Continuously Variable Transmission (cvt) 01j - Internal Components, Servicing Audi A4 B6

General Repair Notes

To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

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

Transmission

1. Observe rules of cleanliness for working on the transmission --> «Rules for cleanliness when working on transmission»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__rules-for-cleanliness-when-working-on) .
2. After transmission repairs, clean ATF lines and ATF cooler --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
3. Reusable components must be cleaned, checked and reconditioned if necessary before installation --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)
4. The old transmission should be installed and put into operation as quickly as possible to prevent corrosion on the newly installed components.

After installing, following fluid levels must be checked and topped off if necessary

1. Top off ATF level after repair --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
2. Gear oil in front final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
3. Capacities and specifications --> «00 - GENERAL, TECHNICAL DATA»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

O-rings, gaskets, seals

1. O-rings, gaskets and seals must be replaced.
2. After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
3. Open sides of oil seals face fluid side.
4. To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.

1. Coat O-rings with transmission fluid or Vaseline before inserting to prevent crushing rings during installation.
2. Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
3. When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
4. Replace paper seals, always clean sealing surfaces and remove old seals completely.

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.

Scheme 1430

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.
4. Replace spring pins. Installation position: Slot is longitudinal to line of force.

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.

Contact corrosion!

General

Contact corrosion can occur if non-approved fasteners are used on vehicle (bolts, nuts, washers, etc.).

For this reason, all fasteners used in production are specially treated. These parts can be identified by their greenish color.

Rubber, plastic and adhesives also consist of non-conductive materials.

If you are not sure whether used parts can be re-installed, always install new parts.

The following points should be observed especially for transmission

1. Multitronic transmission 01J or 0AN housing is made of magnesium alloy.
2. Bolts and other components which have direct contact with transmission have a surface coating which is matched to magnesium transmission housing.
3. On magnesium transmissions, bolts must always be replaced on following bolted connections: Transmission housing cover and final drive cover on transmission housing as well as engine bolts on transmission.
4. Contact corrosion occurs when incorrect components (bolts, nuts, washers, etc.) are used. The transmission housing will be damaged.

1. Transmission housing, transmission cover and differential cover must all be of same material.
2. If you are not sure whether used parts can be re-installed, always install new parts.

Rules for cleanliness when working on transmission

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.

ATF flushing process

Special tools, testers and auxiliary items required

Scheme 1431

1. Vehicle Diagnosis, Testing and Information System VAS 5051 with Diagnostic cable VAS 5051/5A

Scheme 1432

1. ATF filler system F/CVT gearbox VAS 5162

Scheme 1433

1. Triple square socket driver 3357
2. Drip tray
3. Safety glasses

Work procedure

1. Transmission installed.

With normal ATF change, only about 55 to 60% of total ATF in transmission is replaced.

"ATF flush" procedure is necessary when old ATF in transmission must be removed completely.

ATF must always be flushed with following procedures

1. Changing input shaft
2. Servicing input shaft

In addition, test run must be performed 2 times and afterwards ATF must be changed, as described below.

Only by doing this will ATF in transmission be changed completely.

1. After installing transmission: --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .

Check whether update programming in the Transmission Control Module (TCM) J217 must be carried out.

1. Vehicle Diagnosis, Testing, and Information System VAS 5051 connected.

1. Vehicle-specific access to Vehicle Diagnosis, Testing, and Information System VAS 5051 in "Guided Fault Finding".
2. Using Goto button, select "Complaint registration " function in test plan and find following selection

1. Press " Transfer" text line and select test program " Jerking when accelerating from stop".

Note. Through this process in Vehicle Diagnosis, Testing, and Information System VAS 5051 update programming is only carried out for the Transmission Control Module (TCM) J217 if this is necessary.

1. If necessary, carrying out update programming in Transmission Control Module (TCM) J217.

ATF flush

1. > «Input shaft adjustment (air gap), checking»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-adjustment-air-gap-checking)
2. First test run pass through: --> «Carry out ATF flush test run»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__carry-out-atf-flush-test-run) .
3. Second test run pass through: --> «Carry out ATF flush test run»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__carry-out-atf-flush-test-run) .
4. Check and correct ATF level --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Note. Observe all notes and test requirements for "Checking ATF level and topping off".

After ATF level is checked and restored, flushing process is complete.

Input shaft adjustment (air gap), checking

1. ATF filled

1. Drive vehicle off hoist.

Note. On vehicles with air suspension, vehicle lifting mode must be deactivated --> 43 - SELF-LEVELING SUSPENSION . ATF filled

1. Place vehicle on level surface.

Note. With parking brake released, vehicle may roll forward or backward by itself when in selector lever position "N".

1. Start engine.
2. Place selector lever in position "N".

1. Do not engage parking brake.
2. Do not operate brake pedal.

1. Press accelerator.

1. Vehicle should not be allowed to roll.

If vehicle rolls in selector lever position "N"

1. Adjust selector lever cable --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j)

If selector lever cable adjustment is OK but vehicle still rolls in selector lever position "N"

1. Input shaft, servicing --> «Input shaft, servicing with 6 lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) or --> «Input shaft, servicing with 7 lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

Note. In this case, input shaft adjustment (air gap) was not performed correctly.

If vehicle does not roll in selector lever position "N"

The input shaft adjustment with evaluation of air play is OK.

1. Carry out ATF flush First test run pass through: under «ATF flush»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-flush)

Carry out ATF flush test run

1. ATF filled --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .
2. The input shaft (air gap) adjustment is OK --> «Input shaft adjustment (air gap), checking»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-adjustment-air-gap-checking)

1. Drive vehicle off hoist.

Note. On vehicles with air suspension, vehicle lifting mode must be deactivated --> 43 - SELF-LEVELING SUSPENSION .

1. Follow specifications exactly and carry out all safety instructions.

1. Start engine.
2. Place selector lever in position "D".
3. Shift selector lever into "Tiptronic gate".
4. Move wheels by lightly pressing accelerator.

1. Note driving mode display in instrument cluster
2. Move from 1st to highest gear by moving selector level towards "+".
3. Then move back to 1st gear by moving selector lever back towards "-".

Note. Press brake pedal if necessary

1. Press brake pedal and brake wheels down to 0 km/h.
2. Place selector lever in position "R".
3. Accelerate wheels up to 20 km/h by lightly pressing accelerator.
4. Press brake pedal and brake wheels down to 0 km/h.

1. Place selector lever in position "D" again and repeat same procedure 5 times.

Note. Process must be repeated five times so that all old ATF is mixed with new ATF.

1. Place selector lever in position "P" afterwards and switch engine off.
2. Drain ATF --> «ATF, draining for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-draining-for-atf-flushing-process) .
3. Fill with ATF --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .
4. Carry out ATF flush «ATF flush»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-flush)

ATF, draining for ATF flushing process

1. Vehicle on a flat surface

Note. Observe disposal regulations! Activate vehicle lifting mode --> 43 - SELF-LEVELING SUSPENSION before driving vehicle with air suspension onto hoist, that is, with all four wheels hanging.

Scheme 1434

1. Loosen fasteners - 2 - and - 3 - and remove rear noise insulation - B -.
2. Place an oil receptacle underneath transmission.

Scheme 1435

1. Remove ATF drain plug - A - using triple square socket driver 3357 and drain ATF.
2. Tighten ATF drain plug again.

1. Tightening torque: 24 Nm.

ATF, filling for ATF flushing process

1. Vehicle on a flat surface

Scheme 1436

Note. The illustration on the reservoir for ATF filler system F/CVT gearbox VAS 5162 in upper left graphic refers to the use of special ATF for CVT transmissions. The illustration also shows pictures of the steps required to fill the transmission. These steps will be explained in the following.

Scheme 1437

1. Secure filled reservoir of ATF filler system F/CVT gearbox VAS 5162 as high as possible on the vehicle.

1. The shut-off valve on the ATF filler system F/CVT gearbox VAS 5162 must be closed.

1. Remove ATF check plug - B -.
2. Thread connection on shut-off valve of ATF filler system F/CVT gearbox VAS 5162 into opening of ATF check plug - B -.

1. Rotate shut-off valve in direction of filler hose - lower arrow -. ATF flows into transmission.
2. Fill transmission with 5 Liter ATF.
3. Selector lever in "P" , start engine and let it run at idle.

1. Start engine
2. By pressing the gas pedal, run engine at high speed at "2500 - -3000 RPM" for approx. 5 seconds.
3. Press brake pedal and hold.
4. Shift through all selector lever positions "P, R, N, D, S" and let each position remain shifted at idle for approx. 2 seconds.

1. Selector lever in "P" and let engine continue to run at idle.

1. Thread connection on shut-off valve of ATF filler system F/CVT gearbox VAS 5162 from ATF check plug opening - B -.
2. Allow excess ATF to drain off.
3. Install ATF check plug - B -.

1. Tightening torque: 20 Nm.

Scheme 1438

Special tools, testers and auxiliary items required

1. Holding plate VW 309
2. Holding fixture VW 313
3. Transmission support VW 353
4. Engine and Transmission Holder VW 540

1. Workshop crane VAS 6100
2. Lifting tackle T40013

Scheme 1439

1. Secure transmission to assembly block with 2 bolts.
2. Install transmission support VW 353 onto holding plate VW 309.
3. Using Shop Crane VAS 6100 , insert transmission into Holding Fixture VW 313.

Scheme 1440

1. Bolt transmission onto engine/transmission holder VW 540 - arrows -.
2. Using Shop Crane VAS 6100 , insert transmission into Holding Fixture VW 313.

Selector shaft seal, replacing

Special tools, testers and auxiliary items required

Scheme 1441

1. Tube VW 418 A

Work procedure

1. Transmission removed.

Scheme 1442

1. Remove bolt - B - completely and remove lever for selector shaft - A - upward.
2. Carefully pry selector shaft seal lying below out with screwdriver.

Note. Sealing surface and selector shaft must not be damaged.

1. Coat outer circumference of new shaft seal with ATF.
2. Slide on new shaft seal over selector shaft and press in.
3. Drive in shaft seal until it stops using tube VW 418 A.
4. Connect lever for selector shaft - A - to selector shaft and tighten bolt - B -.

Torque specification

ATF breather pipe, removing and installing

If ATF flows out at underside of transmission bell housing, input shaft seal and/or ATF breather pipe may be leaking. Before replacing any parts, be sure to find actual cause of malfunction.

1. Input shaft seal must be replaced if leaking --> «Input shaft seal, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-seal-replacing) .
2. ATF breather pipe must be replaced if leaking.

Removing

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . Transmission removed

Scheme 1443

1. Remove bolt - B -.
2. Pull ATF breather pipe - A - out of mount.

Installing

Installation in reverse order of removal, note the following

1. Insert new ATF breather pipe - A - until it reaches stop.
2. Tighten ATF breather pipe with strap and bolt - B - on transmission housing.

Torque specification

End cover, transmission removed, removing and installing

Special tools, testers and auxiliary items required

Scheme 1444

1. Old oil collecting and extracting device V.A.G 1782

Note. Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . General repair notes --> Repair instructions . To remove the end cover, the transmission must "not" be removed. End cover, removing with transmission installed --> 38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS

Removing

1. Transmission fastened vertically to assembly stand --> «Transmission, attaching to assembly stand»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

1. Place used oil collection and extraction device V.A.G 1782 under transmission.

1. Remove ATF drain plug - A - using triple square socket driver 3357 and drain ATF.
2. Tighten ATF drain plug again.

1. Tightening torque: 24 Nm.

Scheme 1445

1. Remove bolts - arrows - and remove end cover.

Installing

Install in reverse order of removal, note the following

Note. Replace seals and bolts for end cover.

Scheme 1446

1. Slide new gasket - A - with double lip outward onto connector on Transmission Control Module (TCM) J217.
2. Clean sealing surfaces on transmission housing and on end cover.
3. If bushings were installed in transmission housing or in cover, they must be re-mounted in the same location.

Scheme 1447

1. Place new seal for end cover - A - onto transmission housing.

Note. There are metal and paper seals. The new seal must be made of the same material as the old one . Make sure bushings are seated properly.

1. Put on end cover and make sure the seal does not slip.

1. Tighten new bolts - arrows - first hand-tight and in diagonal sequence, and then to tightening torque.
2. Check installation position of gasket - A

1. Gasket must fit flush (sealing lips must not be twisted).

Note. All instructions and steps for "Changing ATF or filling after a repair" must be followed exactly --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

1. Fill with ATF --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Torque specifications

Transmission Control Module (TCM) J217 , removing and installing

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission .

Removing

The Transmission Control Module (TCM) J217 can be removed with transmission installed.

1. Remove end cover --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Scheme 1448

1. Remove bolts - arrows - and pull out Transmission Control Module (TCM) J217 without tilting it.
2. Remove twin lip oil seal - A - from Transmission Control Module (TCM) J217.

Note. When positioning Transmission Control Module (TCM) J217 , ensure sensor on control module is not damaged.

Installing

Install in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

Scheme 1449

1. If necessary, clean sensors - A - , - C - and - D - of soiling and metal shavings.
2. Clean selector shaft --> «Selector shaft, cleaning»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__selector-shaft-cleaning) .

Scheme 1450

1. Before installing Transmission Control Module (TCM) J217 , coat new O-rings - A - on hydraulic control module with ATF.

Scheme 1451

1. Install Transmission Control Module (TCM) J217 without canting it.

1. Harness connectors - A - , - B - and - C - on rear side of control module must engage on hydraulic control module.

1. Tighten bolts - arrows -.
2. Install end cover --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

After connecting Transmission Control Module (TCM) J217 , the following steps must be performed

1. Complete coding for new Transmission Control Module (TCM) J217.
2. Perform adaptation for Transmission Control Module (TCM) J217.

Use Vehicle Diagnosis, Testing and Information System VAS 5051 for this.

Torque specification

Selector shaft, cleaning

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission .

Work procedure

1. Remove end cover --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
2. Remove Transmission Control Module (TCM) J217 --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__transmission-control-module-tcm-j217) .

Scheme 1452

1. Clean catch - arrow - of selector shaft. Do not use fluffy materials for cleaning. Clean contact surfaces of magnet especially thoroughly of metal shavings and the like.

Note. Make sure that spring - A - and roller - B - are properly secured.

1. If necessary, clean sensors - A - , - C - and - D - of soiling and metal shavings.
2. Install Transmission Control Module (TCM) J217 --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__transmission-control-module-tcm-j217) .
3. Install end cover --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Hydraulic control module, removing and installing

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . Always replace a dirty or faulty hydraulic control module.

Removing

1. Remove end cover --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
2. Remove Transmission Control Module (TCM) J217 --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__transmission-control-module-tcm-j217) .

1. Pull slider for selector lever position - C - downward out of bearing hole of hydraulic control module.
2. Disengage spring - A - from selector shaft - D -.

1. Remove bolts - arrows - and remove hydraulic control module.

Installing

Install in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

Scheme 1453

1. Replace axial sealing elements - A - (qty. 4) and - B -.
2. Coat axial sealing elements with ATF before installing.

1. Axial sealing elements - A - must be inserted into mounts with smaller diameter facing transmission.

1. Install cover - C - , while doing so note locating tab.

1. Locating tab on rear side of cover must be inserted into small hole on transmission surface.

1. Push lever for selector shaft - 2 - completely toward front until it stops so that shifting cam - 1 - stands almost vertically (with slight tilt toward right).

Scheme 1454

1. Press control piston - B - on rear side of hydraulic control module completely inward (left) until it engages into assembly spring - A -.
2. Insert hydraulic control assembly into transmission. Align unit properly to fit without jamming.

Note. When installing control module, make sure that shifting cam (item 1 in (Scheme 1453) ) engages into free groove - arrow - on control piston - B -.

1. Hand-tighten bolts - arrows -. Bolt - arrow 1 - is shorter than the other two bolts.
2. Check that cover is properly mounted.

1. Locating tab - B - must be inserted into hole intended for it on the transmission.

Check function of control piston

Scheme 1455

1. Move selector shaft at detent plate - C - or at lever for selector shaft several times toward left and right.

1. When doing this, control piston - B - must travel outward and inward accordingly - arrow -.

If control piston does not move, shifting cam has not engaged into groove - arrow - at control piston on rear side of hydraulic control module. In this case

1. Remove hydraulic control module once again and insert again.

1. Tighten bolts - arrows -.

Installing slider for selector lever position

1. Connect roller - B - with collar downward onto slider for selector lever position - C -.
2. Engage spring - A - into selector shaft - D - and slider for selector lever position.
3. Slide slider for selector lever position into bearing hole in housing of hydraulic control module.

Note. For the sake of illustration, transmission is shown without hydraulic control module.

1. Shift lever for selector shaft - 2 - toward front and rear until stop

1. Detent plate - arrow - moves toward front or toward rear.
2. When doing this, it must allow the roller - B - to be engaged in the individual notches.
3. Slider for selector lever position - C - moves in steps toward front or rear.
4. Roller must be installed with collar facing downward so that it cannot be pulled off upward.

1. Clean selector shaft --> «Selector shaft, cleaning»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__selector-shaft-cleaning) .
2. Insert Transmission Control Module (TCM) J217 with new O-rings --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__transmission-control-module-tcm-j217) .
3. Install end cover --> «38 - AUTOMATIC TRANSMISSION - GEARS, HYDRAULIC CONTROLS»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
4. Fill with ATF --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .

1. After installing transmission, check ATF level and correct --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Torque specification

Input shaft seal, replacing

1. If ATF flows out at underside of transmission bell housing, input shaft seal and/or ATF breather pipe may be leaking. Before replacing any parts, be sure to find actual cause of malfunction.
2. Input shaft seal must be replaced if leaking.
3. ATF breather pipe must be replaced if leaking --> «ATF breather pipe, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) .

Special tools, testers and auxiliary items required

Scheme 1456

1. Seal remover T40014

Scheme 1457

1. Thrust piece T40015

Work procedure

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . Transmission removed.

Scheme 1458

1. Rotate seal ring extractor T40014 by hand into shaft seal until the tool has a good hold in the shaft seal. Then tighten puller with an opened wrench.
2. You can pull out shaft seal a short distance by screwing in rear bolt of puller.
3. Re-tighten puller T40014 so that it re-engages securely in the shaft seal and continue tightening shaft seal by installing bolt.
4. Repeat procedure until shaft seal has been pulled out completely.

1. Input shaft and flange cover must be installed to install seal.

Scheme 1459

1. Coat new shaft seal - A - with ATF.
2. Slide shaft seal onto input shaft with open side facing transmission.

Note. Slide shaft seal as far as possible into cover so that it cannot bend when driving in.

Scheme 1460

1. Drive in shaft seal until it stops using thrust piece T40015.
2. Fill with ATF --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .
3. After installing transmission, check ATF level and correct --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Input shaft, removing and installing

Special tools, testers and auxiliary items required

Scheme 1461

1. Puller T40050

Removing

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . Transmission removed and secured vertically to assembly stand Suspending transmission vertically .

1. Drain ATF --> «ATF, draining for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-draining-for-atf-flushing-process) , pivot transmission in installation position (level)

Note. Transmission must not be turned so that flange points downward.

Scheme 1462

1. Remove bolts - arrows -.
2. Using a plastic mallet, carefully knock input shaft flange cover so that input shaft flange cover loosens itself from seal.

Scheme 1463

1. Secure Puller T40050 on transmission input shaft.
2. Check Puller T40050 for secure seating on input shaft.

1. Circlip must be pushed all the way down.

1. Pull input shaft with flange cover and forward clutch on Puller T40050 out of transmission housing - arrow -.

Scheme 1464

Installing

Install in reverse order of removal, note the following

1. Check wear on transmission components --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)
2. Clean sealing surfaces on transmission housing and flange cover.

Scheme 1465

1. Check whether bushings - arrows - for centering flange cover on transmission housing are installed and seated securely.

Scheme 1466

1. Check condition of sealing ring - arrow - , replace if necessary.

1. Installation position of oil seal: Sealing lip towards flange cover.

1. Place paper gasket in position.

Scheme 1467

1. Align clutch discs of reverse gear clutch e.g. using a straight-edge.

1. Splines must stand exactly in a row.

1. Check installation dimension of oil pipe - arrow

1. If oil pipe is inserted completely, the dimension from its end to the input shaft is approx. 11.5 mm.

If the dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.

If the dimension is larger, it is not pushed in far enough.

1. Insert entire input shaft into transmission housing.

Scheme 1468

1. Use back and forth rotating motions - arrow - on input shaft until clutch discs of reverse gear clutch have engaged. Raise input shaft slightly when doing this.
2. Just before the input shaft is fully in position, rotate it counter-clockwise over the last few millimeters so that it engages in the teeth of the helical intermediate gearing.

1. Tighten bolts - arrows - in diagonal sequence and in stages.
2. Fill with ATF --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .

Torque specification

Torsen differential cover, removing and installing

Special tools, testers and auxiliary items required

1. Seal remover T40014

Scheme 1469

1. Pressure stand T40099
2. Ice spray
3. Protective gloves

Removing

1. Input shaft removed --> «Input shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-removing-and-installing) .

1. Pull oil pipe - arrow - upward and out to avoid damage.

Scheme 1470

1. Check all 8 screws - arrows - on Pressure Stand T40099.

1. Screws must be installed flush to 25 Nm Assembly instructions for pressure stand T40099.

Scheme 1471

1. Insert input shaft in pressure stand T40099.
2. Rotate seal ring extractor T40014 by hand into shaft seal until tool has a good hold in the shaft seal. Then tighten puller with an opened wrench.
3. You can pull out shaft seal a short distance by installing rear bolt - arrow -.
4. Re-tighten Seal ring extractor T40014 so that puller engages securely in shaft seal again and continue turning bolt to pull out shaft seal.

1. Repeat procedure until shaft seal has been pulled out completely.

Scheme 1472

1. Remove input shaft cover circlip - A -.
2. Measure and note thickness of removed circlip.

Note. When installing, circlip must be replaced with a new circlip of same thickness.

Scheme 1473

1. Clean cover sealing surface - arrow -.

Scheme 1474

1. Cool hollow shaft - 1 - on inside of ball bearing - 2 - seat - arrow 2 - over opening - arrow 1 - of removed oil pipe with ice spray, for example.

Note. Shaft represented in section here. Shaft must be cooled so that ball bearing - 2 - can be pressed off more easily and not be damaged.

Scheme 1475

1. Clean surface of pressure stand T40099.
2. Insert input shaft in pressure stand T40099.

1. Input shaft sealing surface must be flush.
2. There must be no objects such as cable ties or dirt between input shaft sealing surfaces and surface of pressure stand T40099.

1. Also cool shaft from outside - arrow - with ice spray, for example.

Note. Shaft must be cooled so that ball bearing can be pressed off more easily and not be damaged.

1. Place input shaft together with pressure stand T40099 on hydraulic press thrust plate.

Note. Pressure stand T40099 should lie on as much surface of hydraulic press as possible.

Scheme 1476

1. Hold shaft from below and at the same time, press shaft out of cover with hydraulic press.

Scheme 1477

1. Place input shaft on assembly tool T10219/1.

Note. Ignore screwdriver and arrows.

Installing

1. Replace ball bearing in input shaft cover --> «Ball bearing in input shaft cover, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__ball-bearing-in-input-shaft-cover)

Scheme 1478

1. Place input shaft cover on input shaft and press on by hand as far as possible.

Scheme 1479

1. Place input shaft - B - on Thrust plate VW 401.

1. With hydraulic press, press input shaft cover - A - with Tube VW 416 B onto input shaft up to stop.

Input shaft cover circlip, installing

Scheme 1480

1. When installing, circlip - A - must be replaced with a new circlip of same thickness.

Note. Check for correct circlip seating.

Oil pipe, installing

1. Check wear on transmission components --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

Scheme 1481

1. Replace O-ring on oil pipe - 2 -.

1. The oil pipe is pressed into the input shaft with the O-ring - 2 -.
2. Oil pipe must engage noticeably, rotor blades - arrow A - on oil pipe must lie completely in input shaft.

1. Press oil pipe - arrow - down into input shaft to stop.

1. If oil pipe is inserted completely, the dimension from its end to the input shaft is approx. 11.5 mm.

If dimension is smaller, the oil pipe possibly is damaged as it was pushed in too far and is broken at the end.

If dimension is larger, it is not pushed in far enough.

Ball bearing in input shaft cover, replacing

1. Input shaft cover removed --> «Torsen differential cover, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__torsen-differential-cover-removing-and-installing) .

Scheme 1482

Assembly overview

1. Circlip, measure and always replace
2. Ball bearing, always replace
3. Input shaft cover

Removing

Scheme 1483

1. Remove circlip - A -.
2. Measure and note thickness of removed circlip.

Note. When installing, circlip must be replaced with a new circlip of same thickness.

Scheme 1484

1. Lay input shaft cover - 1 - on pressure stand T40099 and place under hydraulic press.
2. Press ball bearing with Tube VW 416 B out of input shaft cover.

Note. In some cases, ball bearing can also be pressed out by hand without hydraulic press. Ball bearing must be replaced.

Installing

1. Check cover sealing surface - arrow - and cover for damage

1. Surface of sealing surfaces must not show any damage.
2. Input shaft cover must not be broken cracked.

Note. The illustration is shown with input shaft.

If sealing surface or cover is damaged

1. Replace input shaft cover.

Note. A new ball bearing is installed with a new input shaft cover.

If sealing surface and cover are not damaged

1. Replace ball bearing.

1. Clean ball bearing seat in cover - arrow B -.

1. Install ball bearing - 2 - flush and press in by hand as far as possible.

Scheme 1485

1. Lay input shaft cover on Thrust plate VW 401.
2. Using a Tube 2010 , press ball bearing in as far as stop.

1. When installing, circlip - A - must be replaced with a new circlip of same thickness.
2. Check for correct circlip seating, push ball bearing in or use next thinnest circlip, if necessary.

Input shaft, servicing with 7 lining discs

There are two types of transmissions. They are differentiated according to transmission code

1. Transmission with 7 lining discs serviced

These transmissions are installed in vehicles with 4-cyl. 1.9L TDI engine, 4-cyl. 2.0L TDI engine, 6-cyl. 2.5L TDI engine, 6-cyl. 3.0L MPI gasoline engine and 6-cyl. 3.2L FSI gasoline engine.

1. > «Input shaft with 7 lining discs, assembly overview»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs)
2. > «Input shaft with 7 lining discs, disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs)

2. Transmission with 6 lining discs serviced

These transmissions are installed in vehicles with all other engines.

1. > «Input shaft with 6 lining discs, assembly overview»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs)
2. > «Input shaft with 6 lining discs, disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs)

Input shaft with 7 lining discs, assembly overview

Scheme 1486

1 - Input shaft seal

1. Replace --> «Input shaft seal, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-seal-replacing)

2 - Input shaft cover circlip

1. Replace with same thickness

3 - Input shaft cover

1. After removing cover, input shaft cover ball bearing must be replaced --> «Ball bearing in input shaft cover, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__ball-bearing-in-input-shaft-cover)

4 - Piston

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

5 - Pressure plate

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

6 - Corrugated spring washer

7 - Upper adjustment disc

1. Determine thickness --> «Input shaft with 7 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs)
2. Replace

8 - Coated plate

1. Qty. 7
2. Replace

9 - Outer plate

1. Qty. 6
2. Replace

10 - Lower adjustment disc

1. Determine thickness --> «Input shaft with 7 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs)
2. Replace

11 - Input shaft cylinder

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

12 - O-Ring

1. Replace

13 - Oil pipe

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

Input shaft with 7 lining discs, disassembling and assembling

Scheme 1487

Special tools, testers and auxiliary items required

1. Pressure plate VW 401
2. Seal remover T40014
3. Assembly tool T10219/1
4. Tube 2010

1. Tube VW 416 B

Scheme 1488

Special tools, testers and auxiliary items required

1. Pressure stand T40099
2. 2 piece ruler T40100
3. 4 piece calipers T40101
4. 2 piece feeler gauge T40102 for input shafts with 7 lining discs

1. Digital depth gauge VAS 6087
2. Protective gloves
3. Ice spray

Input shaft, disassembling

1. Transmission removed

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission .

1. Remove input shaft --> «Input shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-removing-and-installing) .
2. Remove input shaft cover from shaft --> «Torsen differential cover, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__torsen-differential-cover-removing-and-installing)

1. Place input shaft on assembly tool T10219/1.
2. Carefully raise thrust plate with pistons with two screwdrivers - arrows -.

Scheme 1489

Precautionary measures

Scheme 1490

1. Carefully guide thrust plate - 1 - with pistons - 2 - up over shaft - 3 -.

1. Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.

Disc pack, removing

Scheme 1491

1. Remove corrugated spring washer - 5 - , they must be used again.
2. Remove upper adjustment disc - 4 - from input shaft cylinder - A -.
3. Measure adjustment disc thickness - 4 - and note measurement.
4. Remove all lining discs - 2 - and outer discs - 3 - from input shaft cylinder - A -.

Note. With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must also be replaced with new disc pack with 7 lining discs and 6 outer discs .

1. Remove lower adjustment disc - 1 - from input shaft cylinder - A -.
2. Measure adjustment disc thickness - 1 - and note measurement.

Input shaft, assembling

1. Replace ball bearing in input shaft cover --> «Ball bearing in input shaft cover, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__ball-bearing-in-input-shaft-cover) .
2. Adjust input shaft and determine air gap --> «Input shaft with 7 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs)

Scheme 1492

1. Place input shaft on assembly tool T10219/1.

1. Insert determined lower adjustment disc - 1 - in input shaft cylinder - A -.
2. Insert alternately and with same alignment each lining disc - 2 - (7 pieces) and outer disc - 3 - (6 pieces, 1.9 mm thickness).

Scheme 1493

Lining disc alignment

Note. With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must also be replaced with new disc pack with 7 lining discs and 6 outer discs .

1. Insert determined upper adjustment disc - 4 - in input shaft cylinder - A -.
2. Lastly, insert corrugated spring washer - 5 -.

1. Press piston - 1 - into stop on thrust plate - 2 -.

1. Carefully guide pressure plate - 1 - with pistons - 2 - down over shaft - 3 -.

1. Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.

1. Press thrust plate with pistons uniformly into input shaft up to stop.

Scheme 1494

Checking air play with feeler gauge T40102

1. Insert both feeler gauges T40102 under thrust plate - A -.
2. A second technician must push thrust plate - A - down to stop - arrow 1 - with Tube VW 416 B.
3. Guide both feeler gauges T40102 circularly in direction of - arrow - back and forth under thrust plate.

1. Both feeler gauges T40102 must be guided oppositely.
2. Feeler gauges T40102 must not be angled.
3. Entire circular area must be checked.
4. Both feeler gauges T40102 must always move freely without slightest resistance.

If feeler gauges T40102 cannot be guided in direction of - arrow - without blocking

1. Repeat input shaft adjustment --> «Input shaft with 7 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs) .

If feeler gauges T40102 can be guided in direction of - arrow - without blocking

1. Install input shaft cover --> «Torsen differential cover, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__torsen-differential-cover-removing-and-installing) .

1. Install input shaft --> «Input shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-removing-and-installing) .

1. Install input shaft seal - A - --> «Input shaft seal, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-seal-replacing) .
2. Fill with ATF --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .

Input shaft with 7 lining discs, adjusting with air gap determination

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . All components must be cleaned thoroughly before inserting.

Clutch measurement

Scheme 1495

Note. Distance - K - of the clutch from the upper contact ring shim on the shaft (Thrust plate contact surface) is determined. The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.

1. Place input shaft on assembly tool T10219/1.

Scheme 1496

1. Insert new lower adjustment disc - 1 - of same thickness as old in input shaft cylinder - A -.
2. Insert corrugated spring washer - 2 -.

Note. The corrugated spring washer is installed at the bottom only for measurement, it is installed again at the time during assembly.

1. Insert alternately and with same alignment each lining disc - 3 - (7 pieces) and outer disc - 4 - (6 pieces, 1.9 mm thickness).

Lining disc alignment

Note. With old version of input shaft, only 6 lining discs and 5 outer discs are installed. They must be replaced with new disc pack with 7 lining discs and 6 outer discs .

1. Last, insert new upper shim - 5 - of same thickness as old in input shaft.

Note. For the following measurements, all tool and component surfaces must be completely clean in order to obtain exact values.

Scheme 1497

1. Place 4 calipers T40101 on upper shim.

Scheme 1498

1. Lay a ruler T40100 centered over every 2 calipers T40101.

Scheme 1499

1. Measure shim with digital depth gauge VAS 6087 and note measurement - A -.

1. Digital depth gauge VAS 6087 must lie flush on both rulers T40100 when measuring.

Scheme 1500

1. Measure with digital depth gauge VAS 6087 on shaft contact ring (Thrust plate contact surface) and note measurement - B -.

1. Subtract both measurements "B A" , to obtain clutch distance - K -.

Clutch distance calculation - K - : "B A = K"

Note. The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.

1. Repeat measurement on opposite side of input shaft and also determine clutch distance - K -.
2. Insert 4 calipers T40101 and 2 rulers T40100 at 90° on input shaft and repeat measurements.
3. Using 4 values determined for clutch distance - K - , calculate average M K .

Average: " (Value 1 + Value 2 + Value 3 + Value 4) : 4 = M K "

Thrust plate measurement

1. First check for damage and replace, if necessary.
2. Rotate thrust play and lay on level and clean surface.

Scheme 1501

1. Place 2 calipers T40101 on cleaned thrust plate running surface.

1. Calipers T40101 must lie completely on clean running surfaces and must not lie on edge

Scheme 1502

1. Lay rulers T40100 centered on calipers T40101.
2. Measure shim with digital depth gauge VAS 6087 on upper running surface and note measurement - A -.

Scheme 1503

1. Measure with digital depth gauge VAS 6087 on lower running surface and note measurement - B -.
2. Subtract value of both measurements "B A" to determine distance "D" of both running surfaces to thrust plate.

Thrust plate distance calculation "D" : "B A = D"

1. Repeat measurement on 2 additional places on thrust plate off-set at 120°.
2. Using these three measurements, calculate thrust plate average M D .

Average: " (Value 1 + Value 2 + Value 3) : 3 = M D "

Determining air play

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

Air gap = " M D " " M K "

Air gap specified value: 1.8 ± 0.2 mm.

If specified value is not obtained

A - Measured value too small

1. Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.
2. Check air gap again after installing new adjustment disc --> «Input shaft with 7 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs) .

B - Measured value too large

1. Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.
2. Check air gap again after installing new adjustment disc --> «Input shaft with 7 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs) .

Following adjustment discs are available

Note. Air gap can be adjusted using upper and lower adjustment discs.

If specified value is obtained

1. Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer - 5 - , - 4 - , - 3 - , - 2 - and - 1 - from input shaft cylinder - A -.

1. Assemble input shaft «Input shaft, assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-assembling) .

Input shaft, servicing with 6 lining discs

There are two types of transmissions. They are differentiated according to transmission code

1. Transmission with 7 lining discs serviced

These transmissions are installed in vehicles with 4-cyl. 1.9L TDI engine, 4-cyl. 2.0L TDI engine, 6-cyl. 2.5L TDI engine, 6-cyl. 3.0L MPI gasoline engine and 6-cyl. 3.2L FSI gasoline engine.

1. > «Input shaft with 7 lining discs, assembly overview»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs)
2. > «Input shaft with 7 lining discs, disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-7-lining-discs)

2. Transmission with 6 lining discs serviced

These transmissions are installed in vehicles with all other engines.

1. > «Input shaft with 6 lining discs, assembly overview»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs)
2. > «Input shaft with 6 lining discs, disassembling and assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs)

Input shaft with 6 lining discs, assembly overview

Scheme 1504

1 - Input shaft seal

1. Replace --> «Input shaft seal, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-seal-replacing)

2 - Input shaft cover circlip

1. Replace with same thickness

3 - Input shaft cover

1. After removing cover, input shaft cover ball bearing must be replaced --> «Ball bearing in input shaft cover, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__ball-bearing-in-input-shaft-cover)

4 - Piston

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

5 - Pressure plate

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

6 - Corrugated spring washer

7 - Upper adjustment disc

1. Determine thickness --> «Input shaft with 6 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs)
2. Replace

8 - Coated plate

1. Qty. 6
2. Replace

9 - Outer plate

1. Qty. 5
2. Replace

10 - Lower adjustment disc

1. Determine thickness --> «Input shaft with 6 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs)
2. Replace

11 - Input shaft cylinder

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

12 - O-Ring

1. Replace

13 - Oil pipe

1. Check for wear --> «Transmission components, evaluating wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

Input shaft with 6 lining discs, disassembling and assembling

Special tools, testers and auxiliary items required

1. Pressure plate VW 401
2. Seal remover T40014
3. Assembly tool T10219/1
4. Tube 2010

1. Tube VW 416 B

Scheme 1505

Special tools, testers and auxiliary items required

1. Pressure stand T40099
2. 2 piece ruler T40100
3. 4 piece calipers T40101
4. 2 piece feeler gauge T40117 for input shafts with 6 lining discs

1. Digital depth gauge VAS 6087
2. Protective gloves
3. Ice spray

Work procedure

1. Transmission removed

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission .

1. Remove input shaft --> «Input shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-removing-and-installing) .
2. Remove input shaft cover from shaft --> «Torsen differential cover, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__torsen-differential-cover-removing-and-installing)

1. Place input shaft on assembly tool T10219/1.
2. Carefully raise thrust plate with pistons with two screwdrivers - arrows -.

Precautionary measures

1. Carefully guide thrust plate - 1 - with pistons - 2 - up over shaft - 3 -.

1. Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.

Disc pack, removing

Scheme 1506

1. Remove corrugated spring washer - 5 - , they must be used again.
2. Remove upper adjustment disc - 4 - from input shaft cylinder - A -.
3. Measure adjustment disc thickness - 4 - and note measurement.
4. Remove all lining discs - 2 - and outer discs - 3 - from input shaft cylinder - A -.

1. Remove lower adjustment disc - 1 - from input shaft cylinder - A -.
2. Measure adjustment disc thickness - 1 - and note measurement.

1. Replace ball bearing in input shaft cover --> «Ball bearing in input shaft cover, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__ball-bearing-in-input-shaft-cover) .
2. Adjust input shaft and determine air gap --> «Input shaft with 6 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs) .

1. Place input shaft on assembly tool T10219/1.

1. Insert determined lower adjustment disc - 1 - in input shaft cylinder - A -.
2. Insert alternately and with same alignment each lining disc - 2 - (6 pieces) and outer disc - 3 - (5 pieces, 1.9 mm thickness).

Lining disc alignment

1. Insert determined upper adjustment disc - 4 - in input shaft cylinder - A -.
2. Lastly, insert corrugated spring washer - 5 -.

1. Press pistons - 1 - into stop on thrust plate - 2 -.

1. Carefully guide pressure plate - 1 - with pistons - 2 - down over shaft - 3 -.

1. Inner running surfaces of thrust plate - 1 - and pistons - 2 - must not touch shaft.

1. Press thrust plate with pistons uniformly into input shaft up to stop.

Scheme 1507

Checking air play with feeler gauge T40117

1. Insert both feeler gauges T40117 under thrust plate - A -.
2. A second technician must push thrust plate - A - down to stop - arrow 1 - with Tube VW 416 B.
3. Guide both feeler gauges T40117 circularly in direction of - arrow - back and forth under thrust plate.

1. Both feeler gauges T40117 must be guided oppositely.
2. Feeler gauges T40117 must not be angled.
3. Entire circular area must be checked.
4. Both feeler gauges T40117 must always move freely without slightest resistance.

If feeler gauges T40117 cannot be guided in direction of - arrow - without blocking

1. Repeat input shaft adjustment --> «Input shaft with 6 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs) .

If feeler gauges T40117 can be guided in direction of - arrow - without blocking

1. Install input shaft cover --> «Torsen differential cover, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__torsen-differential-cover-removing-and-installing) .

1. Install input shaft --> «Input shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-removing-and-installing) .

1. Install input shaft seal - A - --> «Input shaft seal, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-seal-replacing) .
2. Fill with ATF --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .

Input shaft with 6 lining discs, adjusting with air gap determination

Note. Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . All components must be cleaned thoroughly before inserting.

Clutch measurement

Note. The distance - K - of the clutch from the upper contact ring shim on the shaft (Thrust plate contact surface) is determined. The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.

1. Place input shaft on assembly tool T10219/1.

Scheme 1508

1. Insert new lower adjustment disc - 1 - of same thickness as old in input shaft cylinder - A -.
2. Insert corrugated spring washer - 2 -.

Note. The corrugated spring washer is installed at the bottom only for measurement, it is installed again at the time during assembly.

1. Insert alternately and with same alignment each lining disc - 3 - (6 pieces) and outer disc - 4 - (5 pieces, 1.9 mm thickness).

Lining disc alignment

1. Last, insert new upper shim - 5 - of same thickness as old in input shaft.

Note. For the following measurements, all tool and component surfaces must be completely clean in order to obtain exact values.

1. Place 4 calipers T40101 on upper shim.

1. Lay a ruler T40100 centered over every 2 calipers T40101.

1. Measure shim with digital depth gauge VAS 6087 and note measurement - A -.

1. Digital depth gauge VAS 6087 must lie flush on both rulers T40100 when measuring.

1. Measure with digital depth gauge VAS 6087 on shaft contact ring (Thrust plate contact surface) and note measurement - B -.

1. Subtract both measurements "B A" , to obtain clutch distance - K -.

Clutch distance calculation - K - : "B A = K"

Note. The corrugated spring washer - 1 - is installed under the disc pack to perform measurements.

1. Repeat measurement on opposite side of input shaft and also determine clutch distance - K -.
2. Insert 4 calipers T40101 and 2 rulers T40100 at 90° on input shaft and repeat measurements.
3. Using 4 values determined for clutch distance - K - , calculate average M K .

Average: " (Value 1 + Value 2 + Value 3 + Value 4) : 4 = M K "

Thrust plate measurement

1. First check for damage and replace, if necessary «Checking pistons and thrust plate for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__checking-pistons-and-thrust-plate-for) .
2. Rotate thrust play and lay on level and clean surface.

1. Place 2 calipers T40101 on cleaned thrust plate running surface.

1. Calipers T40101 must lie completely on clean running surfaces and must not lie on edge

1. Lay rulers T40100 centered on calipers T40101.
2. Measure shim with digital depth gauge VAS 6087 on upper running surface and note measurement - A -.

1. Measure with digital depth gauge VAS 6087 on lower running surface and note measurement - B -.
2. Subtract value of both measurements "B A" to determine distance "D" of both running surfaces to thrust plate.

Thrust plate distance calculation "D" : "B A = D"

1. Repeat measurement on 2 additional places on thrust plate off-set at 120°.
2. Using these three measurements, calculate thrust plate average M D .

Average: " (Value 1 + Value 2 + Value 3) : 3 = M D "

Determining air play

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

Air gap = " M D " " M K "

Air gap specified value: 1.4 ± 0.2 mm.

If specified value is not obtained

A - Measured value too small

1. Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.
2. Check air gap again after installing new adjustment disc --> «Input shaft with 6 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs) .

B - Measured value too large

1. Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.
2. Check air gap again after installing new adjustment disc --> «Input shaft with 6 lining discs, adjusting with air gap determination»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-with-6-lining-discs) .

Following adjustment discs are available

Note. Air gap can be adjusted using upper and lower adjustment discs.

If specified value is obtained

1. Remove all adjustment discs, lining discs, outer discs and the corrugated spring washer - 5 - , - 4 - , - 3 - , - 2 - and - 1 - from input shaft cylinder - A -.

1. Assemble input shaft «Input shaft, assembling»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) .

Left flange shaft seal, replacing

Special tools, testers and auxiliary items required

Scheme 1509

1. Extractor lever VW 681

Scheme 1510

1. Driver 2062

Work procedure

1. Transmission installed

1. Remove left flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Scheme 1511

1. Pull out flange shaft seal using Extractor lever VW 681.

Note. Do not damage shaft seal seating surfaces.

Scheme 1512

Setup of flange shaft with polygon bearing

1. Flange shaft
2. Needle bearing (polygon bearing)
3. Spacer ring
4. Circlip
5. Not installed

Note. If the polygon bearings do not run smoothly with the flange shaft removed, this does indicate that the bearings are faulty. A test for noisy bearings can only be performed with the bearings installed. Watch for damage to the polygon bearings (e.g. cracks in bearing outer ring) If polygon bearings are damaged, flange shaft must be replaced.

1. Moisten outer circumference and shaft seal lip with axle oil.

1. Installation position: Open side of shaft seal faces transmission.

Scheme 1513

1. Drive in new left flange shaft seal uniformly with Driver 2062.

1. Production drive-in depth 5.5 mm below cover surface.
2. If re-using the used flange shaft, repair drive-in depth is 6.5 mm.

Note. Do not angle shaft seal when driving in.

1. Install left flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
2. Check gear oil level in front final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Scheme 1514

Special tools, testers and auxiliary items required

1. Pressure plate VW 401
2. Pressure plate VW 402
3. Punch VW 407
4. Punch VW 412

1. Extractor lever VW 681
2. Driving sleeve 32 - 109

Special tools, testers and auxiliary items required

Scheme 1515

1. Tube 2040

1. Driver 2062

Scheme 1516

Work procedure

1. Remove right flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Removing shaft seal

1. Remove securing ring - arrow A - for grooved ball bearing.

Scheme 1517

1. Press flange shaft out of mounting bracket for flange shaft as shown in the illustration.
2. Pull flange shaft seal out of mounting bracket using Extractor lever VW 681.

Scheme 1518

Removing grooved ball bearing

1. Press grooved ball bearing out of mounting bracket.

Scheme 1519

Installing grooved ball bearing

1. Press new grooved ball bearing into mounting bracket.

Scheme 1520

Installing shaft seal

1. Coat outer edge and sealing lip of shaft seal with axle oil.

1. Installation position: Open side of shaft seal faces transmission.

1. Drive in new right flange shaft seal uniformly with Driver 2062.

1. Production drive-in depth 5.5 mm below mounting bracket surface.
2. If re-using the used flange shaft, repair drive-in depth is 6.5 mm.

Note. Do not angle shaft seal when driving in.

Scheme 1521

1. Press mounting bracket with grooved ball bearing onto flange shaft.

1. Insert securing ring - arrow A -.
2. Install right flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
3. Check gear oil level in front final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Scheme 1522

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. Socket T10023
3. Thrust pad T40107
4. Assembly lever

1. Cleaning solution D 009 401 04

Work procedure

1. The differential shaft seal can be replaced with transmission installed.

1. Drain ATF --> «ATF, draining for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-draining-for-atf-flushing-process) .
2. Remove differential --> «Differential, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__differential-removing-and-installing)
3. Remove right flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Note. In the case of insufficient accessibility in the vehicle, right flange shaft must not be completely removed. In that case, it only needs to be pulled out of transmission housing a little in order to create enough room to remove and install shaft seal.

Scheme 1523

1. Place a punch on a side hole of pinion shaft seal and punch a small hole - arrow - to install a metal screw in shaft seal.

Scheme 1524

1. Install metal screw with large head in shaft seal hole.

Scheme 1525

1. Use a stable lever - 1 - with center notch - arrow - to install metal screw.
2. Position lever on metal screw.

1. Remove shaft seal.

Scheme 1526

1. Clean breather tube - arrow - using pressurized air and lay a cloth on interior side of breather tube.

Scheme 1527

1. Clean differential shaft sealing surface with cleaning solution D 009 401 04 and a soft cloth; to do so turn differential shaft.

1. Selector shaft lever must not be in position "P".

1. Remove stubborn deposits with the fingernail, do not use tools at all.

1. Coat outside circumference of shaft seal with ATF.
2. Check assembly aid T40107/2 for cracks or burrs. Do not use a damaged assembly aid.

Scheme 1528

1. Place assembly aid T40107/2 on pressure sleeve T40107/1 and slide shaft seal - 1 - onto pressure sleeve.

1. Closed side of shaft seal points towards tool.

1. Remove assembly aid T40107/2.
2. Connect pressure sleeve T40107/1 with shaft seal - 1 - to differential shaft.

Scheme 1529

1. Place selector shaft lever in "P" position (all the way back).
2. Rotate nuts on spindle T40107/3 all the way back.
3. Rotate spindle T40107/3 to stop with open-end wrench.

Note. This installs spindle securely on differential shaft.

1. Bring pressure sleeve T40107/1 into correct position.

1. Tabs - arrows - pressure sleeve circumference must engage in notches on transmission housing.

Scheme 1530

1. Press shaft seal into transmission housing with pressure sleeve and tighten nut to 17 Nm using Torque wrench V.A.G 1331 and Socket T10023.

1. Shaft seal must settle for 2 minutes.

1. After waiting 2 minutes, remove nut and remove pressure sleeve in driving direction.

Scheme 1531

1. Check whether shaft seal lip visible from outside lies on cylindrical differential shaft sealing surface and not on chamfer - arrow - ; press shaft seal on, if necessary
2. Install right flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
3. Install differential housing and front final drive cover --> «Differential, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__differential-removing-and-installing) .

With transmission removed

Note. To check for leaks, transmission must be reinstalled in vehicle so that a road test can be performed. Transmission, removing and installing --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All

1. Fill with ATF --> «ATF, filling for ATF flushing process»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__atf-filling-for-atf-flushing-process) .

Scheme 1532

1. Perform an extended test drive and finally check for leaks on bleeder hole - arrow A - on front final drive cover.

Note. The bleeder hole is covered with a protective plate in certain transmissions. On new transmissions, the bleeder hole is placed to the side so a leak is only visible at side of front final driver cover. If oil escapes at the bleeder hole, repair must be repeated.

Scheme 1533

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Puller T10037
3. Drift VW 295

Removing

Note. Front final drive cover, removing and installing on installed transmission --> 39 - FINAL DRIVE, DIFFERENTIAL Observe general repair notes --> Repair instructions . Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . Transmission removed and secured to assembly stand --> Transmission, attaching to assembly stand .

Scheme 1534

1. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
2. Tightly thread lower support of puller T10037 on front differential cover - arrow -.

Note. To avoid damage to the needle bearings (polygon bearings) or differential during removal, the flange shaft must be removed evenly, parallel and without one sided pressure

1. Remove left flange shaft with Puller T10037.
2. Clamp flange shaft in vise, using jaw protectors.

Flange shaft circlip must always be replaced.

Scheme 1535

1. Press circlip with new circlip - A - out of flanged shaft groove.

Scheme 1536

1. Tighten bolts on front final drive cover - 11 to 1 - in sequence.

Scheme 1537

1. Secure differential - arrow - against falling out.

Installing

Scheme 1538

1. Ensure that magnet under plastic cover in front final drive cover is installed.

Scheme 1539

1. Replace O-ring - 1 - in front final drive cover.
2. Check cover for secure seating - 2 -.

1. Check differential - arrow - for correct seating in transmission.

Scheme 1540

1. Position front final drive cover on transmission housing.
2. Replace all bolts on front final drive cover.
3. If present, install shield - B - between final drive cover and bolt - 1 -.

Note. The shield - B - should protect the bleeder hole - arrow A - from dirt and water.

Tightening sequence

1. Tighten bolts on front final drive cover in 2 stages in sequence shown as follows
2. Stage: Hand-tighten bolts in - 1 to 11 - sequence.
3. Stage: Tighten bolts in - 1 to 11 - sequence in several stages to tightening torque.
4. Check left flange shaft seal, replace if necessary --> «Left flange shaft seal, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__left-flange-shaft-seal-replacing)

1. Install left flange shaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
2. Fill axle oil and check level in front final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Torque specification

Differential, removing and installing

Removing

With transmission installed

1. Remove front final drive cover --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

With transmission removed

1. Remove front final drive cover --> «Front final drive cover (on removed transmission), removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) .

All

1. Carefully remove differential - arrow -.

Installing

1. Carefully install differential - arrow -.

With transmission installed

1. Install front final drive cover --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

With transmission removed

1. Install front final drive cover --> «Front final drive cover (on removed transmission), removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) .

Input shaft, checking for wear

4 - Piston

1. Checking for wear «Checking pistons and thrust plate for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__checking-pistons-and-thrust-plate-for)

5 - Pressure plate

1. Checking for wear «Checking pistons and thrust plate for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__checking-pistons-and-thrust-plate-for)

11 - Input shaft cylinder

1. Check running and sealing surfaces for wear «Check input shaft cylinder running and sealing surfaces for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)
2. Checking for signs of wear caused by coated plate --> «Check inner circumference of input shaft cylinder for scoring from lining discs»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

13 - Oil pipe

1. Checking for wear «Checking oil pipe for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

Checking pistons and thrust plate for wear

1. Remove pistons - 1 - from thrust plate - 2 -.

Check thrust plate - 2

1. Check thrust plate running and sealing surfaces - arrow A - for wear.
2. Check thrust plate running and sealing surfaces - arrow D - for wear.

1. If running or sealing surfaces - arrow A - show grooves, scratches or scoring, thrust plate - 2 - must be replaced.
2. If running or sealing surfaces - arrow D - show grooves, scratches or scoring, thrust plate - 2 - and pistons - 1 - must be replaced.

Checking pistons - 1

1. Check seal - arrow B - on outer piston circumference - 1 - for damage.
2. Check running surface - arrow C - on interior piston circumference - 1 - on shaft.

1. If seal - arrow B - is damaged or piston running surface - arrow C - shows grooves, scratches, scoring or uneven thickness from wear, piston - 1 - must be replaced.

Scheme 1541

1. Check input shaft running and sealing surfaces - arrow A - for wear.

Note. Shaft seal in input shaft cover seals at this sealing surface - arrow A -. Light scoring from shaft seal is normal.

1. Check ball bearing running surface - arrow B - in input shaft cover for wear.
2. Check shaft seal - arrow C - for damage.

1. If seal - arrow C - is damaged or shaft running surfaces - arrow B - or - arrow A - show deep scoring or grooves, entire input shaft must be replaced.

Scheme 1542

1. Check inner circumference of input shaft cylinder for scoring from lining discs - arrows -.

1. If there is scoring on interior circumference of input shaft cylinder from lining discs - arrows - , entire input shaft must be replaced.

Scheme 1543

1. Check oil pipe seal - 1 - for damage.

1. The seal must have a gap - arrow B -.
2. If gap - arrow B - is completely closed, oil pipe must be replaced.

1. Check oil pipe running surfaces - arrows - and rotor blades - arrow A - for wear, cracks and damage.

1. If seal - 1 - or rotor blades - arrow A - are damaged or running surfaces - arrow - show deep scoring or grooves, oil pipe must be replaced.
2. The O-ring - 2 - must always be replaced.

1. Always check oil pipe running surfaces in suction jet pump --> «Suction jet pump, checking wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__suction-jet-pump-checking-wear)

Suction jet pump, checking wear

1. Input shaft removed --> «Input shaft, removing and installing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing__input-shaft-removing-and-installing)

Scheme 1544

1. Check oil pipe running surfaces - arrow - in suction jet pump for scoring, scratches or damage.

1. The oil pipe running surface in suction jet pump - arrow - must not have any noticeable, cascaded scoring or scratches.

In case of noticeable, cascaded scoring or damage to the wear surface by the oil pipe, suction jet pump must be replaced.

1. Always check oil pipe «Checking oil pipe for wear»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing)

Differential shaft, checking for wear

1. Differential removed
2. Shaft seal removed --> «Differential shaft seal, replacing»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) .

1. Check differential shaft sealing surface for scratches or damage.

1. The differential shaft sealing surface must not be scratched or scored.

Note. Even the smallest scratches or damage on the differential shaft sealing surface will cause lack of seal, even with a new shaft seal.

See also:
• 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
• 43 - SELF-LEVELING SUSPENSION
• Rules for cleanliness when working on transmission
• Transmission components, evaluating wear
• ATF, filling for ATF flushing process
• Input shaft adjustment (air gap), checking
• Carry out ATF flush test run
• ATF flush
• ATF, draining for ATF flushing process
• Input shaft seal, replacing
• Selector shaft, cleaning
• Transmission Control Module (TCM) J217 , removing and installing
• Input shaft, removing and installing
• Ball bearing in input shaft cover, replacing
• Torsen differential cover, removing and installing
• Input shaft with 7 lining discs, assembly overview
• Input shaft with 6 lining discs, assembly overview
• Input shaft, assembling
• Checking pistons and thrust plate for wear
• Differential, removing and installing
• Left flange shaft seal, replacing
• Suction jet pump, checking wear