GENERAL SAFETY PRECAUTIONS AND PROCEDURE SPECIFICATIONS
Note. Always check with the importer before performing any work on the hybrid system should there be any questions regarding the terms "technician trained in electrical systems", "Audi high voltage technician" or "Audi high voltage expert".
Working near high voltage components and visually checking them
| CAUTION | Damaged high voltage components have life threatening voltage. Pay attention to the following when working near high voltage components and high voltage cables: Cutting, shaping or sharp-edged tools, sources of heat, such as welding, soldering and hot air or using thermal adhesive is not permitted. Inspect all high voltage components in the area before starting any work. When working inside the engine compartment, visually inspect the electric drive power and control electronics -JX1-, the electro-drive drive motor -V141-, the electrical A/C compressor -V470- and the high voltage cable. Visually inspect the high voltage cable and covers when working on the underbody. Visually inspect the high voltage cables and the electro box using high voltage system maintenance connector -TW - when working at the back of the vehicle. Visually inspect all potential equalization cables. Visually inspect the following: All components must not be damaged on the outside. The insulation on the high voltage cables and potential equalization cables must not be damaged. The high voltage cables must not be deformed. Every high voltage component must be identified by a red warning sticker. |
Working when the ignition must be on.
| CAUTION | When working with the ignition turned on or with the vehicle ready to be driven, there is the danger the engine could start unexpectedly or there is the danger of poisoning in a closed area. Danger of body parts and/or clothing getting caught and pulled. Do the following before turning on the ignition: Move the selector lever into P. Activate the parking brake. Turn off the ignition. Open the hood. Connect the battery charger, for example, battery charger VAS 5095A to the battery jump start terminal for the 12V vehicle electrical system. Turn on the ignition. |
General Safety Precautions and Safety Precautions when working with the ignition turned on.
| WARNING | Danger of the engine starting unexpectedly When working on a high voltage vehicle, turn off the ignition and remove the key from the passenger compartment. |
| WARNING | Working with high voltage cables: Never support yourself or place tools on high voltage cables and their components. This could damage the insulation. Never bend high voltage cable excessively. This could damage the insulation. The round high voltage connectors are coded by a color ring on the outside and are also coded mechanically by the guide/code tabs. Always pay attention to this coding when connecting the round high voltage connectors to prevent mechanical damage to the connectors. |
To prevent personal injury or damage to the vehicle note the following
| WARNING | Engaging a gear unintentionally with the engine running can cause serious personal injury or an accident. Shift the transmission into "P" and set the parking brake to lock the electro-mechanical parking brake before working on a running engine. The exhaust fumes from a running engine are poisonous. Always connect an exhaust hose to the vehicle when working on a running engine. |
Safety Precautions for vehicles with Start/Stop
| WARNING | Danger of personal injury caused by the engine starting automatically on vehicles with the Start/Stop System. When the Start/Stop System is on (recognizable by a message in the instrument cluster), the engine may start automatically. Make sure the Start/Stop System is off whenever working on the vehicle. Turn off the ignition and turn it back on only when necessary. |
To prevent serious personal injury or damage to electric/electronic components, note the following
- Connect and disconnect test equipment only with the ignition turned off.
| CAUTION | Danger of causing damage to electronic components when disconnecting the battery. Complete the steps for disconnecting the battery. Disconnect the battery only with the ignition turned off. |
Disconnect the battery. Refer to [For engine(s) CAEB, CALA, CCBA] Removal and Installation .
If testing equipment is needed on road tests, follow the information below
| WARNING | An accident could happen if testing equipment is not secured and falls over. The passenger airbag could be dangerous if it deploys during an accident. Operating testing equipment while driving is a distraction. Testing equipment that is not secured probably increases the risk of injury. Always secure testing equipment on the rear seat with a strap. Have a second technician in the back to operate the equipment. |
REAR FINAL DRIVE IDENTIFICATION
Rear Final Drive 0BC is allocated to the following transmissions
- 6-speed manual transmission 0B2 AWD
- 6-speed manual transmission 0B4 AWD
- 7-speed DSG transmission 0B5 AWD
- Automatic transmission 0B6 AWD
- 8-speed automatic transmission 0BK AWD
- 8-speed automatic transmission 0BW AWD (Audi Q5 hybrid only)
Rear Final Drive Allocation
- Audi A4 from MY 08 «TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES»(/audi/a4/b8-2007-2012/remont/automatic-trans/#general-technical-data-rear-final-drive-0bc-sedan__transmission-allocations-ratios-and-capacities)
- Audi A5 Coupe from MY 08
- Audi A5 Cabriolet from MY 09
- Audi Q5 from MY 08
- Audi Q5 Hybrid from MY 08
- Audi A6 from MY 11
- Audi A7 from MY 11
- Audi A8 from MY 10
Allocation to the Rear Final Drive
Scheme 218
Final drive 0BC -arrow 1- and 0AR
Code and build date -arrow 2
Final Drive 0BC -arrow- and 0AR
Scheme 219
Note. "0AR" is always on the rear final drive housing. The changes to the housing are what differentiate the "0BC" final drive from the "0AR" final drive. The locations of the threaded holes -arrows- for attaching the crossmember to the rear final drive are also different. The "0BC" final drive has 4 threaded holes -arrows- in its housing, used for attaching the crossmember. In addition to this, there is an additional threaded hole under the flange/driveshaft used for attaching the final drive to the subframe.
Rear Final Drive Code and Date of Manufacture
Scheme 220
| Example | JKS | 15 | 03 | 07 |
|---|---|---|---|---|
| I | I | I | I | |
| Code letters | Day | Month | Year of manufacture -2007 |
The other data is not needed.
Note. When replacing a rear final drive, always pay close attention to the code, the PR number and the engine code. This is the only way to make sure the allocation is correct.
REPAIR INFORMATION
To perform a problem-free and successful transmission repair, extreme caution and cleanliness, as well as properly functioning tools are an important requirement. Understandably, general safety guidelines apply when performing repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the Repair Information, are summarized under the term "components" COMPONENTS . They apply for this repair information.
COMPONENTS
Rear Final Drive
- When replacing the rear final drive, check and if necessary, correct oil level in final drive. Refer to «REAR FINAL DRIVE GEAR OIL, CHECKING»(/audi/a4/b8-2007-2012/remont/axle-shafts/#rear-final-drive-0bc-sedan__rear-final-drive-gear-oil-checking) .
- Capacities and specifications, refer to «SPECIFICATIONS»(/audi/a4/b8-2007-2012/remont/automatic-trans/#general-technical-data-rear-final-drive-0bc-sedan) .
- Clean the contact surfaces before installing the brackets and waxed components. Contact surfaces must be free of wax and grease.
- Thoroughly clean all connections and the surrounding area before disconnecting.
Oil, Environment and Disposal Regulations
- Be very careful when handling transmission fluid and other fluids.
- Dispose of the drained fluids properly.
- Follow all environment and disposal regulations.
- Be sure to read the instructions on the fluid containers.
O-rings, Seals and Gaskets
Scheme 221
- Always replace the O-rings, seals and gaskets.
- Check the contact surfaces on the housing and shaft for burrs and damage after removing the seals.
- Thoroughly clean the separating surfaces on the housing before assembling.
- Before installing, lightly oil the outer circumference of the shaft seals and fill gap between sealing lips -arrow- half way with sealing grease G 052 128 A1.
- The open side on the shaft seals faces the fluid to be sealed off.
- Lightly lubricate O-rings before installing, this prevents the rings from being pinched when inserting.
- Check transmission oil level after replacing gaskets and seals. Refer to «REAR FINAL DRIVE GEAR OIL, CHECKING»(/audi/a4/b8-2007-2012/remont/axle-shafts/#rear-final-drive-0bc-sedan__rear-final-drive-gear-oil-checking) .
Circlips
Scheme 222
- Do not stretch the circlips.
- Always replace damaged or stretched circlips.
- The circlips must touch the bottom of the groove.
- Replace the adapter sleeves. Installation position: Slot -A- is longitudinal to line of force -arrow-.
Bolts and Nuts
- Loosen and tighten the bolts and nut from the covers and housings diagonally.
- Do not cant, rather loosen and tighten especially sensitive parts in diagonal manner in stages.
- Tightening specifications for unlubricated bolts and nuts are given.
- Always replace self-locking nuts and bolts.
- Using a wire brush, clean threads of bolts (replace outer driveshaft bolts) which are secured with locking compound. Install the bolts with locking fluid AMV 185 101 A1.
- If self-locking bolts were installed or if regular bolts were installed with locking fluid, then the threaded holes must be cleaned with a thread cutter. If the holes are not cleaned, then the bolts could break off the next time they are removed.
SPECIAL TOOLS AND EQUIPMENT
Complete list of special tools used in this repair information.
DRIVETRAIN OVERVIEW
- Illustrated with 6-speed manual transmission 0B4 AWD.
Note. Arrows- point in direction of travel.
Scheme 223
- 1 - Engine
- 2 - Drive Plate With a needle bearing for the input shaft mounting
- 3 - Clutch Module Consists of a pressure plate, clutch plate and the dual mass flywheel with transfer plate
- 4 - Front Differential
- 5 - Input Shaft (main shaft)
- 6 - Front Pinion with Side Shaft
- 7 - Output Shaft
- 8 - Manual Transmission
- 9 - Center Differential
- 10 - Driveshaft
- 11 - Rear Pinion
- 12 - Rear Differential
- I - 1st Gear
- II - 2nd Gear
- III - 3rd Gear
- IV - 4th Gear
- V - 5th Gear
- VI - 6th Gear
- R - Reverse Gear
- S - Intermediate Drive Gear Wheels
- A1 - Front Final Drive
- A2 - Rear Final Drive
TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES
| Rear Final Drive | 0BC | ||||
|---|---|---|---|---|---|
| Code letters | JKP | JKQ | JKR | ||
| Ratio | Final drive Z 2 : Z 1 | 37 : 10 = 3.700 | 37 : 10 = 3.700 | 37 : 9 = 4.111 | |
| Driveshaft flange diameter | 70.7 mm | 75.5 mm | 70.7 mm | ||
| Gear oil capacity | Refer to the appropriate Service Information. | ||||
| Rear Final Drive | 0BC | ||||
|---|---|---|---|---|---|
| Code letters | JKS | KCC | KLL | ||
| Ratio | Final drive Z 2 : Z 1 | 35 : 9 = 3.889 | 43 : 13 = 3.308 | 35 : 8 = 4.375 | |
| Driveshaft flange diameter | 75.5 mm | 75.5 mm | 70.7 mm | ||
| Gear oil capacity | Refer to the appropriate Service Information. | ||||
| Rear Final Drive | 0BC | ||||
|---|---|---|---|---|---|
| Code letters | KRT | LYF | MNA | ||
| Ratio | Final drive Z 2 : Z 1 | 42 : 9 = 4.666 | 37 : 9 = 4.111 | 37 : 9 = 4.111 | |
| Driveshaft flange diameter | 75.5 mm | 75.5 mm | 70.7 mm | ||
| Gear oil capacity | Refer to the appropriate Service Information. | ||||
| Rear Final Drive | 0BC | ||||
|---|---|---|---|---|---|
| Code letters | MNB | ||||
| Ratio | Final drive Z 2 : Z 1 | 37 : 9 = 4.111 | |||
| Driveshaft flange diameter | 75.5 mm | ||||
| Gear oil capacity | Refer to the appropriate Service Information. | ||||