6-speed Automatic Transmission (09l - Awd) Audi A6 С6

Transmission identification

The "6-speed automatic transmission 09 all wheel drive " is installed in combination with various engine types, and is identified accordingly on the transmission type plate. Application --> Code letters, transmission application, ratios, equipment .

The transmission code letters are given on the type plate - arrow - located on bottom front of transmission next to 16-pin connector.

Scheme 166

The type plate lists the following information

1. Serial number of transmission
2. Part number
3. Transmission designation, in this example 6HP19
4. Code letters, in this example GZV

Additional data are production-related.

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

Notes on the automatic 6-speed transmission 09L

Transmission

The 6-speed automatic transmission 09L (all wheel drive) has six hydraulically activated forward gears. When the lock-up clutch is closed these forward gears become mechanically driven gears by cutting out the torque converter slip.

Torque converter

The torque converter is equipped with a slip-controlled lock-up clutch.

Mechatronics unit

The mechatronics unit incorporates the hydraulic control system, the electronic Transmission Control Module (TCM) J217 , the Multi-Function Transmission Range (TR) Switch F125 and the sensors and actuators as a complete unit. The mechatronics unit is installed in the transmission within the oil pan.

Transmission Control Module (TCM) J217

The control module is part of the mechatronics unit in the transmission.

The switching points are calculated automatically (depends on driving situation and driving resistance).

Advantages

1. Gear changes are timed for maximum fuel economy.
2. Maximum engine output is always available
3. Individual adaptation of gear change points in all driving situations
4. Gear change points are infinitely variable

Self-diagnosis

Before performing repairs to the automatic transmission, determine the cause of the fault as precisely as possible using "Guided fault finding".

"Guided fault finding" is performed using the vehicle diagnostic, testing and information system VAS5051.

Gearshift point variations for hills

An additional gear change map automatically selects gear changes for hills depending on accelerator pedal position and driving speed.

1. Gear change map for extreme uphill stretches is matched to engine output
2. Gear change map for extreme downhill stretches is matched to the braking effect of the engine
3. The engine braking effect can also be fully exploited via a specific gear, e.g. on hills when towing a trailer, by directly selecting a gear with the tiptronic.

Code letters, transmission application, ratios, equipment

Application of mechatronics unit according to transmission code letters.

Application of mechatronics unit according to transmission code letters.

Rear final drive identification

The final drive 01R is allocated to the automatic transmission 09L all wheel drive.

Assembly allocation --> 00 TECHNICAL DATA .

Scheme 167

Location on final drive

Code letters and date of manufacture - arrow1

Final drive 01R - arrow2

Scheme 168

Final drive 01R - arrow2

Scheme 169

Final drive code letters and date of manufacture - arrow 1

Additional data is production-related.

Code letters, ratios, capacities --> 00 TECHNICAL DATA .

Planetary gearbox

ATF is available as a replacement part.

Container size 1.0 ltr. Part No. G 055 005 A2

Use only the correct type of ATF (available as a replacement part) for the planetary gearing in automatic transmission09L. Other oils cause faults and/or failure of the transmission.

1. Checking ATF level in planetary gearbox --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Front final drive

Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in the following container sizes

1. 0.5 ltr. - Part No. G 052 145 A1
2. 1.0 ltr. - Part No. G 052 145 S2

1. Checking oil in front final drive --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Transfer gear

Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement part in the following container sizes

1. 0.5 ltr. - Part No. G 052 145 A1
2. 1.0 ltr. - Part No. G 052 145 S2

1. Check transfer gear oil --> «Transfer gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Rear final drive

1. Check gear oil in rear final drive --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

Capacities and specifications --> 00 TECHNICAL DATA .

Notes on towing

Note. It is not possible to start the engine by means of tow-starting, for instance in the case of insufficient battery charge or if starter is not working.

Contact corrosion

1. Contact corrosion can occur if non-approved fasteners are installed on the vehicle (bolts, nuts, washers etc.).
2. For this reason, all fasteners used are treated with a special surface coating. These parts can be identified by their greenish color.
3. Rubber, plastic and adhesives also consist of non-conductive materials.
4. If you are not sure whether used parts can be re-installed, always install new parts.

General repair instructions

The maximum possible care and cleanliness and proper tools are essential for satisfactory and successful transmission repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places in the article - are summarized here. They apply to the work described in this article.

Special tools

For a complete list of special tools used in this article "Special tools".

Jacking mode (vehicles with pneumatic suspension)

Before raising the vehicle on a platform (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Manual release of the selector mechanism

If the battery has been removed or is empty and you wish to tow or push the vehicle please note that you will have to manually release the selector mechanism from position "P" in order to be able to move it from "P" to "N" --> Operating manual selector mechanism release .

Transmission

1. Read the rules when working on the automatic transmission --> «Read the rules»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.
3. If transmission has been removed from vehicle, secure torque converter to prevent it from falling out.
4. Thoroughly clean all joints and surrounding areas before disassembling.

1. Before installing transmission check position of torque converter.
2. When installing transmission ensure dowel sleeves are correctly seated.
3. Carefully cover or seal open components if repairs cannot be carried out immediately.
4. When installing a new automatic transmission, check the following fluid levels and top off if necessary: ATF in the planetary gearbox --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) , the gear oil in the front final drive --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) , the gear oil in the transfer gear --> «Transfer gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

1. When installing a new rear final drive, check the oil level in the rear final drive and top off if necessary. Capacities and specifications --> «00 TECHNICAL DATA»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

O-rings, oil seals, gaskets

1. Always install new O-rings, oil seals and gaskets.
2. After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.

Scheme 170

1. Before installing oil seals, fill the space between the sealing lips - arrow - about half full with grease G 052 128 A1 .
2. The open side of the oil seals faces toward the side with fluid filling.
3. Before installing, lightly lubricate outer circumference of seal and sealing lips with ATF or gear oil, depending on location.
4. Lightly lubricate O-rings with ATF before installation to prevent them getting crushed during assembly.

1. Use only ATF in ATF area. Other lubricants will cause the transmission hydraulics to malfunction.
2. When installing a new oil seal, position the seal in the housing so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).
3. Replace paper gaskets, clean all sealing surfaces thoroughly and remove previous gaskets completely.
4. After installing, check the relevant fluid levels and top off if necessary: ATF in planetary gearbox --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) , gear oil in front final drive --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) , transfer gear oil --> «Transfer gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) , gear oil in rear final drive --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

Nuts, bolts

1. Loosen bolts in reverse sequence to the specified tightening sequence.
2. Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified.
3. The tightening torques stated apply to non-oiled nuts and bolts.
4. Always replace self-locking bolts and nuts.

1. Use a wire brush to clean the threads of bolts which are secured by a locking compound. Then apply locking fluid AMV 185 101 A1 to bolts before installing.
2. Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being removed.

Retaining rings/circlips

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

Bearings

1. Lubricate bearings with gear oil or ATF, depending on location.

Mechatronics unit

1. Replace the transmission if any of the shift elements are scorched.
2. Allocate mechatronics unit according to transmission code letters.

Scheme 171

Guided fault finding, vehicle self-diagnosis and testing system

1. Before servicing the automatic transmission, the exact cause of the failure must be determined as precisely as possible via the vehicle diagnostic, testing and information system VAS5051 in the modes "Guided Fault Finding" , "vehicle self-diagnosis" and "testing system".

Read the rules

1. Observe the general repair instructions --> «General repair instructions»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__general-repair-instructions) .

1. Thoroughly clean all joints and surrounding areas before disassembling.
2. Place removed parts on a clean surface and cover them. Use sheeting and paper. Use lint-free cloths.
3. Carefully cover or seal open components if repairs cannot be carried out immediately.
4. Only install clean components: do not remove replacement parts from packaging until just before installation.

Torque converter

Note. Read the rules when working on the automatic transmission --> Read the rules . General repair instructions --> General repair instructions . Apply thin coat of ATF to seals. Other types of lubricant will cause the transmission hydraulics to malfunction.

Scheme 172

There are various types of torque converter. They are marked with code letters - arrow -.

Torque converter/transmission application --> Code letters, transmission application, ratios, equipment .

Torque converter, draining

Special tools, testers and auxiliary items required

Scheme 173

1. Oil extractor V.A.G1358A
2. Oil extractor probe V.A.G1358A/1

Scheme 174

If the ATF has become fouled by abrasion or when performing a major transmission overhaul, drain the torque converter as follows

1. Extract ATF from torque converter using oil extractor V.A.G1358A and oil extractor probe V.A.G1358A/1.

Torque converter oil seal, replacing

Special tools, testers and auxiliary items required

Scheme 175

1. Extractor lever VW 681

Scheme 176

1. Thrust piece T10137

Work procedure

1. Remove transmission --> «Transmission on vehicles with 6-cyl. GDI engine, removing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transmission-on-vehicles-with-6-cyl-gdi) .
2. Mount transmission on assembly stand --> «Securing transmission to assembly stand»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Carefully pull out torque converter.

Scheme 177

1. Remove oil seal for torque converter using oil seal extractor VW681.
2. Lightly lubricate outer circumference and sealing lips of oil seal with ATF.

1. Installation position: open side of oil seal points toward transmission

Scheme 178

1. Drive in torque converter oil seal with thrust piece T10137 until thrust piece reaches stop.

Scheme 179

1. Check hub - arrow - of torque converter for scoring.

Note. The torque converter is welded together and must be replaced as a complete unit in the event of any damage or faults.

Torque converter, installing

Special tools, testers and auxiliary items required

1. Depth gauge

Installing

1. Press torque converter hub through oil seal as far as first stop.
2. Lightly press torque converter inwards and turn until slots on torque converter hub engage in drive lugs on ATF pump gear and torque converter slides in a noticeable distance.

Scheme 180

Installation depth

If the torque converter is correctly installed, the depth between the contact surface of the tapped holes on the torque converter and the contact surface of the torque converter bell housing is at least 19 mm.

1. Use new ribbed bolts to secure torque converter to drive plate.

When installing the transmission, adhere to the following instruction.

Scheme 181

Data Link Connector (DLC)

Location: below knee padding on left side of steering wheel

The following components can be tested in the "Guided Fault Finding" using vehicle diagnostic, testing and information system VAS5051.

Scheme 182

Mechatronics unit, Transmission Control Module (TCM) -J217- , Multi-function Transmission Range (TR) switch -F125- , Sensor for transmission RPM -G182- and Sender for transmission output RPM -G195

Location: the mechatronics unit is bolted to the underside of the transmission housing and covered by the transmission oil pan.

The mechatronics unit incorporates the hydraulic control system, the electronic control module and the sensors and actuators as a complete synchronized unit. This includes

1. Transmission Control Module (TCM) J217
2. Multi-Function Transmission Range (TR) Switch F125
3. Sensor for transmission RPM G182
4. Sender for transmission output RPM G195

The "mechatronics" unit can only be replaced as a complete unit.

Note. All components mentioned are tested via Self-diagnosis.

1. Removing and installing mechatronics unit --> «Mechatronics unit , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__mechatronics-unit-removing-and-installing) .

Scheme 183

Internal wiring harness in transmission

Location: the wiring harness - A - with connector - C - is attached to the mechatronics unit - B -.

1. Removing and installing wiring harness --> «Wiring harness in transmission, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__wiring-harness-in-transmission-removing-and) .

Scheme 184

Transmission Range (TR) Display Y6

Location: integrated into instrument cluster

Note. The Transmission Range (TR) Display Y6 can only be replaced together with instrument cluster.

Scheme 185

Kick Down Switch F8

Location: The Kick Down Switch F8 is located on the pedal cluster.

Note. The Kick Down Switch F8 is tested via Self-diagnosis.

1. Removing and installing Kick Down Switch F8 --> «20 - FUEL SUPPLY SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32l-v6-4v-generic-scan-tool-engine-codes-bkh) for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH «20 - FUEL SUPPLY»(ref-281373-S42835762992008031100000) for 4.2 LITER V8 4V GENERIC SCAN TOOL, ENGINE CODE(S): BVJ 20 FUEL SUPPLY for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK «20 - FUEL SUPPLY»(ref-281371-S33024851562008031100000) for 5.2 LITER 10-CYL. 4V GENERIC SCAN TOOL, ENGINE CODE(S): BXA .

Scheme 186

Ttiptronic switch F189

Location: The tiptronic switch F189 is integrated in the printed circuit of the symbol panel, which is located in the selector mechanism cover - A -.

Note. The tiptronic switch F189 is tested via Self-diagnosis.

1. Removing and installing tiptronic switch F189 --> «Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-sensor-system-control-module)

Selector mechanism, servicing

Ignition key removal lock, checking

1. Turn ignition key to "ignition on" position.
2. Press and hold brake pedal.

1. When interlock button in selector lever handle is pressed, it should be possible to move selector lever out of position "P" without "catching".

1. Switch off ignition.

1. It should not be possible to remove the ignition key when the selector lever is in any position other than "P".

1. Shift selector lever to position "P".
2. Remove ignition key.

1. It should only be possible to remove ignition key in selector lever position "P".
2. Selector lever can then not be shifted out of "P" position with interlock button pressed and brake pedal depressed.

If the ignition key removal lock does not function as described, check Access/Start Authorization Switch E415 via "Guided Fault Finding" using vehicle diagnosis, testing and information system VAS 5051 A.

Selector mechanism, checking

1. It should not be possible to operate the starter while the selector lever is in position "S" , "D" , "R" or in the "Tiptronic gate".
2. When travelling at speeds above 5 km/h and shifting into selector lever position "N" , the solenoid for the selector lever lock must not engage and block the selector lever. The selector lever can be shifted into a driving gear.
3. When travelling at speeds below 2 km/h (almost stationary) and shifting into selector lever position "N" , the solenoid for the selector lever lock should only engage after about 1 second. Selector lever cannot be shifted out of "N" position until brake pedal is depressed.

Selector lever in "P" position and ignition switched on

1. Do not depress brake pedal.

1. Selector lever is locked and cannot be shifted out of "P" position. Shift Lock Solenoid N110 blocks selector lever.

1. Press and hold brake pedal.

1. Shift Lock Solenoid N110 releases selector lever. It is possible to shift into a driving gear. Shift selector lever slowly from "P" position through "R, N, D and S" and check whether the Transmission Range (TR) Display Y6 in the instrument cluster shows the correct selector lever position in each case.

Selector lever in "N" position and ignition switched on

1. Do not depress brake pedal.

1. After a short waiting time: Selector lever is locked and cannot be shifted out of "N" position without pressing the interlock button on the selector lever handle. Shift Lock Solenoid N110 blocks selector lever.

1. Depress brake pedal.

1. Shift Lock Solenoid N110 releases selector lever. It is possible to shift into "D" position.

Selector lever in "D" position, ignition and lights switched on

1. Shift selector lever into "Tiptronic gate".

1. The illuminated "D" symbol in the Selector Lever Transmission Range (TR) Position Display Y26 should go out and the "+" and "-" symbols should light up.
2. The Transmission Range (TR) Display Y6 in the instrument cluster should change from "PRNDS" to "654321" when the selector lever is moved into the "Tiptronic gate".

If specifications are not attained

1. Adjust selector lever cable --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-adjusting) .
2. Check ignition key removal lock --> «Ignition key removal lock, checking»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__ignition-key-removal-lock-checking) .

Scheme 187

1 - Securing clip

2 - Noise insulation

3 - Retaining clip

1. Secures selector lever cable to selector housing

4 - Selector lever cable

1. Do not bend or kink
2. Removing and installing --> «Selector lever cable, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-removing-and-installing)
3. Selector lever cable must be replaced if rubber sleeve is damaged
4. Before installing, lightly lubricate ball socket with polycarbamide grease G052142 A2 .

1. When installing, make sure that rubber sleeve (on transmission end) is not twisted
2. Adjusting --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-adjusting)

5 - Clamping bolt, 13 Nm

6 - Pin for selector lever cable

1. To remove selector lever cable pull plastic locking spring on selector mechanism forward slightly and push up pin just far enough to release cable.

7 - Shift Lock Solenoid N110

1. Removing and installing --> «Shift Lock Solenoid N110 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__shift-lock-solenoid-n110-removing)

8 - Selector Lever Transmission Range (TR) Position Display Y26

1. Removing and installing --> «Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-transmission-range-tr-position)

9 - Clamp

1. To secure selector lever handle to selector lever
2. Removing and installing --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing)

10 - Selector lever boot

1. Detaching from selector lever handle --> «Removing selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd)

11 - Selector lever handle

1. Removing and installing --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing)

12 - Trim ring

1. Removing and installing --> «Removing selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd)

13 - 1.2 Nm

14 - Selector Lever Sensor System Control Module J587 and Tiptronic switch F189

1. Removing and installing --> «Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-sensor-system-control-module)

15 - Transmission Park Selector Switch F305

1. Removing and installing --> «Transmission Park Selector Switch F305 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transmission-park-selector-switch-f305)

16 - 10 Nm

17 - Selector housing

1. Can only be renewed as a complete unit
2. Removing and installing --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-mechanism-removing-and-installing)

18 - Selector mechanism cover (bottom)

19 - 10 Nm

Scheme 188

1 - Clamp

1. To secure selector lever handle to selector lever
2. Removing and installing --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing)

2 - Trim ring

1. Removing and installing --> «Removing selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd)

3 - Selector lever handle

1. Removing and installing --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing)

4 - Selector lever boot

1. Removing from selector lever handle --> «Removing selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd)

5 - Selector Lever Transmission Range (TR) Position Display Y26

1. Removing and installing --> «Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-transmission-range-tr-position)

Operating manual selector mechanism release

Note. If the battery is disconnected or discharged, the selector lever cannot be shifted from position "P". When you operate the manual release mechanism the Shift Lock Solenoid N110 will release the lock without current supply.

Scheme 189

1. Remove insert for front ashtray.
2. Use screwdriver to pry off cover cap in ashtray housing - arrow -.

Scheme 190

1. Use a screwdriver or similar to press on manual release lever - arrow - and simultaneously shift the selector lever out of position "P".

Selector lever handle, removing and installing

Special tools, testers and auxiliary items required

Scheme 191

1. Hose clamp pliers V.A.G 1275

Scheme 192

Removing

1. Shift selector lever to position "N".

Note. The selector lever handle is removed together with the selector lever boot.

1. Unclip retaining frame for selector lever boot - 1 - from center console and lift off - arrows -.

Scheme 193

1. Use a cable tie to secure the interlock button in pulled-out position - arrow - , as shown in the illustration.

Scheme 194

1. Turn up selector lever boot - 1 - over selector lever handle - 2 -.
2. Release clamp - arrow - and detach selector lever handle together with selector lever boot. Avoid touching the interlock button.

Installing

Note. To install the selector lever handle the interlock button has to be pulled out to the stop and must be secured with either a cable tie - arrow - or with the assembly aid supplied together with the new handle. If, by mistake, the interlock button has not been secured, it must not be pulled out of the selector lever handle using mechanical tools. Apply a compressed air gun at the bottom of the handle and press the interlock button out with compressed air.

1. Place selector lever handle fully on selector lever - interlock button points toward the driver.

1. The handle must engage in selector lever annular groove.

1. Remove cable tie or assembly aid, allowing the interlock button mechanism to engage in the vertical groove on the selector lever. If necessary, press the interlock button into the selector lever handle.

1. Secure selector lever handle - 2 - onto selector lever with clamp - arrow -. Use hose clamp pliers V.A.G 1275 for this purpose.
2. Clip retaining frame for selector lever boot - 1 - onto center console.

Scheme 195

Removing

1. Remove selector lever handle --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing) .
2. Tie together selector lever handle spring tips - 1 - using cable tie - 3 - as shown in illustration.
3. Slide sleeve - 2 - of selector lever boot past retainer tabs on spring tips - arrow -.
4. Remove cable tie and detach sleeve with selector lever boot from selector lever.

Installing

Installation is carried out in reverse sequence. Note the following

Installation position of selector lever boot

1. The longer side of the retaining frame for the selector lever boot faces drivers side.

1. Install selector lever handle --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing) .

Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing

Removing

1. Shift selector lever to position "N".
2. Unclip the retaining frame for selector lever boot - 1 - from center console and lift off - arrows -.
3. Turn up selector lever boot.

Scheme 196

1. Release retaining spring - 2 - and detach Selector Lever Transmission Range (TR) Position Display Y26 - 1 - - arrow -.
2. Disconnect electrical connector.

Installing

Perform installation in reverse sequence of removal.

Selector mechanism components, assembly overview

Note. Lubricate all bearings and moving surfaces with polycarbamide grease G052142 A2 .

Scheme 197

1 - Rubber sleeve for selector lever cable

1. Check rubber sleeve for selector lever cable is correctly engaged on bottom cover of selector mechanism and make sure it seals properly.

2 - Selector lever cable

1. Do not bend or kink
2. Removing and installing --> «Selector lever cable, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-removing-and-installing)
3. Selector lever cable must be replaced if rubber sleeve is damaged
4. Before installing, lightly lubricate ball socket with polycarbamide grease G052142 A2 .

1. When installing, make sure that the rubber sleeve (on transmission end) is not twisted
2. Adjusting --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-adjusting)

3 - Pin for selector lever cable

1. To remove selector lever cable pull plastic locking spring on selector mechanism forwards slightly and push up pin just far enough to release cable.

4 - Shift Lock Solenoid N110

1. Removing and installing --> «Shift Lock Solenoid N110 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__shift-lock-solenoid-n110-removing)

5 - Selector Lever Sensor System Control Module J587 and Tiptronic switch F189

1. Removing and installing --> «Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-sensor-system-control-module)

6 - 1.2 Nm

7 - 10 Nm

8 - Selector housing

1. Can only be replaced as a complete unit
2. Removing and installing --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-mechanism-removing-and-installing)

9 - Retaining clip

1. Secures selector lever cable to selector housing

10 - Selector mechanism cover (bottom)

11 - 10 Nm

Shift Lock Solenoid N110 , removing and installing

Removing

1. Shift selector lever to position "S".

Scheme 198

1. Grip Climatronic Control Module J255 at recesses on bottom (operating and display unit).
2. Pull out Climatronic Control Module J255 (operating and display unit) from retaining frame - arrows -.
3. Put Climatronic Control Module J255 (operating and display unit) on a cloth and place onto center console, to avoid damaging the surface.

Scheme 199

1. Disconnect electrical connectors in sequence - AD - by releasing the retainer tab - F -.
2. Disconnect electrical connector - E -.

Scheme 200

1. Remove trim cover above ashtray - arrow -.

Scheme 201

1. Open front ashtray.
2. Remove insert for front ashtray.
3. Remove bolts - 1 - and - 2 -.
4. Remove housing for front ashtray - 3 - - arrow -.

1. Disconnect electrical connector if installed.

Scheme 202

1. Disconnect electrical connector - 1 - from Shift Lock Solenoid N110.
2. Release retainer - arrow A - and pull out Shift Lock Solenoid N110 from the front - arrow B -.

Note. For illustration purposes selector mechanism shown removed.

Installing

1. Selector lever in position "S".

1. Move manual release lever - arrow - upward.

Note. The operating lever - 1 - for Shift Lock Solenoid N110 moves into installation position when the manual release lever is moved upward.

Scheme 203

1. At the same time place Shift Lock Solenoid N110 into guide at an angle from above.

1. Press Shift Lock Solenoid N110 into guide until it engages.

1. At the same time the ball head - 2 - of the Shift Lock Solenoid N110 should engage in the operating rod of the selector mechanism.

Perform remaining installation operations in reverse sequence of removal.

Tightening torque

Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing

Note. Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 are combined in one unit. The magnets for the Tiptronic Switch F189 are secured on the cover.

Removing

1. Remove selector lever handle --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing) .
2. Remove front and rear sections of center console --> «68 - INTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/gauges-instrument-panels/#body-interior) .

Scheme 204

1. Disconnect electrical connector - 1 -.
2. Remove bolts - arrows - and remove Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189.

Installing

Installation is carried out in reverse sequence. Note the following

1. Install front and rear sections of center console --> «68 - INTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/gauges-instrument-panels/#body-interior) .
2. Install selector lever handle --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-handle-removing-and-installing) .

Tightening torque

Selector mechanism, removing and installing

Removing

Scheme 205

1. Remove rear cross piece - arrows -.

Scheme 206

1. Unfasten quick-release catches - 2 - and detach rear noise insulation.

Scheme 207

1. Remove front cross piece - arrows -.
2. Remove drive shaft --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

Scheme 208

1. Loosen inner side of covers on vehicle underside (left and right).
2. Remove heat shield - arrow -.

Scheme 209

1. Mark installation position of support bracket for selector lever cable.
2. Pry ball socket - 1 - of selector lever cable off selector shaft lever.
3. Remove bolts - arrows - of support bracket for selector lever cable.

Note. Do not bend or kink the selector lever cable.

Scheme 210

1. Remove front and rear sections of center console --> «68 - INTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/gauges-instrument-panels/#body-interior) .
2. Disconnect electrical connectors - 2 - and - 4 -.
3. Remove bolts - 1 - , - 3 - , - 5 - and - 6 -.

Note. The assistance of a second mechanic is required to detach the selector mechanism from below.

1. Press retaining clips - arrows - inward and lower selector mechanism.

Installing

Installation is carried out in reverse sequence. Note the following

Note. Before installing, lightly lubricate ball socket on selector lever cable with polycarbamide grease G052142 A2 . Do not bend or kink the selector lever cable.

1. Install support bracket for selector lever cable according to marking on the transmission.
2. Adjust selector lever cable --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-adjusting) .
3. Install exhaust system so it is free of stress --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
4. Install rear cross piece --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Install front cross piece --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install rear and front sections of center console --> «68 - INTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/gauges-instrument-panels/#body-interior) .
3. Check selector mechanism --> «Selector mechanism, checking»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-mechanism-checking) .

Tightening torque

Transmission Park Selector Switch F305 , removing and installing

The Transmission Park Selector Switch F305 consists of two microswitches. The two microswitches form the signal required by the electronic ignition key removal lock to release the key only in selector position P.

The first switch is closed when the Shift Lock Solenoid N110 is not actuated in selector position "P" , (brake pedal not depressed) and the manual release of the selector lever below the ashtray is not operated.

The second switch is closed when the button on the selector lever handle is not operated in selector position "P".

Note the following before replacing Transmission Park Selector Switch F305

1. The two switches are connected in series, i.e. both switches must be closed before the ignition key can be removed. The switches can be checked with the vehicle diagnosis, testing and information system VAS 5051A in the Guided Fault Finding. After performing the vehicle system test, select the test program F305 - Gear selector position P switch (Powertrain / Automatic transmission 09L / 01 - systems capable of self-diagnosis / 02 - transmission electronics / electrical components).
2. It is possible to perform an electrical check on the switches. When performing a continuity test using a multimeter, note that the resistance is approx. 470 Ohm with both switches closed.

Removing

1. Remove selector mechanism --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-mechanism-removing-and-installing)

1. Remove bolts - arrows - and remove Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189.

Scheme 211

1. Release connector - D - and detach from Shift Lock Solenoid N110.
2. Release connector - E - and disconnect by pulling it off upward.
3. Press tab - C - in direction of - arrow 1 -.
4. Remove microswitch - B - by pulling it off in direction of - arrow 2 -.

1. Disengage electrical wire at selector mechanism - arrows A -.

Scheme 212

1. Unclip retaining clips - A - on both sides of selector mechanism.
2. Press parking lock button - C - downward and hold.
3. Pull selector rod - B - upward and shift selector lever in direction of - arrow - into selector lever position "S" onto stop.

Scheme 213

1. Push locating pin - A - forward through rear opening for retaining clip in direction of - arrow - using a screwdriver

Note. The locating pin - A - can remain installed; it is sufficient to press it forward far enough for the microswitch - B - to be removed.

1. Remove microswitch - B - toward front.
2. Disengage electrical wire at lug - arrows C - and remove microswitch out of selector mechanism.

Installing

Installation is carried out in reverse sequence. Note the following

1. Take hold of the long electrical wire and guide microswitch into selector mechanism through opening below parking lock button.
2. Install microswitch - B - into gearshift gate.

Note. The microswitch must be seated flush.

1. Secure wire to lug - arrows C -.
2. Using a screwdriver, press in locating pin - A - as far as stop in opposite direction of arrow.

Note. The locating pin - A - locates the microswitch - B - in the gearshift gate. If the microswitch is not correctly installed or not located properly, the ignition key removal lock will not function as required.

1. Locate electrical wire - arrows A - on the selector mechanism as shown in the illustration.
2. Install microswitch - B -.

Note. If the microswitch is not correctly installed or not located properly, the ignition key removal lock will not function as required.

1. Connect connector - D - onto Shift Lock Solenoid N110.
2. Clip in connector - E - from above.

1. Clip in retaining clips - A - on both sides of selector mechanism.
2. Install Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 --> «Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-sensor-system-control-module)
3. Install selector mechanism --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-mechanism-removing-and-installing) .

Scheme 214

1 - Selector shaft lever

2 - Retaining clip

1. Secures selector lever cable to support bracket

3 - Selector lever cable

1. Do not bend or kink
2. Removing and installing --> «Selector lever cable, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-removing-and-installing)
3. Selector lever cable must be replaced if rubber sleeve is damaged
4. Before installing, lightly lubricate ball socket with polycarbamide grease G052142 A2 .

1. When installing, make sure that rubber sleeve (on transmission end) is not twisted
2. Adjusting --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-adjusting)

4 - Clamping bolt for selector lever cable, 13 Nm

5 - Pin for selector lever cable

1. To remove selector lever cable pull plastic locking spring on selector mechanism forward slightly and push up pin just far enough to release cable.

6 - Retaining clip

1. Secures selector lever cable to selector housing

7 - Rubber sleeve for selector lever cable

1. Check that rubber sleeve for selector lever cable is correctly engaged on bottom cover of selector mechanism and make sure it seals properly.

8 - Bolt, 10 Nm

1. Securing support bracket to transmission

9 - Support bracket for selector lever cable

Selector lever cable, removing and installing

Removing

1. Shift selector lever to position "S".

1. Remove rear cross piece - arrows -.

1. Unfasten quick-release catches - 2 - and detach rear noise insulation.

1. Remove front cross piece - arrows -.
2. Remove drive shaft --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .

1. Loosen inner side of covers on vehicle underside (left and right).
2. Remove heat shield - arrow -.

1. Mark installation position of support bracket for selector lever cable.
2. Pry ball socket - 1 - of selector lever cable off selector shaft lever.
3. Remove support bracket bolts - arrows - for selector lever cable.

Note. Do not bend or kink the selector lever cable.

Scheme 215

1. Pry off lock washers - 1 -.
2. Push noise insulation - 2 - forwards.
3. Detach rubber sleeve - 3 - from bottom cover for selector mechanism - 4 -.
4. Remove nuts - 5 -.

1. Fold bottom cover for selector mechanism and noise insulation to front.

Scheme 216

1. Remove retaining clip - 1 - for selector lever cable by pulling it off downward at the selector mechanism.
2. Pull plastic securing spring - 2 - slightly forward and press pin - 3 - upward, but only as far as is necessary using a screwdriver.

Note. Make sure that pin is not pressed out completely.

1. Pull selector lever cable - 4 - out of selector mechanism.

Installing

Installation is carried out in reverse sequence. Note the following

Note. Do not bend or kink the selector lever cable. Before installing, lightly lubricate ball socket on selector lever cable with polycarbamide grease G052142A2 .

Scheme 217

1. Push selector lever cable into selector mechanism and secure cable with retaining clip - 1 -.

1. Installation position: angled end of retaining clip must point toward rear.

1. Insert end of selector lever cable - 4 - into joint on selector lever.
2. Push pin - 3 - down - arrow -.
3. Check plastic securing spring - 2 - has locked pin.
4. Install support bracket for selector lever cable to new selector lever cable.

1. Install support bracket for selector lever cable according to marking on transmission.
2. Adjust selector lever cable --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-adjusting) .
3. Check selector mechanism --> «Selector mechanism, checking»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-mechanism-checking) .
4. Install drive shaft --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r)

1. Install exhaust system so it is free of stress --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
2. Install rear cross piece --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install front cross piece --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Tightening torques

Selector lever cable, adjusting

Special tools, testers and auxiliary items required

Scheme 218

1. Socket and key T40031

Procedure

1. Unclip retaining frame for selector lever boot - 1 - from center console and lift off - arrows -.

Scheme 219

1. Shift selector lever to position "S".

Note. Clamping bolt can only be accessed with selector lever in position "S". Loosen clamping bolt approx. 1 turn - do not remove.

1. Loosen clamping bolt for selector lever cable approx. 1 turn using socket and key T40031.
2. Switch on ignition.

1. Symbol "S" in the "PRNDS" display should be highlighted in the Transmission Range (TR) Display Y6 on the instrument cluster

If this is not the case

1. Loosen bolts - arrows - on support bracket for selector lever cable.

Scheme 220

1. Adjust exact position "S" on transmission by slightly moving selector shaft lever - 2 -.

1. Tighten bolts - arrows - on support bracket for selector lever cable.

If symbol "S" in "PRNDS" display is highlighted in Transmission Range (TR) Display Y6 on instrument cluster

1. Carefully move selector lever slightly forward and backward, without shifting lever into a different selector lever position. The selector lever cable is thereby loosened.

Note. When tightening the clamping bolt, the selector lever must not be pulled forward or backward, as otherwise the setting will not be accurate.

1. Tighten clamping bolt on selector lever cable - arrow - in this position.

Assemble in reverse sequence.

Tightening torque

Transmission, removing and installing

Overview

1. Removing transmission on vehicles with 6-cyl. GDI engine --> «Transmission on vehicles with 6-cyl. GDI engine, removing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transmission-on-vehicles-with-6-cyl-gdi)
2. Removing transmission on vehicles with 8-cyl. engine --> «Transmission on vehicles with 8-cyl. engine, removing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transmission-on-vehicles-with-8-cyl-engine)
3. Installing transmission --> «Transmission, installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transmission-installing)

Transmission on vehicles with 6-cyl. GDI engine, removing

1. Observe repair instructions --> «Repair instructions»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Scheme 221

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G1383 A
2. Transmission support 3282
3. Adjustment plate 3282/48
4. Pin 3282/50

1. Drip tray for workshop hoist VAS 6208
2. Adapter T40058
3. Bolt M10x20 (1x)

Note. All cable ties which are released or cut open during removal must be installed in the same position when installing.

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Switch off ignition.

Note. When disconnecting the battery, the ignition key must remain in the ignition lock so that wheels can be turned after the battery has been disconnected. On vehicles with all wheel drive the electronic parking brake must be released prior to disconnecting the battery so that the drive shaft can be turned for removal.

Scheme 222

1. Remove luggage compartment floor covering.
2. Disconnect Ground (GND) wire - arrow - at battery.

1. Release quick-release fasteners - 1 - and - 2 - and detach front and rear noise insulation.

Scheme 223

1. Remove noise insulation in wheel housing (left and right) - arrows -.

Scheme 224

1. Remove heat shield from transmission above left drive axle - arrows -.
2. Remove left and right drive axles from transmission flanges.

1. Remove front cross piece - arrows -.

Scheme 225

1. Disconnect exhaust system at clamp - arrow -.

Scheme 226

Note. The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10 ° - otherwise it can be damaged.

1. Remove bolts - arrows - at center bracket for front exhaust pipe.

Scheme 227

1. Remove nuts - arrows - and remove front exhaust pipe with main catalytic converter.

Scheme 228

1. Remove bolts - arrows - at tunnel cross member.
2. Remove tunnel cross member with front exhaust pipe center bracket.

Scheme 229

1. Remove heat shield - A - for drive shaft - arrows -.
2. Remove bolts at transmission/drive shaft flange.
3. Slide drive shaft together toward rear final drive. The constant velocity joints can be moved axially.
4. Tie up drive shaft to body.

Scheme 230

1. Loosen bolts - arrows - at stop for torque reaction support.
2. Press stop for torque reaction support upward and tighten bolts again.

Note. Adjusting the stop for torque reaction support prevents the engine from tilting at the front after the transmission is removed.

Scheme 231

1. Set up transmission support 3282 on engine/transmission jack V.A.G 1383 A.

Note. The stud 3282/50 is flattened at the side - arrow - , the flattened side should face the oil pan when inserting stud into transmission.

1. Place adjustment plate 3282/48 on transmission support 3282 as shown in illustration.
2. Align transmission support arms according to holes in adjustment plate.
3. Attach support elements as illustrated on adjustment plate.
4. Place engine/transmission jack V.A.G 1383 A with transmission support 3282 underneath transmission.

Note. The arrow symbol on the adjustment plate 3282/48 points in the direction of travel.

1. Align adjustment plate 3282/48 parallel with transmission.

Scheme 232

1. Bolt support to rear left tapped hole on transmission - arrow1 - using one bolt (M10x20).
2. Insert flattened stud 3282/50 into mounting hole at right rear of transmission housing - arrow 2 -.

Scheme 233

1. Insert stud into mounting hole at left front of transmission housing - arrow 2 -.
2. Insert stud into recess in housing at right front of differential housing - arrow 1 -.
3. Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly.

Scheme 234

1. Remove bolts - arrows - for transmission mounting (left and right).

Scheme 235

1. Remove bracket - arrow - for ATF lines on top section of oil pan.

Scheme 236

1. Remove bracket - arrow - for the ATF lines at the bottom section of transmission.
2. Place drip tray for VAS 6100 VAS 6208 under transmission.

Scheme 237

1. Remove bolt - arrow -.

Note. Place a piece of cloth below connection points to catch escaping ATF.

1. Detach ATF lines from transmission.
2. Plug lines and openings at transmission with clean plugs.

Scheme 238

1. Remove bolts - 1 - and - 2 - and lower subframe slightly at the rear.

Scheme 239

1. Mark position of ATF lines in relation to one another with a water-proof pen.
2. Loosen both ATF line union nuts - arrows - and disconnect ATF lines.
3. Plug open ends of lines with clean plugs.
4. Remove ATF lines from between subframe and transmission.

Scheme 240

1. Disconnect wires - 2 - and - 3 - at starter.
2. Remove starter --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment)

Scheme 241

1. Insert adapter T40058 guide pin so that the large diameter - arrow 1 - faces engine. The smaller diameter - arrow 2 - faces adapter.

Scheme 242

1. Counter-hold crankshaft using adapter T40058 to loosen torque converter bolts.

Note. Arrow - can be disregarded.

Scheme 243

1. Remove 3 Torx socket head bolts - arrows - of the torque converter through the opening for the removed starter (turning the crankshaft 1 / 3 turn each time).

Scheme 244

1. Disconnect electrical connector at transmission by turning fastener cap counter-clockwise - arrow -.
2. Move all electrical wiring clear of transmission housing.

Scheme 245

1. Remove bolts - 4 - , - 5 - and - 9 - and remove left transmission support with transmission mounting.

Scheme 246

1. Remove bolts - 4 - , - 8 - and - 9 - and remove right transmission support with transmission mounting.

Note. Mark support bracket installation position for selector lever cable with a felt-tip pen.

1. Pry ball socket - 1 - of selector lever cable off selector shaft lever.
2. Remove support bracket from transmission - arrows -.
3. Move clear selector lever cable.
4. Lower transmission slightly at rear using engine/transmission jack V.A.G 1383 A.

Scheme 247

1. Remove Engine Speed (RPM) Sensor G28 on transmission - arrow -.

Scheme 248

1. Remove bolts - arrows - on left and right evenly.
2. Remove stabilizer bar.

Scheme 249

1. Remove bolts - 3...10 - from engine/transmission flange.

Scheme 250

1. Using a tire iron or other suitable lever, pry torque converter away from engine drive plate - arrow -.
2. Press transmission off dowel sleeves and lower it carefully.

Scheme 251

1. Lower rear edge of the transmission by adjusting the transmission support 3282 accordingly.
2. Guide transmission out diagonally downward/to the rear.

Transmission on vehicles with 8-cyl. engine, removing

1. Observe repair instructions --> «Repair instructions»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Note. All cable ties which are released or cut open during removal must be installed in the same position when installing.

1. The transmission is removed with the engine, then the two components are separated.
2. Removing and installing engine --> 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «10 - ENGINE - ASSEMBLY»(ref-281367-S32869335672008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK

Transmission, installing

Installation is carried out in reverse sequence. Note the following

Note. Clean ATF lines and ATF cooler before installing exchange transmission --> ATF lines and ATF cooler, cleaning . Replace self-locking nuts and bolts when performing assembly work. Replace oil seals and gaskets, and bolts which are tightened by turning through a specified angle. Re-attach heat shield sleeves at the same locations when re-installing. Hose connections and hoses for charge air system must be free from oil and grease before installing. Secure all hose connections with the correct hose clips (as original equipment). Re-attach all cable ties at the same locations when re-installing.

1. Before installing transmission, you must make sure that the torque converter is properly installed in the transmission.

1. If the torque converter is correctly installed, the depth between the contact faces at the tapped holes on the torque converter and the contact surface of the torque converter bell housing is approx. 19mm.

1. Before installing transmission, check for correct positioning of dowel sleeves - A - at cylinder block. Install new dowel sleeves if necessary.
2. If an intermediate plate was installed between engine and transmission, reinstall plate in same position.
3. Before joining engine and transmission, turn torque converter and drive plate (on engine) until one hole and one tapped hole are in line with the opening for the removed starter.
4. When pushing the engine and transmission together, ensure that no cables, lines, etc. can become trapped.

When you then install the transmission, adhere to the following instructions.

1. Bolt transmission onto engine.

Note. Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant. Do not use parts which have been degreased. Tolerance for tightening torques ± 15%.

1. Insert adapter T40058 guide pin so that the large diameter - arrow 1 - faces engine. The smaller diameter - arrow 2 - faces adapter.

1. Counter-hold crankshaft using adapter T40058 to secure torque converter bolts.

Note. Arrow - can be disregarded.

1. Use new ribbed bolts to secure torque converter to drive plate.

1. Screw in 3bolts - arrow - for torque converter hand-tight through opening of removed starter (turning crankshaft 1 / 3 turn each time).
2. Tighten torque converter bolts to torque (turning crankshaft 1 / 3 turn each time).
3. Install starter --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Loosen bolts - arrows - for torque reaction support.
2. Allow stop for torque reaction support to settle on rubber buffer for torque reaction support and re-tighten bolts.

On vehicles with 6-cyl. GDI engine

1. Install transmission supports and transmission mountings.

Scheme 252

On vehicles with 8-cyl. engine

1. Install transmission support, transmission mounting and tunnel cross member.

Note. When replacing transmission, take off transmission support from transmission to be exchanged and install to replacement transmission

All models

1. Secure drive shaft to transmission --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
2. Bolt drive axles to flange shafts --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Electrical connections and routing Electrical Wiring Diagrams, Troubleshooting Component Locations
4. Check selector lever cable adjustment --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-lever-cable-adjusting) .

1. Check oil level in final drive (front) --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Check oil level in transfer gear --> «Transfer gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Install exhaust system free of stress --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
4. Follow steps required after connecting battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Fill cooling system --> «19 - ENGINE - COOLING SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «19 - ENGINE - COOLING SYSTEM»(ref-281367-S34562108182008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK «19 - ENGINE - COOLING SYSTEM»(ref-281368-S21687354792008031100000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
2. Check ATF level in planetary gearbox --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening torques

Securing engine/transmission assembly on vehicles with 6-cyl. GDI engine

*Bolt strength 10.9

Scheme 253

Securing engine/transmission assembly on vehicles with 8-cyl. engine

*Bolt strength 10.9

Automatic transmission, transporting

Special tools, testers and auxiliary items required

Scheme 254

1. Attachment and holding rig 3457

Scheme 255

Attachment and holding rig 3457 can be used to transport the automatic gearbox and also when setting up transmission support 3282.

1. Install attachment and holding rig 3457 to attachment points on transmission housing and secure in place.

Scheme 256

Special tools, testers and auxiliary items required

1. Attachment and holding rig 3457
2. Support clamp VW313
3. Support plate VW309
4. Workshop crane V.A.G1202A

Procedure

1. Remove transmission --> «Transmission on vehicles with 6-cyl. GDI engine, removing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transmission-on-vehicles-with-6-cyl-gdi) .

1. Install attachment and holding rig 3457 to attachment points on transmission housing and secure in place.
2. Bolt transportation tool onto support plate VW309 and install into support clamp VW313 with the aid of workshop crane.

Note. If the filled transmission with oil pan is to be turned upside down on assembly stand, the transmission housing and final drive breathers must be sealed.

Removing and installing transmission mounting, transmission support and tunnel cross member on vehicles with 6-cyl. GDI and 8-cyl. engine

Special tools, testers and auxiliary items required

Scheme 257

1. Engine/transmission jack V.A.G 1383 A
2. Block of wood

Scheme 258

Removing transmission mounting - 2 - and transmission support - 4

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Release quick-release fasteners - 1 - and - 2 - and detach noise insulation panels.

Scheme 259

1. Remove bolts - 13 - and remove rear bracket for front exhaust pipe.
2. Apply lifting column of engine/transmission jack V.A.G 1383 A at transfer gear behind tunnel cross member (place a block of wood between lifting column and transfer gear).

1. Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly.

Scheme 260

1. Remove bolts - arrows - for tunnel cross member.

Scheme 261

1. Remove bolts - 1 - and - 2 - and move tunnel cross member slightly towards rear.

1. Remove transmission mounting - 2 - between transmission and tunnel cross member.
2. Remove bolts - 3 - and detach transmission support - 4 - from transmission.

Installing transmission mounting - 2 - and transmission support - 4

Perform installation in reverse sequence of removal.

1. Install transmission support - 4 -.
2. Install transmission mounting - 2 -.
3. Install tunnel cross member - 2 - Removing tunnel cross-member under «Removing and installing transmission mounting, transmission support and tunnel cross member on vehicles with 6-cyl. GDI and 8-cyl. engine»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__removing-and-installing-transmission-mounting-transmission)
4. Install exhaust system free of stress --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .

1. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering)

Tightening torques

Scheme 262

Removing tunnel cross-member - 1

1. Activate jacking mode --> Running gear, front-wheel drive and four-wheel drive «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Release quick-release fasteners - 1 - and - 2 - and detach noise insulation panels.

1. Remove bolts - 13 - and remove rear bracket for front exhaust pipe.

Scheme 263

1. Loosen clamps - 1 - and - 2 -.
2. Remove front exhaust pipe with catalytic converter (left-side) --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .

1. Tie up front exhaust pipe (right) to the side or support from below.

1. Remove front cross member - arrows -.
2. Apply lifting column of engine/transmission jack V.A.G 1383 A at transfer gear behind tunnel cross member (place a block of wood between lifting column and transfer gear).

1. Use engine/transmission jack V.A.G 1383 A to lift transmission up slightly.

1. Remove bolts - arrows - for tunnel cross member.

1. Remove nuts - 1 -.
2. Remove tunnel cross member.

Installing tunnel cross-member - 1

Installation is carried out in reverse sequence. Note the following

Tightening torques

1. Install exhaust system free of stress --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
2. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering)

Removing and installing transmission support and transmission mounting (right and left) on vehicles with 6-cyl. GDI engine

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

Removing

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Unfasten quick-release catches - 2 - and detach rear noise insulation.

Scheme 264

1. Remove front cross piece - arrows -.

Scheme 265

1. Detach universal mounting bracket V.A.G 1359/2 from engine/transmission jack V.A.G 1383 A.
2. Place telescopic column of engine/transmission jack V.A.G 1383 A centered below cast lug on transmission housing - arrow - and raise transmission slightly.

Transmission support and transmission mounting (left-side) on vehicles with 6-cyl. GDI engine

1. Remove front exhaust pipe with catalytic converter (left side) --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .

1. Remove bolts - 1 -.
2. Remove bolts - 4 - , - 5 - and - 9 - and remove left transmission support with transmission mounting.

Transmission support and transmission mounting (right-side) on vehicles with 6-cyl. GDI engine

1. Remove bolts - 1 -.
2. Remove bolts - 4 - , - 8 - and - 9 - and remove right transmission support with transmission mounting.

Installing

Installation is carried out in reverse sequence. Note the following

1. Install exhaust system free of stress --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
2. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening torques of transmission mounting (right-side) on vehicles with 6-cyl. GDI engine

1. 23 Nm
2. Subframe
3. Transmission mounting (right-side)
4. 23 Nm
5. Transmission support (right-side)
6. Washer
7. 40 Nm
8. 23 Nm
9. 23 Nm

Tightening torques of transmission mounting (left-side) on vehicles with 6-cyl. GDI engine

1. 23 Nm
2. Subframe
3. Transmission mounting (left-side)
4. 23 Nm
5. 23 Nm
6. 40 Nm
7. Washer
8. Transmission support (left-side)
9. 23 Nm

ATF level in planetary gearbox

Note. Read the rules when working on the automatic transmission --> Read the rules .

Scheme 266

Special tools, testers and auxiliary items required

1. Vehicle diagnostic, testing and information system VAS5051
2. Drip tray for workshop hoist VAS 6208
3. ATF charging device V.A.G 1924
4. Safety goggles

Test conditions

1. Transmission must not be in emergency running (backup) mode.
2. Vehicle must be level (horizontal).
3. Selector lever in position "P" , engine idling.
4. Air conditioner and heating system switched off.

1. Vehicle diagnostic, testing and information system VAS5051 connected up; vehicle self-diagnosis and vehicle system "02 - Gearbox electronics" selected.
2. The ATF temperature at the beginning of the test must not be higher than 30 ° C. If necessary, first allow the transmission to cool down.

Note. The ATF temperature is taken from the reading on the vehicle diagnostic, testing and information system VAS5051. The ATF level will vary according to the ATF temperature. If the ATF level is checked when the ATF temperature is too low, this will result in overfilling. If the level is checked when the ATF temperature is too high, this will result in underfilling. Both overfilling and underfilling have a detrimental effect on the functioning of the transmission Use only the correct type of ATF (available as a replacement part) for the planetary gearing in automatic transmission 09L. Other oils cause malfunctions and/or failure of the transmission.

Scheme 267

ATF temperature reading

Display on VAS5051

1. From list - 1 - select diagnostic function "08 - Read data block (measured value block)".

Scheme 268

Display on VAS5051

1 - Enter display group

1. Use keypad - 2 - to enter "4" for "Display group number 4" and confirm by touching Q key.

Scheme 269

Display on VAS5051

1. Reading for ATF temperature is shown in display zone - 1 -.

Checking and correcting ATF level

Note. The ATF level is checked at the ATF inspection plug. At an ATF temperature between 35 ° and 45 ° C (50 ° C for tropical countries) a small amount of fluid should drain out of the inspection bore if the transmission is filled with the proper quantity of ATF (this is normal as the fluid expands as it heats up).

1. Drive vehicle onto a four-column lifting platform or over an inspection pit in order for it to be absolutely horizontal.

Note. Before raising the vehicle on a lifting platform (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

1. Fill container of ATF charging device V.A.G 1924 with ATF for automatic transmission 09L.

Scheme 270

1. Secure container for ATF charging device V.A.G 1924 as high as possible on vehicle.
2. Start engine and let it idle.
3. Place drip tray for workshop hoist VAS 6208 under transmission.

Scheme 271

1. When an ATF temperature of 35 ° C is reached, remove ATF inspection plug - arrow B - and drain off any surplus ATF.

Scheme 272

1. Replace ATF inspection plug seal - arrow -.

Scheme 273

If ATF emerges from the inspection opening before the ATF has reached 40 ° C the ATF level is OK - arrow -.

Note. The ATF inspection plug must be screwed in again at the latest when ATF reaches a temperature of 45 ° C (countries with hot climates: 50 ° C).

If still no ATF emerges from ATF inspection opening when ATF has reached 45 ° C, top off with ATF.

1. Install new seal on ATF inspection plug and tighten to 80 Nm. The ATF check is now completed.
2. End function "08 - Read data block (measured value block)" by touching <-- key.
3. Press "06 - End output".
4. Switch off ignition and disconnect diagnostic connector.

Note. If the vehicle has been raised on a lifting platform you must also de-activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Filling up ATF

If still no ATF emerges from ATF inspection opening when ATF has reached 40 ° C, top off with ATF.

Note. The ATF inspection plug must be screwed in again at the latest when temperature reaches 45 ° C (hot climates: 50 ° C). If necessary, switch off engine, allow gearbox to cool down and repeat the test.

Scheme 274

1. Guide ATF charging device V.A.G 1924 filler nozzle in from below through an opening in the deflector cap - arrow - , taking care not to push deflector cap upward out of position.
2. Fill with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole.

Note. The ATF level must not be too low or too high, otherwise this would impair the function of the transmission.

1. Install new seal on ATF inspection plug and tighten to 80 Nm.
2. End function "08 - Read data block (measured value block)" by touching <-- key.
3. Press "06 - End output".
4. Switch off ignition and disconnect diagnostic connector.

Note. If the vehicle has been raised on a lifting platform you must also de-activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Draining ATF or filling up after performing repairs

Special tools, testers and auxiliary items required

Scheme 275

1. Drip tray for workshop hoist VAS 6208

Scheme 276

1. ATF charging device V.A.G 1924
2. Safety goggles

Procedure

1. Engine not running.

1. Drive vehicle onto a lifting platform or over an inspection pit in order for it to be absolutely horizontal.

Note. Before raising the vehicle on a lifting platform (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

1. Fill container of ATF charging device V.A.G 1924 with ATF for automatic transmission 09L

1. Secure container for ATF charging device V.A.G 1924 as high as possible on vehicle.

1. Unfasten quick-release catches - 2 - and detach rear noise insulation.

Draining ATF

1. Place drip tray for workshop hoist VAS 6208 under transmission.
2. Remove ATF drain plug - arrow A -.
3. Drain ATF.

Note. Observe relevant disposal regulations. The engine must not be started and vehicle must not be towed without ATF in transmission. The drain plug with seal must be replaced.

1. Tighten new drain plug - arrow A - to 12 Nm.

Filling transmission with ATF

1. Remove ATF inspection plug - arrow B -.

1. Guide ATF charging device V.A.G 1924 filler nozzle in from below through an opening in deflector cap - arrow - , taking care not to push deflector cap upward out of position.
2. Fill with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole.
3. Shift selector lever to position "P".
4. Start engine.

Note. This process of starting the engine for a short period of time and then turning it off is required to ensure that the ATF pump does not draw in air. This prevents the building up of foam in the ATF, which would result in an inaccurate reading of the ATF level.

1. Continue filling with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole again.
2. Start engine and allow to idle.
3. With the engine idling, continue filling with ATF using ATF charging device V.A.G 1924 until ATF comes out of inspection hole again.
4. Tighten ATF inspection plug.

1. With engine idling, press brake pedal and shift selector lever through all selector lever positions leaving selector lever at least 10seconds in each position.
2. Shift selector lever to position "N".
3. Increase engine speed to 2000 rpm and maintain for at least 60 seconds.
4. Shift selector lever to position "P".

1. Check ATF level --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

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

ATF lines

Note. General repair instructions --> General repair instructions .

ATF lines and ATF cooler, assembly overview

Note. Read the rules when working on the automatic transmission --> Read the rules . Thoroughly clean all joints and surrounding areas before disassembling. Check ATF level after replacing ATF lines/hoses or ATF cooler --> ATF level, checking and correcting .

ATF lines and ATF cooler - assembly overview for vehicles with 6-cyl. GDI engine

ATF lines and ATF cooler - assembly overview for vehicles with 8-cyl. engine

Scheme 277

1 - O-rings

1. Always replace
2. Lubricate with ATF when installing

2 - Bolt, 21 Nm

1. Do not tighten until lines have been fully inserted

3 - ATF line

1. Note correct location
2. Push ATF lines fully into transmission by hand as far as stop, then bolt on.

4 - ATF line

1. Note correct location
2. Push ATF lines fully into transmission by hand as far as stop, then bolt on.

5 - Bracket for ATF line

6 - Bolt, 5 Nm

7 - Bolt

1. 3 Nm, all other 6-cyl. engines except for 6-cyl. 3.2 ltr. 4V engine (direct injection)
2. 10 Nm, only on vehicles with 6-cyl. 3.2 ltr. 4V engine (direct injection)

8 - Bracket

9 - ATF line

1. Note correct location

10 - ATF line

1. Note correct location

11 - ATF cooler

1. Clean ATF cooler --> «ATF lines and ATF cooler, cleaning»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__atf-lines-and-atf-cooler-cleaning) .

12 - ATF line

1. Note correct location
2. Push ATF lines fully into cooler by hand as far as stop, then bolt on

13 - Bracket

14 - ATF line

1. Note correct location
2. Push ATF lines fully into cooler by hand as far as stop, then bolt on

15 - Bolt, 5 Nm

16 - Bolt, 5 Nm

17 - Nut, 5 Nm

18 - Bracket for ATF line

19 - Bolt, 5 Nm

20 - Bracket

Union nut - arrows - , 29 Nm

1. For connecting ATF lines
2. Note location of ATF lines

Scheme 278

1 - O-rings

1. Always replace
2. Lubricate with ATF when installing

2 - Bolt, 21 Nm

1. Do not tighten until lines have been fully inserted

3 - ATF line

1. Note correct location
2. Push ATF lines fully into gearbox by hand as far as stop, then bolt on.

4 - ATF line

1. Note correct location
2. Push ATF lines fully into gearbox by hand as far as stop, then bolt on.

5 - Bracket for ATF line

6 - Nut, 5 Nm

7 - ATF cooler

1. Clean ATF cooler --> «ATF lines and ATF cooler, cleaning»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__atf-lines-and-atf-cooler-cleaning) .

8 - ATF line

1. Note correct location
2. Push ATF lines fully into cooler by hand as far as stop, then bolt on

9 - ATF line

1. Note correct location
2. Push ATF lines fully into cooler by hand as far as stop, then bolt on

10 - Bolt, 5 Nm

1. Do not tighten until lines have been fully inserted

11 - Bolt, 5 Nm

1. Do not tighten until lines have been fully inserted

12 - Center hex stud, 7 Nm

13 - Bracket

14 - Union nut, 29 Nm

For connecting ATF lines

Note location of ATF lines

ATF cooling lines, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Drip tray
3. Safety goggles

Note. Read the rules when working on the automatic transmission. Thoroughly clean all joints and surrounding areas before disassembling.

Removing

1. Mark position of all ATF cooling lines in relation to one another with different colors to avoid confusion.
2. Place drip tray for workshop hoist VAS 6208 underneath.

1. Disconnect ATF cooling lines.
2. Seal opened cooling lines with clean sealing plugs.

Installing

Installation is carried out in reverse sequence. Note the following

1. Clean ATF cooling lines --> «ATF lines and ATF cooler, cleaning»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__atf-lines-and-atf-cooler-cleaning) .
2. Lightly lubricate O-rings with ATF.
3. First push ATF cooling lines fully into transmission or cooler as far as stop, then bolt on --> «ATF lines and ATF cooler, assembly overview»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__atf-lines-and-atf-cooler-assembly) .
4. Check ATF level --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

ATF lines and ATF cooler, cleaning

Special tools, testers and auxiliary items required

1. Compressed air gun (commercially available)
2. Hose, approx. 18mm dia.
3. Drip tray

Note. Always clean ATF cooling lines and ATF cooler before installing a replacement transmission. Read the rules when working on the automatic transmission. Thoroughly clean all joints and surrounding areas before disassembling.

Scheme 279

Procedure

1. Place drip tray underneath.
2. Remove bolt - 2 -.
3. Connect a hose (approx. 18mmdiameter) to ATF line - A - and secure with a hose clip. Place the other end of the hose into drip tray.

1. Blow through ATF line - B - using a compressed air line (max. 10 bar).
2. Change hose from ATF line - A - over to ATF line - B - and repeat sequence.
3. In addition, flush lines with ATF until they are clean if ATF is very dirty.
4. The ATF used for flushing the lines must not be used again.

1. Always replace O-rings - 1 -.
2. First push ATF cooling lines fully into transmission or cooler as far as stop, then bolt on --> «ATF lines and ATF cooler, assembly overview»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__atf-lines-and-atf-cooler-assembly) .
3. Check ATF level --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Oil pan, ATF strainer and mechatronics unit, removing and installing

Note. General repair instructions --> General repair instructions . Read the Read the rules when working on the automatic transmission --> Read the rules . Always replace mechatronics unit if contaminated or faulty. Lightly lubricate O-rings and seals with ATF. Other types of lubricant will cause the transmission hydraulics to malfunction.

Oil pan, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Safety goggles

Removing

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Release quick-release fasteners - 1 - and - 2 - and detach noise insulation panels.

1. Remove front cross piece beneath transmission oil pan - arrows -.

Note. Item 1 - can be disregarded.

1. Place drip tray for workshop hoist VAS 6208 under the transmission.

1. Remove ATF drain plug - arrow A -.
2. Drain ATF.

Note. Observe relevant disposal regulations. The engine must not be started and vehicle must not be towed without ATF in transmission.

1. Loosen the 24 bolts on oil pan in diagonal sequence and remove oil pan.

Installing

Installation is carried out in reverse sequence. Note the following

Note. Replace seals and gaskets. The drain plug with seal must be replaced.

1. Clean all 6 magnets in oil pan recesses. Ensure that magnets make full contact with oil pan.
2. Clean sealing surface thoroughly, the previous gasket must be removed completely.
3. Tighten oil pan bolts in several stages and in diagonal sequence.
4. Install cross member --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Fill up with ATF --> «Draining ATF or filling up after performing repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__draining-atf-or-filling-up-after) .
2. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening torques

*Replace bolt.

*Tighten diagonally in stages.

ATF strainer, removing and installing

Removing

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove oil pan --> «Oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__oil-pan-removing-and-installing) .

Scheme 280

1. Carefully remove ATF strainer - A - from transmission.

Installing

Installation is carried out in reverse sequence. Note the following

Note. Replace the ATF strainer if it has been damaged.

Scheme 281

Note the following when replacing ATF strainer

1. If installed, carefully remove oil seal for ATF strainer - A - from transmission using a screwdriver or similar.

Note. Take care not to damage sealing surface. For illustration purposes the oil seal is shown with mechatronics unit removed. The new ATF strainer is supplied with oil seal installed.

Continue for new and old ATF strainer

1. Press intake line of ATF strainer - A - carefully onto stop into mounting hole in transmission.

Note. A new ATF strainer is pressed into transmission with oil seal installed.

1. Install oil pan --> «Oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__oil-pan-removing-and-installing) .
2. Fill up with ATF --> «Draining ATF or filling up after performing repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__draining-atf-or-filling-up-after) .
3. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Mechatronics unit , removing and installing

Note. Always replace mechatronics unit if it is contaminated or faulty. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

Removing

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Switch off ignition.

1. Remove luggage compartment floor covering.
2. Disconnect Ground (GND) wire - arrow - at battery.
3. Remove oil pan --> «Oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__oil-pan-removing-and-installing) .
4. Remove ATF strainer --> «ATF strainer, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__atf-strainer-removing-and-installing) .

1. Disconnect electrical connector at transmission by turning fastener cap counter-clockwise - arrow -.
2. Touch vehicle ground with your hand (without gloves) to discharge any static electricity.

Scheme 282

1. Unfasten retaining clip - arrow - for wiring harness connector on outside of transmission housing.

1. Remove securing bolts for mechatronics unit in sequence - 11... 1 -.

Note. Only loosen securing bolts marked - 1... 11 -. If other bolts are loosened, this may affect the operation of the mechatronics unit or the mechatronics unit could come apart.

1. Remove mechatronics unit together with wiring harness from transmission, at the same time guide out connector for wiring harness.

Installing

1. Make sure that seal - B - is properly inserted and secured.
2. Replace O-rings on connector for wiring harness and lightly lubricate with ATF.

1. Clip wiring harness - A - onto mechatronics unit - B - by first attaching tab - arrow - on reverse side of wiring harness to mechatronics unit.

Note. If the tab on the reverse side of the wiring harness breaks off, the wiring harness must be replaced --> Wiring harness in transmission, removing and installing .

1. Install wiring harness connector in transmission housing.

1. Installation position: flat part of rear shoulder faces downward, the lugs at shoulder are horizontal

Scheme 283

1. While installing mechatronics unit without force, insert transmission selector lever pin - arrow - into groove on selector slide - A - (move selector slide backward and forward if necessary).

1. Tighten securing bolts - 1 - and - 2 - for mechatronics unit to 2 Nm.
2. Then tighten securing bolts in specified order - 111 - to 8 Nm.

1. Push retainer clip - arrow - onto wiring harness connector.
2. Install ATF strainer --> «ATF strainer, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__atf-strainer-removing-and-installing) .
3. Install oil pan --> «Oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__oil-pan-removing-and-installing) .
4. Connect battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Fill up with ATF --> «Draining ATF or filling up after performing repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__draining-atf-or-filling-up-after) .
2. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Wiring harness in transmission, removing and installing

Removing

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove mechatronics unit --> «Mechatronics unit , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__mechatronics-unit-removing-and-installing)
3. Touch vehicle ground by hand (without gloves) to discharge any static electricity.

1. Carefully disconnect wiring harness - A - from mechatronics unit - B -. Make sure to detach tab - arrow - on reverse side of wiring harness from mechatronics unit.

Note. If the tab - arrow - on the reverse side of the wiring harness breaks off, the wiring harness must be replaced --> Wiring harness in transmission, removing and installing .

1. Carefully disconnect connector - C - from socket - D - of mechatronics unit.

Installing

Installation is carried out in reverse sequence. Note the following

1. Carefully connect connector - C - to socket - D - on mechatronics unit.
2. Clip wiring harness - A - onto mechatronics unit - B - by first attaching tab - arrow - on reverse side of wiring harness to mechatronics unit.
3. Install mechatronics unit --> «Mechatronics unit , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__mechatronics-unit-removing-and-installing) .
4. Fill up with ATF --> «Draining ATF or filling up after performing repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__draining-atf-or-filling-up-after) .

1. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Front final drive gear oil

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

Front final drive gear oil level, checking

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Safety goggles

Condition

1. Gear oil about 20 ° C (room temperature)

Work sequence

1. Drive vehicle onto a four-column hoist or over an inspection pit so that it is absolutely horizontal.

Note. Before raising the vehicle on a lifting platform (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION

1. Place drip tray for workshop hoist VAS 6208 under transmission.

Scheme 284

1. Remove plug - arrow -.

1. Oil level must be up to lower edge of filler hole.

1. Drain off any excess oil or top off to proper level.

Note. The screw plug with seal must be replaced.

1. Tighten new plug to 35 Nm.

Note. If the vehicle has been raised on a hoist you must also de-activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Front final drive gear oil, topping off gear oil level after repairs

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Safety goggles

Requirements

1. Gear oil about 20 ° C (room temperature)

Topping off

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

1. Drive vehicle onto a four-column hoist or over an inspection pit so that it is absolutely horizontal.

Note. Before raising the vehicle on a hoist (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

1. Place drip tray for workshop hoist VAS 6208 under the transmission.

1. Remove plug - arrow -.
2. Fill front final drive slowly and evenly over at least 5minutes until gear oil comes out at lower edge of oil filler hole.

Note. The top off period of at least 5 minutes is necessary so that the internal oil level can be balanced out between differential and baffle chamber. The screw plug with seal must be replaced.

1. Tighten new plug to 35 Nm.

Note. A subsequent level check is not required. If the vehicle has been raised on a hoist you must also de-activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Front final drive, servicing

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

Scheme 285

1 - Oil seal

1. Between final drive and transmission housing
2. Replacing --> «Final drive/transmission housing oil seal, replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd)

2 - Shim

1. Behind tapered roller bearing outer race

3 - Outer race for tapered roller bearing

4 - O-ring

1. Replace

5 - Screw plug, 35 Nm

1. Replace

6 - Flange shaft (right-side)

1. Removing and installing --> «Flange shaft (right-side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flange-shaft-right-side-removing-and-installing)

7 - Retaining ring

1. Replace

8 - Flange shaft oil seal (right-side)

1. Replacing --> «Flanged shaft oil seal (right side), replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd)

9 - Bolt -23 Nm

1. Follow correct tightening sequence --> «Final drive cover O-ring, replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__final-drive-cover-o-ring-replacing)

10 - Cover for final drive

11 - Shim

1. Behind tapered roller bearing outer race

12 - Outer race for tapered roller bearing

13 - O-ring for final drive cover

1. Replacing --> «Final drive cover O-ring, replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__final-drive-cover-o-ring-replacing)

14 - Differential

15 - Spring pin

16 - Selector shaft lever

17 - Oil seal for selector shaft

1. Replacing --> «Selector shaft oil seal, replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__selector-shaft-oil-seal-replacing)

18 - Bolt, 23 Nm

19 - Flange shaft (left-side)

1. Removing and installing --> «Flanged shaft (left side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flanged-shaft-left-side-removing-and)

Flanged shaft (left side), removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208

Scheme 286

1. Puller T10037

Removing

1. Transmission is removed

1. Place drip tray for workshop hoist VAS 6208 under transmission.

Scheme 287

1. Remove bolts - arrows - on retaining bracket for left-side flange shaft.

Scheme 288

1. Screw puller T10037 onto differential cover - arrow -.
2. Pull out left flange shaft using puller T10037 only until bearing on shaft is removed from transmission housing.

Scheme 289

1. Pull left flange shaft - A - out of transmission, making sure that the shaft remains centered in the opening on the differential - arrow -.

Note. If the shaft is not kept centered, the splines of the shaft will fall against the inner seal between final drive and transmission housing. The seal will be damaged and require replacement --> Final drive/transmission housing oil seal, replacing .

Installing

Installation is carried out in reverse sequence. Note the following

1. Clean flange shaft.

1. Insert flange shaft - A - into transmission and guide shaft into seal on differential - arrow - , keeping it centered.

Note. If the shaft is not kept centered, the splines of the shaft will damage the seal between final drive and transmission housing. The seal will require replacement --> Final drive/transmission housing oil seal, replacing .

Tightening torques

Flange shaft (right-side), removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208

Removing

1. Transmission installed

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Unfasten quick-release catches - 2 - and detach rear noise insulation.
2. Unbolt axle shaft (right-side) from flange on transmission and tie up.

Note. The right-side axle shaft must be removed on vehicles with a front exhaust pipe on the right side --> 40 - FRONT SUSPENSION

1. Place drip tray for workshop hoist VAS 6208 under transmission.

Scheme 290

1. Place a chisel or distance piece - A - under flange shaft and pull flange shaft out by turning bolt - B -.

Note. If the flange shaft does not come out easily, turn the shaft and insert a bolt in the opposite hole to assist removal.

Scheme 291

1. Replace circlip for flange shaft
2. Clamp flange shaft in vise, using jaw protectors. Use new retaining ring - A - to press old retaining ring out of groove in flange shaft.

Installing

Installation is carried out in reverse sequence; note the following

1. Clean flange shaft and seal.
2. If seal is damaged, it must be replaced --> «Flanged shaft oil seal (right side), replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Pack space between sealing lip and dust lip half-full with sealing grease G 052 128 A1 .
4. Insert flange shaft by hand into splines of differential until splines lock properly into place.

1. Press flange shaft in by hand or with mandrel VW295 as far as the stop.

Note. The circlip on the flange shaft should click into place.

1. Bolt right axle shaft to flange shaft --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Check oil level in final drive (front) --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 292

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Extractor lever VW681
3. Thrust piece T10138

Procedure

1. Transmission installed

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Place drip tray for workshop hoist VAS 6208 under transmission.
3. Remove flange shaft (right-side) --> «Flange shaft (right-side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flange-shaft-right-side-removing-and-installing) .

Scheme 293

1. Pull out flange shaft oil seal.
2. Lubricate outer circumference of seal with gear oil

Scheme 294

1. Drive new seal in onto stop (take care to keep seal straight).

1. Installation position: the open side of the seal should face the transmission.

1. Pack space between sealing lip and dust lip half-full with sealing grease G 052 128 A1 .
2. Install flange shaft (right-side) --> «Flange shaft (right-side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flange-shaft-right-side-removing-and-installing) .
3. Check oil level in final drive (front) --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
4. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering)

Final drive cover O-ring, replacing

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208

Procedure

1. Transmission installed

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Place drip tray for workshop hoist VAS 6208 under transmission.
3. Remove flange shaft (right-side) --> «Flange shaft (right-side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flange-shaft-right-side-removing-and-installing) .

Scheme 295

1. Remove bolts on final drive cover in sequence - 11... 1 - and remove cover together with outer race for tapered roller bearing and shim.

Note. Thickness of shim has been measured to fit; the shim must not be replaced with another shim of different thickness.

Scheme 296

1. Replace O-ring - arrow -.

Note the following if the outer race for tapered roller bearing and the shim have dropped out of the final drive cover

1. Lubricate shim and outer race for tapered roller bearing with gear oil and insert in final drive cover as far as stop.

1. Tighten bolts of final drive cover as follows.

1. Install flange shaft (right-side) --> «Flange shaft (right-side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flange-shaft-right-side-removing-and-installing) .
2. Check oil level in final drive (front) --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Deactivate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 297

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Extractor lever VW681
3. Thrust piece T10139

Requirements

1. Transmission is removed
2. Transmission mounted on assembly stand --> «Securing transmission to assembly stand»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Procedure

Note. A faulty seal allows gear oil to enter the torque converter bellhousing. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

1. Place drip tray for workshop hoist VAS 6208 under the transmission.
2. Remove flange shaft (right-side) --> «Flange shaft (right-side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flange-shaft-right-side-removing-and-installing) .

1. Remove bolts on final drive cover in sequence - 11... 1 - and remove cover together with outer race for tapered roller bearing and shim.

Note. The thickness of shim has been measured to fit; the shim must not be replaced with another shim of different thickness.

1. Remove differential.

Scheme 298

1. Remove tapered roller bearing outer race - 1 - for differential and shim - 2 - (behind outer race) from transmission housing by hand.

Note. The thickness of shim has been measured to fit; the shim must not be replaced with another shim of different thickness.

1. Remove flange shaft (left-side) --> «Flanged shaft (left side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flanged-shaft-left-side-removing-and) .

Scheme 299

1. Remove seal.

Note. The oil seal extractor lever VW681 must be applied behind the two sealing lips of the oil seal. Do not apply the lever to the outer circumference of the seal, as this would damage the sealing surface in the transmission. Guide the lever carefully when removing the seal.

1. Examine oil seal seat in transmission housing for damage; reface surface if necessary.
2. Lightly lubricate outer circumference and sealing lip of oil seal with gear oil.

Note. Push seal onto thrust piece with the protruding sealing lip on the seal facing toward the tool.

Scheme 300

1. Drive new oil seal as far as stop using thrust piece T10139.

1. Insert shim - 2 - and tapered roller bearing outer race - 1 - for differential onto stop in transmission housing by hand.

Note. Make sure that shim and outer race are kept straight when inserting.

1. Renew O-ring - arrow -.
2. Install differential in transmission housing.

Note the following if the outer race for tapered roller bearing and the shim have dropped out of final drive cover

1. Lubricate shim and outer race for tapered roller bearing with gear oil and insert in final drive cover as far as stop.

1. Tighten bolts of cover for final drive as follows.

1. Install flange shaft (left-side) --> «Flanged shaft (left side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flanged-shaft-left-side-removing-and) .
2. Install flange shaft (right-side) --> «Flange shaft (right-side), removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__flange-shaft-right-side-removing-and-installing) .
3. Check oil level in final drive (front) --> «Front final drive gear oil»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Selector shaft oil seal, replacing

Special tools, testers and auxiliary items required

Scheme 301

1. Thrust piece T10135

Procedure

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Shift selector lever to position "P".

On vehicles with 6-cyl. GDI engine

1. Remove transmission support (left-side).

All models

1. Pry ball socket - 1 - of selector lever cable off selector shaft lever.

Note. Do not bend or kink the selector lever cable.

Scheme 302

1. Drive out roll pin - 1 - at selector shaft lever - 2 - - arrow - until it is possible to detach selector shaft lever from selector shaft.

Scheme 303

1. Push a small screwdriver through seal and pull it out.
2. Lubricate outer circumference and space between sealing lips of seal with ATF.
3. Install new seal onto selector shaft.

1. Installation position: the open side of the seal should face transmission.

Scheme 304

1. Press on new oil seal using thrust piece T10135 and assembly lever - A - as far as stop; make sure that oil seal remains straight.

Note. To prevent slippage when pressing in oil seal, place something as a base (e.g. piece of rubber) between assembly lever and subframe - arrow -.

1. Before installing, drive roll pin in selector shaft lever back through lever in opposite direction.
2. Push selector shaft lever onto selector shaft and drive in roll pin.

1. Press on ball socket - 1 - of selector lever cable onto selector shaft lever.

Note. Do not bend the selector shaft lever when pressing on the ball socket, as otherwise it will no longer be possible to precisely adjust the gear selector mechanism

1. Check ATF level --> «ATF level, checking and correcting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Transfer gear oil level

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

Transfer gear oil level, checking

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Safety goggles

Condition

1. Gear oil about 20 ° C (room temperature)

Work sequence

1. Drive vehicle onto a four-column hoist or over an inspection pit so that it is absolutely horizontal.

Note. Before raising the vehicle on a hoist (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

1. Place drip tray for workshop hoist VAS 6208 under transmission.

Scheme 305

1. Remove plug - arrow -.

1. Oil level must be up to lower edge of filler hole.

1. Drain off any excess oil or top off to proper level; specification --> «Transfer gear»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transfer-gear) .

Note. The plug with seal must be replaced.

1. Tighten new plug to 35 Nm.

Note. If the vehicle has been raised on a lifting platform you must also de-activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Transfer gear oil, topping off after repairs

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Safety goggles

Test conditions

1. Gear oil about 20 ° C (room temperature)
2. Cover was removed from Transfer gear and all gear oil was thereby drained.

Work sequence

1. Drive vehicle onto a four-column hoist or over an inspection pit so that it is absolutely horizontal.

Note. Before raising the vehicle on a hoist (wheels off the ground) you must first activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

1. Place drip tray for workshop hoist VAS 6208 under transmission.

1. Remove plug - arrow -.

Note. The engine must not be started and vehicle must not be towed without gear oil in transmission.

1. Fill transfer gear slowly and evenly over at least 5minutes with gear oil (specification --> «Transfer gear»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transfer-gear) ).

Note. The top off period of at least 5 minutes is necessary so that the internal oil level can be balanced out between Torsen differential and baffle chamber. The plug with seal must be replaced.

1. Tighten new plug to 35 Nm.

Note. A subsequent level check is not required. If the vehicle has been raised on a hoist you must also de-activate the jacking mode --> 43 - SELF LEVELING SUSPENSION .

Transfer gear, servicing

Torsen differential cover, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop hoist VAS 6208
2. Safety goggles

Removing

1. Transmission installed

Note. General repair instructions --> General repair instructions . Read the rules when working on the automatic transmission --> Read the rules .

1. Activate jacking mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Release quick-release fasteners - 1 - and - 2 - and detach noise insulation panels.

On vehicles with 6-cyl. GDI engine

1. Disconnect exhaust system at clamp - arrow -.

Note. The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent by more than 10 ° - otherwise it can be damaged.

1. Remove bolts - arrows - at center bracket for front exhaust pipe.
2. Tie up front exhaust pipe to side or support from below.

1. Remove bolts - arrows - at tunnel cross member.
2. Remove tunnel cross member with center bracket for front exhaust pipe.

On vehicles with 8-cyl. engine

1. Remove tunnel cross member - 1 -.

All models

1. Remove heat shield - A - for drive axle - arrows -.
2. Remove bolts at transmission/drive shaft flange.
3. Slide drive shaft together toward rear final drive. The constant velocity joints can be moved axially.
4. Tie up drive shaft to side.

Scheme 306

1. Place drip tray for workshop hoist VAS 6208 under transmission.

1. Loosen securing bolts for cover for Torsen differential in sequence - 6 to 1 - and remove; allow gear oil to drain out.

Note. The cover is not equipped with a drain plug; drain the gear oil by removing the cover.

Scheme 307

1. Secure Torsen differential - B - and baffle plate - A - to prevent them dropping out, or pull them off the output shaft toward rear.

Scheme 308

Installing

Installation is carried out in reverse sequence. Note the following

Note. Replace O-ring on Transfer gear cover.

Note the following if the Torsen differential - B - and baffle plate - A - have been removed

1. Clean baffle plate, lubricate with gear oil and insert in transmission.

1. Installation position: tongue - A - on baffle plate should be positioned on transmission so that the side lugs are located above opening - B -.

1. Install Torsen differential - B - onto output shaft splines (turn slightly at same time).

Note. Check installation position of tongue on baffle plate - arrow - again.

1. Check whether attached Torsen differential can be turned manually.
2. Check whether tongue - arrow - on baffle plate is still located properly.
3. Place cover for Torsen differential with shaft installed onto Torsen differential, turn slightly if necessary.

1. Tighten cover bolts for Torsen differential as follows.

1. Install drive shaft --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
2. Install exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
3. Top off Transfer gear oil --> «Transfer gear oil, topping off after repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transfer-gear-oil-topping-off-after)

Tightening torques

Scheme 309

Special tools, testers and auxiliary items required

1. Thrust plate VW401
2. Thrust plate VW402
3. Thrust pad VW447 i
4. Punch VW409

1. Pressure application device T10136

Procedure

1. Remove Torsen differential cover --> «Torsen differential cover, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__torsen-differential-cover-removing-and-installing) .

Scheme 310

1. Remove circlip - arrow - on inner side of cover.

Note. The circlip locates the flange shaft on the bearing in the cover.

Scheme 311

1. Using press tool VW409 , press flanged shaft out of Torsen differential cover by placing cover on thrust plate thrust plate VW401 and thrust plate VW402.

Note. Hold flange shaft - A - with one hand to prevent if from falling.

Scheme 312

1. Pry out oil seal.

Note. To prevent damage to the housing, place something underneath (e.g. metal bar - A - ).

Scheme 313

1. Place cover - A - for Torsen differential on pressure application device T10136.

Note. The peg in the middle of the tool is centered and faces upward in the cover. It serves as a guide and stop for press tool T10136/1.

1. Lubricate outer circumference of seal with gear oil
2. Push new seal onto press tool T10136/1.

1. Installation position: open side of seal should face cover.

Scheme 314

1. Insert press tool T10136/1 with seal into cover from above.

Note. The peg of the pressure application device T10136 serves as a guide from below and also as a stop for press tool T10136/1.

1. Drive new seal in onto stop (take care to keep seal straight).
2. Pack space between sealing lip and dust lip half-full with sealing grease G 052 128 A1 .

Scheme 315

1. Press flange shaft with press tool VW409 and thrust pad VW447 i into cover for Torsen differential. To do so, place cover on thrust plate VW401 and thrust plate VW402.

Note. Only insert flange shaft as far as necessary to install circlip.

1. Install circlip - arrow - in groove of flange shaft on inner side of cover.
2. Install cover for Torsen differential --> «Torsen differential cover, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__torsen-differential-cover-removing-and-installing) .
3. Top off oil in Transfer gear --> «Transfer gear oil, topping off after repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd__transfer-gear-oil-topping-off-after)

See also:
• 00 TECHNICAL DATA
• 43 - SELF LEVELING SUSPENSION
• 20 - FUEL SUPPLY SYSTEM
• 68 - INTERIOR EQUIPMENT
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS
• 50 - BODY - FRONT
• 27 - STARTER, GENERATOR, CRUISE CONTROL
• Code letters, transmission application, ratios, equipment
• Operating manual selector mechanism release
• General repair instructions
• Transmission on vehicles with 6-cyl. GDI engine, removing
• Mechatronics unit , removing and installing
• Wiring harness in transmission, removing and installing
• Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 , removing and installing
• Selector lever cable, adjusting
• Ignition key removal lock, checking
• Selector lever cable, removing and installing
• Shift Lock Solenoid N110 , removing and installing
• Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing
• Selector lever handle, removing and installing
• Transmission Park Selector Switch F305 , removing and installing
• Selector mechanism, removing and installing
• Selector mechanism, checking
• Transmission on vehicles with 8-cyl. engine, removing
• Transmission, installing
• ATF lines and ATF cooler, cleaning
• Removing and installing transmission mounting, transmission support and tunnel cross member on vehicles with 6-cyl. GDI and 8-cyl. engine
• ATF lines and ATF cooler, assembly overview
• Draining ATF or filling up after performing repairs
• Oil pan, removing and installing
• ATF strainer, removing and installing
• Flange shaft (right-side), removing and installing
• Final drive cover O-ring, replacing
• Selector shaft oil seal, replacing
• Flanged shaft (left side), removing and installing
• Transfer gear
• Transfer gear oil, topping off after repairs
• Torsen differential cover, removing and installing