Gears, Hydraulic Controls (Continuously Variable Transmission Internal Components 0aw (sedan)) Audi A4 B8

SELECTOR SHAFT, CLEANING

Procedure

1. End cover removed, refer to «COVER, WITH TRANSMISSION REMOVED»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__cover-with-transmission-removed) .
2. Transmission control module -J217- removed, refer to «Transmission Control Module -J217»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__transmission-control-module-j217) .

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

Clean the selector shaft catch -arrows-. Use a lint-free cloth. Clean contact surfaces of magnet thoroughly. Make sure there no metal shavings on it.

Scheme 241

Note. Make sure that spring -1- and the roller -4- are secured properly.

Check the roller -4- and spring -1- for damage; replace if necessary.

COVER, TRANSMISSION CONTROL MODULE AND HYDRAULIC CONTROL UNIT OVERVIEW

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

Scheme 242

1. Transmission
2. Small Axial Sealing Element Replace
3. Large Axial Sealing Element Replace
4. Roller
5. Lever For the selector lever lock mechanism
6. Spring
7. Seal For the transmission control module -J217- connector
8. Bolt Replace 10 Nm plus an additional 90° turn Qty. 12, tighten in diagonal sequence
9. Cover Removing and installing with the transmission installed, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-cvt-0aw-sedan) Refer to «COVER, WITH TRANSMISSION REMOVED»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__cover-with-transmission-removed)
10. Gasket Replace
11. Bolt 5 Nm plus an additional 90° turn Quantity: 3
12. Transmission Control Module -J217- Removing and installing, refer to «Transmission Control Module -J217»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__transmission-control-module-j217)
13. Bolt 5 Nm plus an additional 90° turn Quantity: 3
14. Hydraulic Control Module Removing and installing, refer to «HYDRAULIC CONTROL MODULE»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__hydraulic-control-module)

Scheme 243

1. Input Shaft Removing and installing, refer to «INPUT SHAFT»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft)
2. Cover For the input shaft Removing and installing, refer to «INPUT SHAFT COVER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft-cover)
3. O-ring Replace
4. Ball Bearing For the input shaft Removing and installing, refer to «INPUT SHAFT BALL BEARING»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft-ball-bearing)
5. Locking Ring Measuring Replace
6. Shaft Seal For the input shaft Removing and installing, refer to «INPUT SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft-seal)
7. Locking Ring Replace Determine thickness «SELECTING THE LOCKING RING THICKNESS -1-Coat the new shaft seal -A- with ATF.»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__selecting-the-locking-ring-thickness-1-coat) .

PRESSURE STAND, ADAPTING TO 0AW TRANSMISSION

Procedure

1. Input shaft removed, refer to «INPUT SHAFT»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft) .

Place the input shaft centered exactly on the pressure stand T40099.

Mark the locations -arrow- where the alignment pins -1- are on the upper ring on the T40099 with color.

Scheme 244

1. The marked location should be somewhat in the center between the connection -2- on the T40099.

Make a punch mark inside the marked field -a- = 6 mm from the inner edge and then make a 11 mm hole.

Scheme 245

Make two cuts with a saw -arrow- as illustrated.

Scheme 246

Remove any burrs on the saw cuts and the hole.

Scheme 247

1. Corrugated Spring Washer Replace
2. Lower Adjustment Disc Replace Determine thickness "E 1 " «REVERSE GEAR CLUTCH, SELECTING ADJUSTING DISCS»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__reverse-gear-clutch-selecting-adjusting-discs) . The thickness of the setting discs under "E 1 " must be at least 2.15 mm
3. Lining Disc Replace Quantity: 7
4. Upper Adjustment Disc Replace Determine thickness "E 2 " «SETTING THE REVERSE GEAR CLUTCH BY DETERMINING THE ADJUSTMENT DISC»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__setting-the-reverse-gear-clutch-by)
5. Outer Clutch Disc Replace Quantity: 6

Scheme 248

1. Lower Adjustment Disc Replace Determine thickness, refer to «ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__adjusting-input-shaft-by-determining-air)
2. Outer Clutch Disc Replace Quantity: 6
3. Lining Disc Replace Quantity: 7
4. Upper Adjustment Disc Replace Determine thickness, refer to «ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__adjusting-input-shaft-by-determining-air)
5. Corrugated Spring Washer
6. Pressure Plate Check for wear, refer to «INPUT SHAFT, CHECKING FOR WEAR»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan)
7. Pistons Check for wear, refer to «INPUT SHAFT, CHECKING FOR WEAR»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan)
8. Cover For the input shaft After removing cover, input shaft ball bearing must be replaced. Refer to «INPUT SHAFT BALL BEARING»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft-ball-bearing) .
9. Locking Ring For the input shaft cover Replace with same thickness
10. Shaft Seal For the input shaft Removing and installing, refer to «INPUT SHAFT SEAL»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft-seal)
11. Input Shaft Check for wear, refer to «INPUT SHAFT, CHECKING FOR WEAR»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan)
12. O-ring Replace
13. Oil Pipe Check for wear, refer to «INPUT SHAFT, CHECKING FOR WEAR»(/audi/a4/b8-2007-2012/remont/axle-shafts/#final-drive-differential-continuously-variable-transmission-internal-components-0aw-sedan)

FASTENER TIGHTENING SPECIFICATIONS

ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY

Special tools and workshop equipment required

1. Assembly Tool T10219/1
2. Calipers T40101
3. Ruler T40100
4. Digital Depth Gauge VAS 6087

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

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. All components must be cleaned thoroughly before inserting.

Place input shaft on T10219/1.

Scheme 249

Insert new lower adjustment disc -1- of the same thickness as the old in input shaft cylinder -A-.

Scheme 250

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.

Insert alternately and with same alignment each lining disc -3- and one externally toothed plate -4-.

Lining disc alignment

Scheme 251

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

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

Place 4 T40101 on the upper shim.

Scheme 252

Lay a T40100 centered over every 2 T40101.

Scheme 253

Measure shim with VAS 6087 and note measurement -A-.

Scheme 254

1. VAS 6087 must lie flush on both T40100 when measuring.

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

Scheme 255

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

Scheme 256

Clutch distance calculation -K- of the clutch: "B - A = K"

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

Repeat measurement on opposite side of input shaft and also determine clutch distance -K-.

Insert 4 T40101 and 2 T40100 at 90° on the input shaft and repeat measurements.

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

First check for damage and replace, if necessary.

Rotate thrust play and lay on level and clean surface.

Place 2 T40101 on cleaned thrust plate running surface.

Scheme 257

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

Lay T40100 centered on T40101.

Scheme 258

Measure shim with VAS 6087 on upper running surface and note measurement -A.-.

Measure with digital depth gauge VAS 6087 on lower running surface and note measurement -B-.

Scheme 259

Subtract value of both measurements "B - A" in order to get the distance "D" between the two areas of the thrust plate.

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

Repeat measurement on 2 additional places on thrust plate off-set at 120°.

Using these three measurements, calculate thrust plate average M D .

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

Determining Air Play

Use the following calculation to determine air gap

Air gap= "M D " - "M K "

1. Air gap specified value: 1.8 +/- 0.2 mm.

If Specified Value Is Not Reached

A - Measured value too small

Insert corresponding thinner adjustment disc, lower adjustment disc must also be replaced, if necessary.

Check air gap again after installing new adjustment disc. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

B - Measured value too large

Insert corresponding thicker adjustment disc, lower adjustment disc must also be replaced, if necessary.

Check air gap again after installing new adjustment disc. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

Following adjustment discs are available

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

If Specified Value Is Reached

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

Assemble input shaft INPUT SHAFT SEAL ..

REVERSE GEAR CLUTCH, SELECTING ADJUSTING DISCS

Special tools and workshop equipment required

1. Digital Depth Gauge VAS 6087
2. Digital Caliper, 150 mm VAS 6335
3. 2x Ruler T40100
4. Clean and flat measuring surface, for example, the Pre-Tensioning Tool T10285

Removing Reverse Gear Clutch

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

1. Transmission removed and mounted vertically to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__transmission-securing-in-enginetransmission-holder) .

Remove the input shaft. Refer to INPUT SHAFT .

Remove the reverse gear clutch and corrugated spring washer -1 through 5- from the transmission.

Scheme 260

MEASURE THE UPPER ADJUSTMENT DISC -4- AND LOWER ADJUSTMENT DISC -2- AND MAKE A NOTE OF IT.

Note. Making a note of the old upper adjustment disc -4- and lower adjustment disc -2- will be used later when installing new adjusting discs. The measurement must be repeated if the values between the old and new adjustment discs deviate from each other.

SETTING THE REVERSE GEAR CLUTCH BY DETERMINING THE ADJUSTMENT DISC

Note. The following measurements serve for the determination of the upper adjustment discs -4- and lower -2- for the setting of the reverse gear clutch.

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

1. Measurement from the Input Shaft Cover Contact Surface to the Corrugated Spring Washer Contact Surface -B

Scheme 261

Clean surfaces on the transmission housing, completely remove remaining seals.

Measure from the input shaft cover contact surface to the corrugated spring washer contact surface inside the transmission housing using VAS 6087.

Make a note of dimension "B1".

Repeat measurement on two different points and note the measured values "B2" and "B3".

Determine and note the average value -B- from the 3 measured values.

Average: B1 + B2 + B33 = dimension -B

Make of note of dimension -B-.

Example

29.0 mm + 28.9 mm + 29.0 mm3 = 28.97 mm

In the example, dimension -B- = 28.97 mm.

2. Measurement of the Pre-Tension Clutch Package, Determination of Dimension -A

Scheme 262

1. The corrugated spring washer -2- is installed under the disc pack to perform measurements.
2. Use a clean and flat measuring surface as a backing -1-. In the following description, the T10285 is used.

Place the corrugated spring washer -A- on the measuring surface -1-.

Scheme 263

Then, alternating with the same direction for each lining disc -C- (7 pieces) and place an outer disc -B- (6 pieces) on the corrugated spring washer.

Allocated all discs cleanly on top of each other.

Place both T40100 measuring straight edges over the disc package.

Note. Through the weight of the T40100 measuring straight edge, the air is pressed from the discs and the corrugated spring washer is subject to 2.5 kg (pretension).

Measure with the VAS 6087 on the working space -1- and note the measurement "a1".

Scheme 264

1. VAS 6087 must lie flush on both T40100 when measuring.

Repeat measurement on the opposite side of the disc package and note the measured value "a2".

Move the 2 T40100 by 90°.

Repeat the measurements and make a note of the values "a3" and "a4".

Determine and note the average value -a- from the 4 measured values.

Average: a1 + a2 + a3 + a44 = -a

Determine dimension -A

Measure and note the thickness -b- of the T40100.

The height of the pre-tension clutch package: -a- - -b- = dimension -A

Make a note of dimension -A-.

3. Measurement of the Input Shaft Cover Contact Surface on the Pistons of the Reverse Gear Clutch, Dimension -C

Scheme 265

Place a clean outer disc -1- on the removed input shaft.

Scheme 266

Note. The externally toothed plate -1- is placed on the reverse gear clutch piston so that a correct measurement can be performed on the highest position of the piston. The thickness -d- of the outer disc -1- will be subtracted later to determine the amount of the piston.

Measure from the contact surface -2- on the input shaft cover to the externally toothed plate -1- laid on it with a digital depth gauge VAS 6087 and then make a note the measurement "D1".

Scheme 267

Repeat the measuring on different point and make a note of dimension "D2".

Determine and note the average value -D- from the 2 measured values.

Average: D1 + D22 = -D

Remove the externally toothed plate from the input shaft and measure the thickness -d- using VAS 6335.

Scheme 268

Determining dimension -C

Calculate the measurement of the input shaft cover contact surface on the pistons of the reverse gear clutch, dimension -C

D- + -d- = dimension -C

Note measurement -C-.

4. Determining the Thickness of Both Adjustment Discs "E total "

Determining the thickness of the adjustment discs using the following formula using dimensions "A", "B" and "C" and a constant air gap of 3.0 mm

"B" + "C" - "A" - 3.0 mm = "E total "

Select the lower adjustment disc "E 1 " and the upper adjustment disc "E 2 " according to the table REVERSE GEAR CLUTCH, SELECTING ADJUSTING DISCS .

Note. Allocate adjustment shims.

Example

The following values are found in the example

1. Dimension "A" = 27.98 mm
2. Dimension "B" = 28.97 mm
3. Dimension "C" = 6.45 mm
4. Constant air gap = 3.0 mm

"B" + "C" - "A" - 3.0 mm = "E total "

28.97 mm + 6.45 mm - 27.98 mm - 3.0 mm = 4.44 mm

"E total " = 4.44 mm

Lower adjustment disc "E 1 " from the table: 1.90 mm

Upper adjustment disc "E 2 " from the table: 2.65 mm

Installing the Reverse Gear Clutch

Note. As a check, compare the thickness of the new adjustment disc with the thickness of the old adjustment disc performed at the beginning MEASURE THE UPPER ADJUSTMENT DISC -4- AND LOWER ADJUSTMENT DISC -2- AND MAKE A NOTE OF IT. . The measurement must be repeated if the values between the old and new adjustment discs deviate from each other.

1. All components must be cleaned thoroughly before inserting.

Insert the corrugated spring washer -6- into the guides -1- (3) inside the transmission.

Insert the lower adjustment disc "E 1 " -2- into the guides inside the transmission.

Alternating with the same direction for each lining disc -3- and place an externally toothed plate -5- into the guides inside the transmission.

Insert the upper adjustment disc "E 2 " -4- into the guides inside the transmission.

Adjust the clutch discs of the reverse clutch, for example, with a straight-edge.

Scheme 269

1. The grooves must stand exactly in a row.

Install input shaft. Refer to INPUT SHAFT .

COVER, WITH TRANSMISSION REMOVED

Note. The cover can also be removed and installed when the transmission is installed. Refer to Removal and Installation .

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782

Removing

1. The transmission is removed and mounted horizontally to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__transmission-securing-in-enginetransmission-holder) .

Place the V.A.G 1782 under the transmission.

Remove the bolts -arrows- and remove the cover.

Scheme 270

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «COVER, TRANSMISSION CONTROL MODULE AND HYDRAULIC CONTROL UNIT OVERVIEW»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__cover-transmission-control-module-and-hydraulic) .

Note. Replace the seal, sealing ring and axial elements. Replace the cover bolts. Do not touch the pins in the connector -A-.

Slide the seal -B- with the double lip toward the outside and onto the connector -A- on the transmission control module -J217-.

Install the cover -A- (if equipped) over the transmission control module.

Scheme 271

Clean the sealing surfaces on the transmission housing and on the cover.

The alignment sleeves in the transmission housing or in the cover must be mounted on the same location.

Place new seal for end cover onto transmission housing.

Note. Make sure the alignment sleeves fit correctly.

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

Check installation position of gasket -A

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

Tighten the new bolts -arrows- by hand first and then in a diagonal sequence to the tightening specification.

TRANSMISSION CONTROL MODULE -J217

Removing

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

Remove end cover. Refer to COVER, WITH TRANSMISSION REMOVED .

Remove the cover -A-, if equipped.

Remove bolts -arrows- and pull out transmission control module without tilting it.

Scheme 272

Remove the double lip seal -B- from the transmission control module.

Note. Do not touch the pins in the connector -A-. When positioning transmission control module, make sure the sensor on the control module is not damaged.

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «COVER, TRANSMISSION CONTROL MODULE AND HYDRAULIC CONTROL UNIT OVERVIEW»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__cover-transmission-control-module-and-hydraulic) .

Note. Replace gaskets and O-rings.

If necessary, clean the sensors -5 through 8- and the connectors -1 through 3- from dirt and metal chips.

Scheme 273

Clean the selector shaft. Refer to SELECTOR SHAFT, CLEANING .

Before installing the automatic transmission control module, coat the new O-rings -A- on the hydraulic control module with ATF.

Scheme 274

Note. Ignore -arrows-.

Install transmission control module without canting it.

Scheme 275

1. The connectors on the back of the control module must lock securely into the terminals -A-, -B- and -C- on the hydraulic control module.

Tighten the bolts -arrows-.

Install the cover -A- (if equipped) over the transmission control module.

Install the cover. Refer to COVER, WITH TRANSMISSION REMOVED .

Fill the ATF and check the level. Refer to General Information .

Select the following menu options under "Functions/Component selection" in Guided Fault Finding on the vehicle diagnosis tester

1. Drive
2. 0AW transmission
3. 01-On Board Diagnostic (OBD) capable systems
4. 02-Transmission electronics
5. 02-Transmission electronics, functions
6. 02-Replace control module

HYDRAULIC CONTROL MODULE

Removing

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

1. End cover removed, refer to «COVER, WITH TRANSMISSION REMOVED»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__cover-with-transmission-removed) .
2. Transmission control module -J217- removed, refer to «Transmission Control Module -J217»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__transmission-control-module-j217) .

Unhook the spring -1- on the slider for selector lever position -2- and on the selector shaft -3-.

Move the selector lever lock mechanism -1- to the right -arrow-. The tab -A- will be removed through the slit on the retaining plate -B-.

Scheme 276

Pull the selector lever lock mechanism lever -1- downward out of bearing hole in the hydraulic control module. When doing this, pay attention to the roller -2-.

Scheme 277

Remove the bolts -arrows-.

Carefully remove the hydraulic control module toward the rear and tilt it downward so that it is possible to remove the long pump shaft.

Note. Ignore -A-.

Remove the axial sealing elements -A and B- from the transmission.

Scheme 278

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «COVER, TRANSMISSION CONTROL MODULE AND HYDRAULIC CONTROL UNIT OVERVIEW»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__cover-transmission-control-module-and-hydraulic) .

Note. Always replace a dirty or faulty hydraulic control module. Replace gaskets and O-rings.

Replace the axial sealing elements -A- (quantity: 3) and -B-.

Scheme 279

1. Installed position: The axial sealing elements -A- must be installed with the sealing lips facing upward, as illustrated.
2. The color identification on the upper edge must be visible.

Coat the axial sealing elements with ATF before installing -arrow-.

PUSH THE GEARSHIFT LEVER -2- IN DIRECTION OF -ARROW- ALL THE WAY FORWARD SO THAT THE SHIFTING CAM -1- IS ALMOST VERTICAL (SLIGHTLY ANGLED TO THE RIGHT).

Press control piston -B- on the back of the hydraulic control module outward (to the right) until it engages into the assembly spring -A-.

Scheme 280

With the pump shaft facing forward, install the hydraulic control module tilted downward into the transmission.

Note. When installing control module, make sure that shifting cam (item 1 in see scheme 53 ) engages into free groove -arrow- on control piston -B-.

Install the bolts -arrows- hand-tight.

Checking the Function of the Control Piston

Move the gearshift lever -A- several times forward and backward -arrow 1-.

Scheme 281

1. When doing this, the control piston -B- must travel outward and inward accordingly -arrow 2-.

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

Remove the hydraulic control module again.

Check for Damage Possibly Caused by an Incorrect Installation

1. It must be possible to easily move the control piston -B- left and right; if not, replace the hydraulic control module.
2. The shifting cam -1- or the selector shaft must have no damage due to an incorrect installation.

Install the hydraulic control module HYDRAULIC CONTROL MODULE .

The control piston moves as described

Tighten the bolts -arrows- to the tightening specification.

Install the Slider for Selector Lever Position

Install the roller -2- with the shoulder of the selector lever lock mechanism lever -1- on the lever.

Slide the selector lever lock mechanism lever -1- into the bearing hole in the hydraulic control module housing.

Moving selector lever lock mechanism lever -1 - to left opposite the direction of -arrow-, by doing this, the retaining tab -A- will turn in slot in retaining plate and -B- will be held there

Install the spring -1- into the selector shaft -3- and the selector lever lock mechanism lever -1-.

Installation position of the spring -1

1. The bent end of the spring must be attached to the selector shaft -3-.
2. The round end of the spring must engage into the selector lever lock mechanism -2-.

Move the gearshift lever -A- all the way forward and backward -arrow 1-.

Note. Ignore -arrow 2- and -B-.

1. The detent plate -upper arrow- moves to the left and to the right.
2. When doing this, it must allow the roller -4- to engage in the individual notches.
3. The roller must be installed with the collar facing down so that it cannot be removed upward.

Install the transmission control module. Refer to Transmission Control Module -J217 .

Select the following menu options under "Functions/Component Selection" in Guided Fault Finding on the vehicle diagnosis tester

1. Drive
2. 0AW transmission
3. 01-On Board Diagnostic (OBD) capable systems
4. 02-Transmission electronics
5. 02-Transmission electronics, functions
6. 02-Replace the hydraulic control module

INPUT SHAFT SEAL

1. The input shaft seal may be leaking if ATF is leaking from underneath the transmission bell housing.
2. Input shaft seal must be replaced if leaking.

Special tools and workshop equipment required

1. Seal Ring Extractor T40014
2. Thrust Piece for Final Drive at Transmission T40167

Procedure

1. Transmission removed.

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

Remove the dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Rotate the T40014 by hand into the shaft seal until the tool has a good hold in the shaft seal. Then tighten puller with an open-end wrench.

Scheme 282

Note. The illustration shows a different transmission.

You can pull out the shaft seal a short distance by screwing in rear bolt of puller.

Tighten the T40014 so that it engages securely in the shaft seal and continue tightening shaft seal by installing bolt.

Repeat the process until the shaft seal is removed completely.

1. Input shaft must be installed in order to install the shaft seal.

Coat the new shaft seal -A- with ATF.

Scheme 283

Install the sealing ring on the input shaft being careful not to touch the splines on the shaft.

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

Note. The shaft seal can be damaged if it touches the input shaft splines. Slide shaft seal as far as possible into cover so that it cannot bend when driving in.

Mount the sealing ring with the T40167 all the way without bending it.

Scheme 284

Install the dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Check the ATF level and correct if necessary after installing the transmission. Refer to Diagnosis and Testing .

INPUT SHAFT

Special tools and workshop equipment required

1. Shop Crane VAS 6100
2. Puller T40050
3. Pressure Stand T40099

Removing

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

1. Transmission removed and mounted vertically to the engine/transmission holder. Refer to «TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#controls-housing-continuously-variable-transmission-internal-components-0aw-sedan__transmission-securing-in-enginetransmission-holder) .
2. T40099 adapted for using with the 0AW transmission. Refer to «PRESSURE STAND, ADAPTING TO 0AW TRANSMISSION»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__pressure-stand-adapting-to-0aw-transmission) .

Drain the ATF. Refer to ATF, DRAINING FOR ATF FLUSH , pivot transmission in installation position (level).

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

Mark the installed position of the cover for the input shaft with color -arrows-.

Scheme 285

Remove the circlip -1-.

Scheme 286

Mount the T40050 on the input shaft.

Scheme 287

Make sure the puller is secure on the input shaft.

1. Circlip must be pushed all the way down.

Pull the input shaft together with the cover and forward gear clutch out of the transmission housing -arrow- using VAS 6100 with T40050.

Note. It is very difficult to loosen the input shaft cover from the transmission housing. Tension the input shaft with VAS 6100 and then carefully hit transmission housing flange with a plastic hammer with a piece of wood placed in between until the cover comes loose.

Scheme 288

Place the input shaft on the T40099.

Scheme 289

Installing

Install in reverse order of removal. Note the following

Check wear on transmission components. Refer to INPUT SHAFT, CHECKING FOR WEAR .

Remove the bolts -arrows- and pull the ATF filter out of the transmission housing.

Scheme 290

Clean the sealing surfaces on the transmission housing and on the input shaft cover.

Adjust and install the reverse gear clutch. Refer to REVERSE GEAR CLUTCH, SELECTING ADJUSTING DISCS .

Make sure the alignment sleeves -arrows- are on the input shaft cover and that they are secure Place the input shaft on the T40099e.

Scheme 291

Replace the axial sealing element (seal) -arrow-.

Scheme 292

1. Installed position: The sealing lip faces upward toward the input shaft cover.

Replace the O-ring on the input shaft cover and coat it with ATF.

Adjust the clutch discs of the reverse clutch, for example, with a straight-edge.

1. The grooves must stand exactly in a row.

Check the installed dimension for the oil pipe -arrow

Scheme 293

1. The distance from the end of the oil pipe up to the input shaft is approximately 11.5 mm -a- when the oil pipe is inserted all the way.

Note. 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.

Insert the input shaft and cover into the transmission housing and align it with the markings -arrows- made earlier during removal.

Move the input shaft back and forth until all splines engage in the reverse gear clutch.

Insert a screwdriver -arrow- through the opening in the housing for the ATF filter and turn the toothed gear -1- until it engages with the toothed gear on the input shaft.

Scheme 294

Make sure the input shaft cover is flush with the transmission housing.

Scheme 295

Only when both parts are flush, then install the input shaft cover by placing a piece of wood on the cover, then carefully hit the wood evenly with a rubber hammer until the cover is all the way in.

Note. Use a new locking ring -1- with the same thickness as the locking ring used before if the same input shaft cover and the same transmission housing are going to be installed. It is necessary to determine the locking ring thickness only if a new input shaft cover and/or new transmission housing is being installed.

SELECTING THE LOCKING RING THICKNESS -1-COAT THE NEW SHAFT SEAL -A- WITH ATF

Try to install the thickest locking ring into the groove in the transmission housing.

1. It should be easy to install the locking ring without bending it.
2. The locking ring must fit inside the bottom of the groove.

Use the next thinner locking ring if the one locking ring does not fit into the groove. Use the thinnest locking ring if necessary.

Replace the ATF filter. Refer to Removal and Installation

Fill the ATF after installing the transmission. Refer to ATF, FILLING FOR ATF FLUSH .

INPUT SHAFT COVER

Special tools and workshop equipment required

1. Seal Ring Extractor T40014
2. Pressure Stand T40099
3. Assembly Tool T10219/1
4. Thrust Plate VW 401
5. Tube 37 mm Dia. VW 416 B
6. Ice spray
7. Protective gloves
8. Protective goggles

Removing

1. Input shaft removed. Refer to «INPUT SHAFT»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft) .
2. T40099 adapted for using with the 0AW transmission. Refer to «PRESSURE STAND, ADAPTING TO 0AW TRANSMISSION»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__pressure-stand-adapting-to-0aw-transmission) .

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

Check all eight bolts -arrows- on the T40099.

Scheme 296

1. Bolts must be installed flush to 25 Nm. Refer to assembly instructions for pressure stand T40099

Insert input shaft in T40099.

Scheme 297

Rotate T40014 by hand into shaft seal until the tool has a good hold in the shaft seal. Then tighten puller with an open-end wrench.

You can pull out shaft seal a short distance by screwing in rear bolt -arrow-.

Re-tighten T40014 so that puller engages securely in shaft seal again and continue turning bolt to pull out shaft seal.

Repeat the process until the shaft seal is removed completely.

Remove the locking ring from the input shaft cover -1-.

Scheme 298

Measure and note thickness of removed locking ring.

Note. When installing, locking ring must be replaced with a new locking ring of same the thickness.

Clean the contact surface on the input shaft cover.

Cool the hallow shaft, for example with ice spray, through the opening -arrow 1- for the removed oil pipe -1- on the inner bearing seat -arrow 2- -2- (transmission input shaft ball bearing).

Scheme 299

Note. The input shaft represented in section here. The input shaft must be cooled so that the input shaft ball bearing can be pressed off more easily and not be damaged.

Clean the surface on the T40099.

Scheme 300

Place the input shaft in the pressure stand.

1. The contact surface on the input shaft cover must be flush.
2. Make sure there are no shavings or dirt on the input shaft cover contact surface and on the surface of the T40099.

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

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

Place the input shaft together with the T40099 on the hydraulic press pressure plate.

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

Hold the input shaft from underneath and push it at the same time out of the cover using the hydraulic press.

Scheme 301

Place input shaft on assembly tool T10219/1.

Scheme 302

Installing

Replace the input shaft ball bearing. Refer to INPUT SHAFT BALL BEARING .

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

Scheme 303

Place input shaft -B- on VW 401.

Scheme 304

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

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

Scheme 305

1. The locking ring must fit inside the bottom of the groove.

Check wear on transmission components. Refer to INPUT SHAFT, CHECKING FOR WEAR .

Replace O-ring on oil pipe -2-.

Scheme 306

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.

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

1. The distance from the end of the oil pipe up to the input shaft is approximately 11.5 mm -a- when the oil pipe is inserted all the way.

Note. 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.

INPUT SHAFT BALL BEARING

Special tools and workshop equipment required

1. Thrust Pate VW 401
2. Tube 37 mm Dia. VW 416 B
3. Sleeve 2010
4. Pressure Stand T40099

Procedure

1. Input shaft cover removed, refer to «INPUT SHAFT COVER»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__input-shaft-cover) .
2. Pressure stand T40099 adapted for using with the 0AW transmission. Refer to «PRESSURE STAND, ADAPTING TO 0AW TRANSMISSION»(/audi/a4/b8-2007-2012/remont/automatic-trans/#gears-hydraulic-controls-continuously-variable-transmission-internal-components-0aw-sedan__pressure-stand-adapting-to-0aw-transmission) .

Remove the circlip -1-.

Scheme 307

Measure and note thickness of removed locking ring.

Note. When installing, locking ring must be replaced with a new locking ring of the same thickness.

Lay input shaft cover -1- on T40099 and place under hydraulic press.

Scheme 308

Remove the input shaft ball bearing from the input shaft cover using VW 416 B.

Note. In some cases, the input shaft ball bearing can also be pressed out by hand without hydraulic press. It is necessary to replace the input shaft ball bearing.

Scheme 309

Replace the input shaft cover if the contact surface -arrow- or the cover itself is damaged.

Note. A new input shaft ball bearing must be installed whenever a new input shaft cover is installed.

Replace the input shaft ball bearing -2- if the contact surface or the cover is not damaged.

Scheme 310

Clean ball bearing seat in cover.

Install the ball bearing flush and press in by hand as far as possible.

Scheme 311

Lay input shaft cover on VW 401.

Scheme 312

Install the input shaft ball bearing all the way in using 2010.

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

Make sure the locking ring fits correctly. Inst.all the ball bearing again or use the next thinner locking ring.

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Seal Ring Extractor T40014
3. Assembly Tool T10219/1
4. Sleeve 2010
5. Tube 37 mm Dia. VW 416 B
6. Pressure Stand T40099
7. 2x Ruler T40100
8. Caliper T40101
9. Feeler Gauge T40102
10. Digital Depth Gauge VAS 6087
11. Protective gloves
12. Ice spray

DISASSEMBLING

1. Transmission removed.

Note. Refer to REPAIR INFORMATION . Refer to CLEAN WORKING CONDITIONS .

Remove input shaft. Refer to INPUT SHAFT .

Remove input shaft cover from shaft. Refer to INPUT SHAFT COVER .

Place input shaft on T10219/1.

Carefully raise thrust plate with pistons with two screwdrivers -arrows-.

Scheme 313

Safety Precautions

Scheme 314

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

Scheme 315

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

Disc Pack, Removing

Remove corrugated spring washer -5-, they must be used again.

Scheme 316

Remove upper adjustment disc -4- from input shaft cylinder -A-.

Measure adjustment disc thickness -4- and note measurement.

Remove all lining discs -2- and outer discs -3- from input shaft cylinder -A-.

Remove lower adjustment disc -1- from input shaft cylinder -A-.

Measure adjustment disc thickness -1- and note measurement.

ASSEMBLING

Replace the input shaft ball bearing. Refer to INPUT SHAFT BALL BEARING .

Adjust input shaft and determine air gap. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

Place input shaft on T10219/1.

Insert determined lower adjustment disc -1- in input shaft cylinder -A-.

Insert alternately and with the same alignment each lining disc -2- and one externally toothed plate -3-.

Lining disc alignment

Insert determined upper adjustment disc -4- in the input shaft cylinder -A-.

Lastly, insert corrugated spring washer -5-.

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

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.

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

Checking Air Play with T40102

Insert both T40102 under thrust plate -A-.

Scheme 317

A second technician must push thrust plate -A- down to stop -arrow 1- with VW 416 B.

Guide both T40102 circularly in direction of -arrow- back and forth under thrust plate.

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

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

Repeat the input shaft adjustment. Refer to ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY .

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

Install input shaft cover. Refer to INPUT SHAFT COVER .

Install the input shaft. Refer to. INPUT SHAFT

Install the input shaft seal. Refer to INPUT SHAFT SEAL .

Fill the ATF after installing the transmission. Refer to ATF, FILLING FOR ATF FLUSH .

Scheme 318

Special tools and workshop equipment required

1. Thrust Plate VW 401
2. Seal Ring Extractor T40014
3. Assembly Tool T10219/1
4. Sleeve 2010
5. Tube 37 mm Dia. VW 416 B

Scheme 319

Special tools and workshop equipment required

1. Pressure Stand T40099
2. 2x Ruler T40100
3. Caliper T40101
4. Feeler Gauge T40102
5. Digital Depth Gauge VAS 6087

Special tools and workshop equipment required

Scheme 320

Scheme 321

Scheme 322

Scheme 323

Scheme 324

Scheme 325

1. Support Bridge 2011
2. Pre-Tensioning Tool T10285
3. Puller T40050
4. Thrust Piece for Final Drive at Transmission T40167
5. Oil Collecting and Extracting Device V.A.G 1782
6. Shop Crane VAS 6100
7. Not illustrated
8. Assembly Tool T10219/1
9. Digital Caliper, 150 mm VAS 6335
10. Thrust Plate VW 401
11. Tube 37 mm Dia. VW 416 B

See also:
• REPAIR INFORMATION
• CLEAN WORKING CONDITIONS
• Removal and Installation
• INPUT SHAFT, CHECKING FOR WEAR
• TRANSMISSION, SECURING IN ENGINE/TRANSMISSION HOLDER
• General Information
• DUAL MASS FLYWHEEL
• Diagnosis and Testing
• ATF, DRAINING FOR ATF FLUSH
• ATF, FILLING FOR ATF FLUSH
• COVER, WITH TRANSMISSION REMOVED
• Transmission Control Module -J217
• HYDRAULIC CONTROL MODULE
• INPUT SHAFT
• INPUT SHAFT COVER
• INPUT SHAFT BALL BEARING
• INPUT SHAFT SEAL
• SELECTING THE LOCKING RING THICKNESS -1-Coat the new shaft seal -A- with ATF.
• REVERSE GEAR CLUTCH, SELECTING ADJUSTING DISCS
• SETTING THE REVERSE GEAR CLUTCH BY DETERMINING THE ADJUSTMENT DISC
• ADJUSTING INPUT SHAFT BY DETERMINING AIR PLAY
• MEASURE THE UPPER ADJUSTMENT DISC -4- AND LOWER ADJUSTMENT DISC -2- AND MAKE A NOTE OF IT.
• COVER, TRANSMISSION CONTROL MODULE AND HYDRAULIC CONTROL UNIT OVERVIEW
• SELECTOR SHAFT, CLEANING
• PRESSURE STAND, ADAPTING TO 0AW TRANSMISSION