pump with outer plate carrier "C"

1. Check inner splines for scoring from lining discs --> «Check inner splines on ATF pump with outer disc carrier "C" for scoring from lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

5 - Plate spring

1. Replace in case of signs of wear or if dished washer tips are bent

6 - Split retaining ring

1. Replace if deformed

8 - Coated plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

9 - Outer plates

1. Checking for wear «Checking coated and outer plates for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

Scheme 1230

1. Check inner splines for signs of wear caused by coated plates.

1. Coated plates must not get caught in scoring - arrows -.

If scoring - arrows - caused by coated plates are greater than 0.5 mm

1. Replace outer plate carrier "C".

Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows

A - Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and coated plates OK, can be reused.

B - Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.

C - Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates overheated and worn, must be replaced.

ATF supply

2 - Locking washer

1. Checking for deformation

4 - ATF pump housing

1. Checking contact surfaces for grooves and signs of wear «Checking components of ATF pump for grooves and signs of wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-components-of-atf-pump-for)
2. Checking brass sleeve for wear «Checking brass sleeve of ATF pump housing for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-brass-sleeve-of-atf-pump)

5 - Ring gear

1. Checking contact surfaces for grooves and signs of wear «Checking components of ATF pump for grooves and signs of wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-components-of-atf-pump-for)

6 - ATF pump wheel

1. Checking contact surfaces for grooves and signs of wear «Checking components of ATF pump for grooves and signs of wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-components-of-atf-pump-for)
2. Check yoke in ATF pump wheel «Check yoke in ATF pump wheel»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__check-yoke-in-atf-pump-wheel)

8 - Intermediate panel

1. Checking contact surfaces for grooves and signs of wear «Checking components of ATF pump for grooves and signs of wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-components-of-atf-pump-for)

10 - ATF supply

1. Checking volume controlling valve of ATF pump for freedom of movement «Checking volume controlling valve in ATF pump»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

14 - Stator shaft

1. Checking brass sleeves for wear «Checking brass sleeves of stator shaft for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
2. Checking splines for wear

16 - Rectangular rings for clutch "B"

1. Checking for wear --> «Checking rectangular rings item - 16 - for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-rectangular-rings-item-16)

17 - Rectangular ring for clutch "A"

1. Checking for wear --> «Checking rectangular ring item - 17 - for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__checking-rectangular-ring-item-17)

18 - Axial needle bearing

1. Perform visual check for damage: Axial needle bearing and their contact surfaces must be like new, replace if necessary

Checking brass sleeve of ATF pump housing for wear

1. Check contact surface of brass sleeve - arrow - for wear.

1. Contact surface must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace ATF pump.

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface.

1. Contact surface must now be like new.

If scores cannot be removed in this manner

1. Replace ATF pump.

1. Check torque converter hub - arrow - for wear.

If wear on torque converter can be recognized

1. Replace torque converter.

Checking components of ATF pump for grooves and signs of wear

1. Check contact surfaces of the following components for grooves and signs of wear

2 - ATF pump housing

3 - Ring gear

4 - ATF pump wheel

5 - Intermediate panel

1. Surfaces of contact surfaces must be matt or shiny but without any sign of groove.

Note. A malfunctioning ATF pump will cause delays in drive and shifting procedures.

Check yoke in ATF pump wheel

1. Check whether coupling plates - arrows - on ATF pump wheel show pressure marks or are broken off, replace ATF pump if necessary.

Causes

A - Torque converter not completely inserted during transmission or engine installation

B - Centering sleeve for torque converter not inserted in crankshaft

Scheme 1231

Check volume controlling valve as follows

1. Move valve piston against spring pressure.

1. Valve piston must move freely in both directions of movement - arrow -.
2. Valve must not have grooves.
3. No shavings must be jammed in opening - 1 -.

Note. If valve piston is stuck or opening - 1 - is plugged, there will possibly be no actuation.

Scheme 1232

1. Check contact surfaces of brass sleeves - arrows - at inside of stator shaft for wear.

1. Contact surfaces must not be heavily scored and/or show blue discoloration.

In case of deep grooves and/or blue color

1. Replace stator shaft.

If no blue discoloration and only small grooves are detected, proceed as follows

1. Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
2. Carefully wipe off with a clean rag and check contact surface.

1. Contact surfaces must now be like new.

If scores cannot be removed in this manner

1. Replace stator shaft.

Checking rectangular rings item - 16 - for wear

Note. Always replace rectangular rings. However, conclusions can be drawn from the signs of wear of the rectangular rings regarding the quality of contact surface for rectangular rings. Evaluating the rectangular rings for wear is therefore essential.

If rectangular rings show strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is normal)

1. Replace stator shaft.

If rectangular rings show strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure thickness of new rectangular ring)

1. Replace cylinder "B".

Checking rectangular ring item - 17 - for wear

Note. Always replace rectangular ring. However, conclusions can be drawn from the signs of wear of the rectangular ring regarding the quality of contact surface for rectangular rings. Evaluating the rectangular ring for wear is therefore essential.

If rectangular ring shows strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is normal)

1. Replace stator shaft.

If rectangular ring shows strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure thickness of new rectangular ring)

1. Replace cylinder "A".

Front final drive and transfer case, servicing

Note. General repair notes --> General Repair Notes . Rules of cleanliness for working on automatic transmissions --> Rules of cleanliness for working on automatic transmissions .

Transfer case with Torsen differential, removing and installing

Transfer case with Torsen differential, removing and installing --> 39 - FINAL DRIVE, DIFFERENTIAL .

Front final drive and transfer case, component overview

Note. Components shown in illustration can be removed with transmission installed.

Scheme 1233

1 - Internal hex bolt, 25 Nm

2 - Driveshaft output flange

3 - Shaft seal

1. Replace --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v)

4 - Bolt, 23 Nm

1. Qty. 4

5 - Housing cover

6 - O-ring

1. Coat with axle oil

7 - Circlip

8 - Grooved ball bearing

1. For spur gear 1
2. Pressing off «Pressing off grooved ball bearing for spur gear 1»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
3. Pressing on «Pressing on grooved ball bearing for spur gear 1»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

9 - Spur gear 1

1. For rear ring and pinion set

10 - Circlip

11 - Needle bearing

1. For spur gear 1
2. Remove only to replace
3. To replace transfer case housing, warm to approx. 100° C and drive needle bearing with drift towards rear (Attention! Wear protective gloves)
4. Drive in with Sleeve 30-21 to stop

12 - Bolt, 23 Nm

1. Loosen or tighten diagonally

13 - Transfer case housing

1. Can be replaced if damaged

14 - Clamping nut

15 - Needle bearing

1. Remove only to replace
2. Replace --> «Needle bearing for spur gear 2, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__needle-bearing-for-spur-gear-2)

16 - Circlip

17 - Spur gear 2

1. For rear ring and pinion set

18 - Grooved ball bearing

1. For spur gear 2
2. Pressing off «Pressing off grooved ball bearing for spur gear 2»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)
3. Pressing on «Pressing on grooved ball bearing for spur gear 2»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

19 - Circlip

20 - Fastening plate

21 - Guide plate

22 - Bolt, 8 Nm

23 - Circlip

24 - Gasket

1. Replace --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v)

25 - Torsen differential

1. Replace complete unit if damaged
2. Removing and installing --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v)

26 - Shaft seal

1. Replace --> «Shaft seal in front final drive intermediate flange, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing)

27 - Magnet

1. Replacing --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v)

28 - Alignment bushing

1. Qty. 2

29 - Bleeder

1. For transfer case
2. With attached cover
3. Installation position: Without cover, breather must project 10 to 11 mm out of housing

30 - Bolt, 23 Nm

1. Loosen and tighten diagonally

31 - Intermediate flange for front final drive

1. Removing and installing --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v)

32 - Gasket

1. Replace --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v)

33 - Alignment bushing

34 - Drive pinion

1. For front final drive
2. Removing and installing --> «Shaft seal in drive pinion, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__shaft-seal-in-drive-pinion-replacing)

35 - Intermediate pinion

1. For front final drive
2. Installation position: gear identification faces toward differential

36 - Pinion gear

1. For front final drive
2. Installation position: gear identification faces toward differential

37 - Shaft seal

1. Replace --> «Shaft seal in drive pinion, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v-front-and-all-wheel-drive-internal-components-servicing__shaft-seal-in-drive-pinion-replacing)

Scheme 1234

A - Separating device 22 to 115 mm Kukko 17/2

Scheme 1235

Scheme 1236

A - Separating device 22 to 115 mm Kukko 17/2

Scheme 1237

Driveshaft output flange shaft seal, replacing

Replace driveshaft output flange shaft seal --> 39 - FINAL DRIVE, DIFFERENTIAL .

Scheme 1238

Note. On the left side of the final drive intermediate flange there is an oil leak inspection opening - arrow - for shaft seal in drive pinion and shaft seal in front final drive intermediate flange.

Work procedure

1. Remove transfer case --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Remove front final drive intermediate flange --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Scheme 1239

1. Drive shaft seal - arrow - out in toward transfer case using a drift.
2. Check shaft seal seating in front final drive intermediate flange for damage, rework if necessary.

Scheme 1240

1. Slide shaft seal onto Thrust Piece 3404.

1. The larger, projecting outer race - arrow - on shaft seal faces toward thrust piece.

1. Drive shaft seal in with Thrust Piece 3404 as far as thrust piece stop.
2. Install front final drive intermediate flange --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
3. Install transfer case --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
4. Check and correct ATF level in planetary gearing --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Shaft seal in drive pinion, replacing

Note. On the left side of the intermediate shaft, there is an oil leak inspection opening - arrow - for shaft seal in drive pinion and shaft seal in intermediate flange.

Work procedure

1. Remove transfer case --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
2. Remove front final drive intermediate flange --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

1. Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.
2. Remove pinion gear together with intermediate pinion, while doing so pull drive pinion - 2 - slightly toward rear.
3. Remove drive pinion - 2 -.
4. Drive out shaft seal with a drift.

Scheme 1241

1. Slide shaft seal onto Thrust Piece 3403.
2. Drive shaft seal in with Thrust Piece 3403 as far as thrust piece stop.

Note. Ignore - A - and - B -.

Scheme 1242

1. Completely cover splines on input shaft - arrow - with insulating tape without creasing or overlapping the tape to prevent damage to gasket when sliding on drive pinion.
2. Install front final drive intermediate flange --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
3. Install transfer case --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .
4. Check and correct ATF level in planetary gearing --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Needle bearing for spur gear 2, replacing

Work procedure

1. Remove transfer case --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

Scheme 1243

Note. The upper part of the illustration illustrates how the pulling hooks of the extractor - B - must be installed in the needle bearing - 1 -.

A - Counter support Kukko 22/1

B - Internal puller Kukko 21/4

1. Slide centering sleeve - 2 - on Internal Puller Kukko 21/4 - B - approx. 4 mm in direction of - arrow - in order to be able to open the pulling hooks far enough.
2. Spread extractor - B - into upper lip of needle bearing - 1 - and secure extractor at nut.
3. Install Counter-support Kukko 22/1 - A - on internal puller - B - as show in the illustration.
4. Support counter-support with Thrust Plate VW 402 and tension at counter-support nut - 3 -.

1. Quickly warm outside of transfer case housing with a hot air gun in area around needle bearing seat to approx. 100° C.
2. Quickly remove needle bearing.
3. Check needle bearing seating in transfer case housing for damage, rework if necessary.

1. Evenly warm outside of transfer case housing with a hot air gun in area around needle bearing seat to approx. 100° C.

Scheme 1244

1. Position Sleeve 2080 A on new needle bearing - 1 -.
2. Drive needle bearing into transfer case housing as far as stop using Punch VW 408 A.
3. Install transfer case --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#5-speed-automatic-transmission-01v) .

See also:
• 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
• 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
• 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK
• Rules of cleanliness for working on automatic transmissions
• Valve body, removing and installing
• Torque converter clutch, checking
• General Repair Notes
• Clutch "C" , disassembling and assembling
• Tower "II" , disassembling and assembling
• Tower "I" , disassembling and assembling
• Transmission, attaching assembly stand
• Shaft seal in drive pinion, replacing
• Clutch "F"
• Clutch "D/G" with freewheel
• Planetary drive "III"
• Clutch "B"
• Clutch "A"
• Clutch "E"
• Clutch "C"
• ATF pump, component overview
• ATF supply
• ATF supply housing with stator shaft, removing and installing
• Stator shaft, removing and installing
• ATF pump and ATF supply housing, removing and installing
• Shavings in ATF
• Checking rotating and locking direction of freewheel
• Checking rectangular rings for wear
• Checking coated and outer plates for wear
• Check cylinder "A" inner circumference for scoring from lining discs
• Check cylinder "A" outer circumference for scoring from lining discs
• Checking contact surface for rectangular ring in cylinder "A" for wear
• Checking components of ATF pump for grooves and signs of wear
• Checking brass sleeve of ATF pump housing for wear
• Check yoke in ATF pump wheel
• Checking rectangular rings item - 16 - for wear
• Checking rectangular ring item - 17 - for wear
• Needle bearing for spur gear 2, replacing