Continuously Variable Transmission (cvt) 01j Audi A6 С6

Transmission identification

The Continuously Variable Transmission (CVT) "multitronic 01J front wheel drive" is installed in conjunction with various engines in the Audi A6 2005 >. Allocation --> Code letters, transmission applications, ratios, equipment .

Location of code letters on transmission

Scheme 316

Code letters and serial number of transmission are stamped on the underside of the transmission housing - arrow -.

Note. The code letters of the transmission are also listed on the vehicle data stickers.

Continuously Variable Transmission (CVT) "multitronic 01J front wheel drive" , general information

Additional information about the function of this transmission 951103Continuously Variable Transmission (CVT) multitronic 01J.

Note. The continuously variable automatic transmission multitronic 01J is also called "Continuously Variable Transmission" , "CVT" for short.

Guided Fault Finding

Always perform "Guided Fault Finding" using Diagnostic Operation System VAS 5051 before starting disassembly and assembly work.

Code letters, transmission applications, ratios, equipment

Capacities

Planetary gearbox

* ATF change interval for planetary gear 4F.

ATF for CVT transmission can be obtained as replacement part, container size

1. 1.0 L - Part No. G 052 180 A2

ATF, checking or changing --> ATF level, checking and topping off .

Front final drive

*Permanent fill: only fill after repair, up to 1.3 liters.

Multitronic gear oil is available as a replacement part and comes in the following container size

1. 0.5 L - Part no. G 052 190 A2

Oil level in front final drive, checking --> Front final drive, checking gear oil level .

Towing instructions

Note. Tow-starting the engine, e.g. when the battery is too weak or the starter is faulty, is not possible.

Repair instructions

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

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

Special tools and equipment

For a complete list of special tools used in the article. See Special Tools.

Transmission

1. Observe rules of cleanliness for working on the transmission --> «Rules for cleanliness when working on transmission»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
2. Do not run engine with the end cover removed or without ATF filling and do not tow vehicle.
3. Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.
4. After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear --> «ATF level, checking and topping off»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__atf-level-checking-and-topping-off) and axle oil in front final drive --> «Front final drive, checking gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__front-final-drive-checking-gear-oil) . Capacities and specifications --> «Capacities»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

O-rings, seals, gaskets

1. Always replace O-rings, gaskets and seals.
2. After removing gaskets, examine contact surface on housing/shaft for burrs resulting from removal or for other signs of damage.
3. Thoroughly clean housing joint surfaces before assembling.
4. To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.

1. Lightly lubricate O-rings with ATF when installing to prevent the rings from being pinched when components are assembled.
2. Only use ATF for automatic transmission components. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
3. Open sides of oil seals face fluid side.
4. When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

1. After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear --> «ATF level, checking and topping off»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__atf-level-checking-and-topping-off) or axle oil in front final drive --> «Front final drive, checking gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__front-final-drive-checking-gear-oil) . Capacities and specifications --> «Capacities»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Bolts and nuts

1. Loosen bolts in reverse of tightening sequence.
2. Nuts and bolts which secure covers and housings should be tightened in stages according to specified sequence and tightening method.
3. Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
4. The tightening torques stated apply to unoiled bolts and nuts.

1. Replace self-locking bolts and nuts.
2. Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts and apply AMV 185 101 A1.
3. Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

Locking elements

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

Bearings

1. Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
2. Insert bearing with axle oil or ATF, depending on installation location.
3. Do not interchange the outer or inner races of bearings of the same size.
4. Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.

Shims

1. Use a micrometer to measure the shims at several points. Varying tolerances make it possible to measure the required shim thickness exactly.
2. Inspect for burrs and signs of damage. Install only shims that are in perfect condition.

Guided Fault Finding

Always perform Guided Fault Finding using the Diagnostic Operation System VAS 5051 before starting disassembly and assembly work.

Rules for cleanliness when working on transmission

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

Scheme 317

Data Link Connector (DLC)

1. Location: Diagnostic connector is located below lower instrument panel cover on drivers side.

Scheme 318

Transmission Control Module (TCM) J217

1. Location: Transmission Control Module (TCM) J217 is on the back end of transmission, secured directly to hydraulic control module.

The following components are integrated in Transmission Control Module (TCM) J217

A - Transmission Output Speed (RPM) Sensor G195 and Transmission Output Speed (RPM) Sensor 2 G196

B - Transmission Fluid Temperature Sensor G93

C - Multi-Function Transmission Range (TR) Switch F125

D - Transmission Input Speed (RPM) Sensor G182

E - Automatic Transmission Hydraulic Pressure Sensor 1 G193

F - Automatic Transmission Hydraulic Pressure Sensor 2 G194

Note. Transmission Control Module (TCM) J217 is monitored with On Board Diagnostics (OBD).

Removing and installing Transmission Control Module (TCM) J217 --> Transmission Control Module (TCM) J217 , removing and installing .

Scheme 319

Hydraulic control module

1. Location: Hydraulic control module is bolted to back end of transmission. Transmission Control Module (TCM) J217 is fastened directly to hydraulic control module.

A - Automatic Transmission Pressure Regulating Valve 1 N215 electrical connector

B - Automatic Transmission Pressure Regulating Valve 2 N216 electrical connector

C - Solenoid Valve 1 N88 electrical connector

Removing and installing hydraulic control module --> Hydraulic control module, removing and installing .

The following valves are integrated into hydraulic control module (not depicted here).

1. Automatic Transmission Pressure Regulating Valve 1 N215 (clutch solenoid valve)
2. Automatic Transmission Pressure Regulating Valve 2 N216 (solenoid valve gear)
3. Solenoid Valve 1 N88 (clutch cooling/safety shut-off)
4. Clutch cooling valve

1. Minimum pressure valve
2. Pressure relief valve
3. Clutch control valve
4. Pressure control valve

Note. Valves are monitored via On Board Diagnostic (OBD).

Scheme 320

Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189

1. Location: Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 are housed in the same component - arrow -.

Selector Lever Sensor system Control Module J587 and Tiptronic Switch F189 , removing and installing --> Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing .

Scheme 321

Shift lock solenoid N110

1. Location: Shift Lock Solenoid N110 - 1 - is clipped onto shift mechanism.

Shift Lock Solenoid N110 , removing and installing --> Shift lock solenoid N110 , removing and installing .

Scheme 322

Transmission Park Selector Switch F305

1. Location: Transmission Park Selector Switch F305 consisting of 2 micro switches is installed in shift mechanism.

Assembly: --> Transmission Park Selector Switch F305 , removing and installing .

Scheme 323

Kick Down Switch F8

Location

A specific value from Throttle Position (TP) Sensor G79 and Accelerator Pedal Position Sensor 2 G185 is saved in engine control module.

Accelerator pedal position sensors are integrated in accelerator module - arrow -.

Note. If accelerator pedal position sensor is faulty, accelerator module must be replaced --> 20 - FUEL SUPPLY SYSTEM .

Scheme 324

Cruise control switch E45

1. Location: Cruise control switch is located on steering column switch.

Steering column switch, removing and installing --> 94 - LIGHTS, SWITCHES - EXTERIOR .

Scheme 325

Transmission Range (TR) Display Y6

1. Location: Transmission Range (TR) Display Y6 is integrated in instrument cluster.

Note. A completely lit display warns of a simple malfunction. A blinking display warns of a critical malfunction. No display indicates a wiring fault or a faulty Transmission Range (TR) Display Y6. If Transmission Range (TR) Display Y6 is faulty, instrument cluster must be replaced --> 90 - INSTRUMENTS .

Scheme 326

Selector Lever Transmission Range (TR) Position Display Y26

1. Selector Lever Transmission Range (TR) Position Display Y26 - 1 - is clipped into center console.

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

Selector mechanism, servicing

Ignition key lock, checking

1. To reach position "ignition on" , briefly turn ignition key lightly toward right.
2. Press brake pedal and hold.

1. It must be possible to shift selector lever out of position "P" without "catching" while locking button on selector lever handle is pressed.

1. Switch ignition off.

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

1. Place selector lever in position "P".
2. Remove ignition key.

1. It must be possible to remove ignition key only in position "P".
2. Selector lever cannot be shifted out of position "P" with the locking button pressed and foot brake operated.

If ignition key removal lock does not function as described, check Access/Start Authorization Switch E415 using Vehicle Diagnostic, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Selector mechanism, checking

1. In selector lever positions "S" , "D" , "R" and "Tiptronic gate" the starter motor will not operate.
2. If selector lever position "N" is selected at speeds greater than 5 km/h, the selector lever lock solenoid must not engage and block the selector lever. Selector lever can be shifted into driving gear.
3. For speeds below 2 km/h (almost standstill) and shifting into selector lever position "N" , the shift lock solenoid must only engage after approx. 1 second. Selector lever can only be shifted out of position "N" with the brake pedal operated.

Selector lever in "P" position and ignition switched on

1. Do not operate brake pedal.

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

1. Press brake pedal and hold.

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, S" and check whether the Transmission Range (TR) Display Y6 in the instrument cluster shows the correct selector lever position.

Selector lever in "N" position and ignition switched on

1. Do not operate brake pedal.

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

1. Operate brake pedal.

1. Shift Lock Solenoid N110 releases selector lever. Selection of position "D" is possible.

Selector lever in position "D" , ignition switched on

1. Shift selector lever into "Tiptronic gate".

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

If specified values are not obtained

1. Adjust selector lever cable --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-cable-adjusting) .
2. Check ignition key removal lock --> «Ignition key lock, checking»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__ignition-key-lock-checking) .

Scheme 327

1 - Lock washer

2 - Noise insulation

3 - Retaining clip

1. Secures selector lever cable to shift mechanism casing

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/#continuously-variable-transmission-cvt-01j__selector-lever-cable-removing-and-installing)
3. In case of damaged rubber boot, selector lever cable must be replaced
4. Lightly lubricate ball socket with polycarbamide grease G 052 142 A2 before installing.

1. When installing, make sure rubber sleeve on transmission side is not twisted
2. Adjusting --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-cable-adjusting)

5 - Locking screw, 13 Nm

6 - Selector lever cable screws

1. To remove selector lever cable, move plastic retaining spring at selector mechanism forward slightly and put screws upward, only as far as necessary.

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/#continuously-variable-transmission-cvt-01j__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/#continuously-variable-transmission-cvt-01j__selector-lever-transmission-range-tr-position)

9 - Clamp

1. For securing 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/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing)

10 - Selector lever boot

1. Separate from selector lever handle --> «Separating selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j)

11 - Selector lever handle

1. Removing and installing --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing)

12 - Trim ring

1. Removing and installing --> «Separating selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j)

13 - 1.2 Nm

14 - Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189

1. Removing and installing --> «Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__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/#continuously-variable-transmission-cvt-01j__transmission-park-selector-switch-f305)

16 - 10 Nm

17 - Selector lever housing

1. Can only be replaced as complete unit
2. Removing and installing --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-mechanism-removing-and-installing)

18 - Shift mechanism bottom cover

19 - 10 Nm

Scheme 328

1 - Clamp

1. For securing 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/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing)

2 - Trim ring

1. Removing and installing --> «Separating selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j)

3 - Selector lever handle

1. Removing and installing --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing)

4 - Selector lever boot

1. Separate from selector lever handle --> «Separating selector lever boot from selector lever handle»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j)

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/#continuously-variable-transmission-cvt-01j__selector-lever-transmission-range-tr-position)

Shift mechanism, operating manual release

Note. When the battery is disconnected or has been discharged, the selector lever cannot be shifted out of the "P" position. By operating the manual release the Shift Lock Solenoid N110 will release the selector lever when there is no power supply.

1. Remove front ashtray insert.

Scheme 329

1. Pry cover cap in ashtray housing out using screwdriver - arrow -.

Scheme 330

1. Press on manual release lever - arrow - , e.g. with a screwdriver, and at the same time, remove selector lever from "P" position.

Selector lever handle, removing and installing

Special tools, testers and auxiliary items required

Scheme 331

1. Hose clamp pliers V.A.G 1275

Scheme 332

Removing

1. Place selector lever in position "N".

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

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

Scheme 333

1. Secure lock button in pulled-out position using a cable tie - arrow - as shown in illustration.

Scheme 334

1. Flip selector lever boot - 1 - upward and over the selector lever handle - 2 -.
2. Open clamp - arrow - and pull off selector lever handle together with selector lever boot, without touching the lock button.

Installing

Note. To install selector lever handle, lock button must be pulled out as far as stop and secured with a cable tie - arrow - or using the assembly aid included with new handle. If the lock button was not secured, it must not be pulled out from the handle using mechanical aids. Apply compressed air gun to bottom of handle and press lock button out with compressed air.

1. Place selector lever handle completely onto selector lever - lock button faces toward driver.

1. When doing this, handle must engage into ring groove of selector lever.

1. Remove cable tie or assembly aid, thereby the lock button mechanism engages in the vertical groove of the selector lever. If necessary, press the lock button into the selector lever handle.

1. Clamp selector lever handle - 2 - to the selector lever, using clamp - arrow -. To do this, use the hose clamp pliers V.A.G 1275.
2. Clip retaining frame for selector lever boot - 1 - onto center console.

Scheme 335

Removing

1. Remove selector lever handle --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing) .
2. Bind the spring tabs - 1 - of selector lever handle together with a cable tie - 3 - , as shown in the illustration.
3. Push sleeve - 2 - of selector lever boot over retaining tabs on spring tabs - arrow -.
4. Remove cable tie and remove sleeve with selector lever boot from selector lever.

Installing

Install in reverse order, paying attention to the following

Installation position of selector lever boot

1. The longer side of the frame for selector lever boot faces toward driver side.

1. Install selector lever handle --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing) .

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

Removing

1. Place selector lever in position "N".
2. Unclip mounting frame for selector lever boot - 1 - from center console and lift it upward and off - arrows -.
3. Flip selector lever boot upward.

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

Installing

Installation is in the reverse order of removal.

Selector mechanism, component overview

Note. Lubricate bearing areas and slide surfaces with polycarbamide grease G 052 142 A2 .

Scheme 336

1 - Selector lever cable rubber boot

1. Check whether selector lever cable rubber boot on lower shift mechanism cover is engaged correctly and properly sealed

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/#continuously-variable-transmission-cvt-01j__selector-lever-cable-removing-and-installing)
3. In case of damaged rubber boot, selector lever cable must be replaced
4. Lightly lubricate ball socket with polycarbamide grease G 052 142 A2 before installing.

1. When installing, make sure rubber sleeve on transmission side is not twisted
2. Adjusting --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-cable-adjusting)

3 - Selector lever cable screws

1. To remove selector lever cable, move plastic retaining spring at selector mechanism forward slightly and put screws upward, only as far as necessary.

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/#continuously-variable-transmission-cvt-01j__shift-lock-solenoid-n110-removing)

5 - Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189

1. Removing and installing --> «Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-sensor-system-control-module)

6 - 1.2 Nm

7 - 10 Nm

8 - Selector lever housing

1. Can only be replaced as complete unit
2. Removing and installing --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-mechanism-removing-and-installing)

9 - Retaining clip

1. Secures selector lever cable to shift mechanism casing

10 - Shift mechanism bottom cover

11 - 10 Nm

Shift lock solenoid N110 , removing and installing

Removing

1. Place selector lever in position "S".

Scheme 337

1. Grasp at bottom of recesses on Climatronic Control Module J255 (operation and display unit).
2. Remove Climatronic Control Module J255 (operation and display unit) from installation frame - arrows -.
3. Lay Climatronic Control Module J255 (operation and control unit) on a cloth on center console to avoid damaging surface.

Scheme 338

1. Disconnect electrical connectors in sequence - A to D - by releasing tab - F -.
2. Disconnect electrical connector - E -.

Scheme 339

1. Remove gap cover over ashtray - arrow -.

Scheme 340

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

1. If equipped, disconnect electrical connector.

1. Disconnect electrical connector - 1 - at Shift Lock Solenoid N110.
2. Release catches - arrow A - and remove Shift Lock Solenoid N110 forward - arrow B -.

Note. Shown with selector mechanism removed to provide a better illustration.

Installing

1. Selector lever in "S" position.

Scheme 341

1. Pull manual release lever - arrow - upward.

Scheme 342

Note. When manual release lever is raised, Shift Lock Solenoid N110 operating lever - 1 - swings into installation position.

1. At the same time, position Shift Lock Solenoid N110 at an angle in guide from above.
2. Press Shift Lock Solenoid N110 into guide until it engages.

1. Shift Lock Solenoid N110 ball head - 2 - must engage in operating lever on selector mechanism.

Installation is in reverse order of removal.

Torque specification

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

Note. Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 are combined in one component. Tiptronic Switch F189 magnets are secured to cover.

Removing

1. Remove selector lever handle --> «Selector lever handle, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing) .
2. Remove front and rear center consoles --> «68 - INTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/gauges-instrument-panels/#body-interior) .

Scheme 343

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

Installing

Installation is in reverse order of removal. Note the following

1. Install rear and front center consoles --> «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/#continuously-variable-transmission-cvt-01j__selector-lever-handle-removing-and-installing) .

Torque specification

Selector mechanism, removing and installing

Removing

Scheme 344

1. Remove rear crossmember - arrows -.

Scheme 345

1. Remove front crossmember - arrows -.

Scheme 346

1. Remove left and right vehicle floor cover - 1 -.

Scheme 347

1. Loosen clamping sleeves - 1 - and - 2 -.

Scheme 348

Note. Flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.

1. Remove bolts - 1 - and - 2 - at front exhaust pipe rear bracket.

Note. Disregard - 3 -.

Scheme 349

1. Tie left and right exhaust system pipes up to body - arrows -.

Scheme 350

1. Remove heat shield - arrow -.

Scheme 351

1. Loosen quick-release connectors - 2 - and remove rear noise insulation.

Scheme 352

1. Mark installation position of support bracket for selector lever cable.
2. Remove bolt - 1 - support bracket for selector lever cable.
3. Press selector lever cable ball joint - 2 - off from selector shaft lever.

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

Scheme 353

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

Note. A second technician is required when detaching shift mechanism below vehicle.

1. Press retaining clamps - arrows - inward and lower selector mechanism downward.

Installing

Installation is in reverse order of removal. Note the following

Note. Lightly grease ball socket of selector lever cable with polycarbamide grease G 052 142 A2 before installing. Do not bend or kink the selector lever cable.

1. Install selector lever bracket according to marking on console.
2. Adjust selector lever cable --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-cable-adjusting) .
3. Install exhaust system and align free of tension --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Install rear crossmember --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Install front crossmember --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install front and rear center consoles --> «68 - INTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/gauges-instrument-panels/#body-interior) .
3. Check shift mechanism --> «Selector mechanism, checking»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-mechanism-checking) .

Torque specification

Transmission Park Selector Switch F305 , removing and installing

Transmission Park Selector Switch F305 consists of two micro switches. The two micro switches create the signal that the electronic ignition key removal lock needs to release the key only in selector lever position P.

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

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

Following points must be observed before replacing Transmission Park Selector Switch F305

1. Both switches are switched electrically in sequence, that is, both switches must be closed for ignition key to be removed. Switches can be checked using Vehicle Diagnosing, Testing and Information System VAS 5051 in Guided Fault Finding. After performing tests on vehicle system, you must select test program F305 - Gear selector position P switch via function/component selection (drive/multitronic 01J front wheel drive/01-On Board Diagnostic (OBD) capable systems/02 - Transmission Electronics/Electrical components).
2. And electrical test on the switch is also possible. If a continuity test is performed with a multimeter, note that in this case, there is a resistance value of approx. 470 Ohm when both switches are closed.

Removing

1. Remove selector mechanism --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-mechanism-removing-and-installing)

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

1. Disconnect connector - D - and remove from Shift Lock Solenoid N110.
2. Disconnect connector - E - and remove upward.
3. Press tab - C - in direction - arrow 1 -.
4. Remove micro switch - B - in direction - arrow 2 -.

1. Disengage electrical line at selector mechanism - arrow A -.

Scheme 354

1. Unclip covers - A - on both sides of selector mechanism.
2. Press parking lock button - C - down and hold.
3. Remove selector rod - B - upward and shift selector lever in direction of - arrow - until it engages in selector lever position "S".

Scheme 355

1. Press retaining screws - A - with a screwdriver through rear clip opening forward in direction - arrow -.

Note. Retaining screws - A - must not be removed. They must only be pressed forward far enough so micro switch - B - can be removed.

1. Remove micro switch - B - forward.
2. Disengage electrical wiring from tab - arrow C - and remove micro switch from shift mechanism.

Installing

Installation is in reverse order of removal. Note the following

1. Guide micro switch on longer electrical line into opening under parking lock button in selector mechanism.
2. Insert micro switch - B - in shift gate.

Note. Micro switch must lie flush on all sides.

1. Engage electrical line in tab - arrow C -.
2. Press retaining screws - A - with a screwdriver opposite direction of - arrow - to stop.

Note. Retaining screws - A - secure micro switch - B - in shift gate. Ignition key removal lock does not function correctly if micro switch is not inserted correctly or properly secured.

1. Secure electrical line - arrow A - at selector mechanism according to illustration.
2. Install micro switch - B -.

Note. Ignition key removal lock does not function correctly if micro switch is not inserted correctly or properly secured.

1. Position connector - D - on Shift Lock Solenoid N110.
2. Engage connector - E - from above.

1. Clip in covers - A - on both sides of selector mechanism.
2. Install Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 --> «Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-sensor-system-control-module)
3. Install selector mechanism --> «Selector mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-mechanism-removing-and-installing)

Scheme 356

1 - 9 Nm

2 - Selector shaft lever

1. With mass damper

3 - 23 Nm

4 - Lock nut, 13 Nm

5 - 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/#continuously-variable-transmission-cvt-01j__selector-lever-cable-removing-and-installing)
3. In case of damaged rubber boot, selector lever cable must be replaced
4. Lightly lubricate ball socket with polycarbamide grease G 052 142 A2 before installing.

1. When installing, make sure rubber sleeve on transmission side is not twisted
2. Adjusting --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-cable-adjusting)

6 - Selector lever cable locking screw, 13 Nm

7 - Selector lever cable screws

1. To remove selector lever cable, move plastic retaining spring at selector mechanism forward slightly and put screws upward, only as far as necessary.

8 - Retaining clip

1. Secures selector lever cable to shift mechanism casing

9 - Selector lever cable rubber boot

1. Check whether selector lever cable rubber boot on lower shift mechanism cover is engaged correctly and properly sealed

10 - 23 Nm

11 - Selector lever cable console

12 - Bracket for selector lever cable

Selector lever cable, removing and installing

Removing

1. Place selector lever in position "S".

1. Remove rear crossmember - arrows -.

1. Remove front crossmember - arrows -.

1. Remove left and right vehicle floor cover - 1 -.

1. Loosen clamping sleeves - 1 - and - 2 -.

Note. Flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.

1. Remove screws - 1 - and - 2 - at front exhaust pipe rear bracket.

Note. Disregard - 3 -.

1. Tie left and right exhaust system pipes up to body - arrows -.

1. Remove heat shield - arrow -.

1. Loosen quick-release connectors - 2 - and remove rear noise insulation.

1. Mark installation position of support bracket for selector lever cable.
2. Remove bolt - 1 - support bracket for selector lever cable.
3. Press selector lever cable ball joint - 2 - off from selector shaft lever.

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

Scheme 357

1. Pry out lock washers - 1 -.
2. Slide noise insulation - 2 - forward.
3. Remove rubber boots - 3 - from lower selector mechanism cover - 4 -.
4. Remove nuts - 5 -.

1. Swing lower selector mechanism cover and noise insulation forward.

Scheme 358

1. Remove selector lever cable retaining clamp - 1 - on shift mechanism downward.
2. Pull plastic securing spring - 2 - slightly to front and push pins - 3 - upward with a screwdriver only as far as necessary.

Note. Make sure that pin is not pushed fully out.

1. Remove selector lever cable - 4 - from shift mechanism.

Installing

Installation is in reverse order of removal. Note the following

Note. Do not bend or kink the selector lever cable. Lightly grease ball socket of selector lever cable with polycarbamide grease G 052 142 A2 before installing.

Scheme 359

1. Slide selector lever cable into selector mechanism and secure with retaining clamp - 1 -.

1. Installation position: Angled end of retaining clamp points toward rear.

1. Insert end of selector lever cable - 4 - into selector lever joint.
2. Press pin - 3 - downward - arrow -.
3. Check whether plastic securing spring - 2 - has locked the pin.
4. Install selector lever cable bracket on new selector lever cable.

1. Install selector lever bracket according to marking on console.
2. Adjust selector lever cable --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-cable-adjusting) .
3. Install exhaust system and align free of tension --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Install rear crossmember --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Install front crossmember --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Check shift mechanism --> «Selector mechanism, checking»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-mechanism-checking) .

Torque specifications

Selector lever cable, adjusting

Special tools, testers and auxiliary items required

Scheme 360

1. Socket and key T40031

Work procedure

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

Scheme 361

1. Place selector lever in position "S".

Note. Clamping screw is only accessible in selector lever position "S". Loosen locking screw approx. 1 turn - do not remove completely

1. Loosen selector lever cable locking screw approximately 1 turn with a long hex socket head 5 mm.

1. Press selector shaft lever forward on transmission with end of selector lever cable - 2 - to stop (position "S" on transmission).
2. Carefully move selector lever lightly toward front and rear without shifting into another selector lever position, this releases the tension on selector lever cable.
3. Check exact setting of selector lever in position "S".

Note. When tightening locking screw, selector lever must not be moved forward or back or adjustment will be incorrect.

1. Tighten selector lever cable locking screw - arrow - in this position.

Installation is in reverse order of removal.

Torque specification

Scheme 362

Special tools, testers and auxiliary items required

1. Hose clamps up to 25 mm dia. 3094
2. Transmission support 3282
3. Adjustment plate 3282/30
4. Engine/transmission jack V.A.G 1383 A

1. Wooden block

Transmission, removing

1. Lock carrier and torque support installed.

Note. Reinstall cable ties that were loosened or cut off during removal at same locations during installation.

1. Switch ignition off.

Note. So that the front wheels can still be turned with the battery disconnected, the battery may only be connected when ignition key is inserted.

Scheme 363

1. Remove luggage compartment floor trim.
2. Disconnect Ground (GND) lead - arrow - at the battery.

Scheme 364

1. Remove rear engine cover - arrows -.

Scheme 365

1. Remove vacuum hoses - 1 - and - 2 - from T-connector on bulkhead.

Scheme 366

1. Remove air intake hose - 1 - at Mass Air Flow (MAF) Sensor G70.
2. Remove bolts for holding plate - 3 - for solenoid valves - arrows -.
3. Disconnect hose - 4 - from air duct - 2 -.

Scheme 367

1. Remove screw - arrow - and air duct - 2 - from Throttle Valve Control Module J338.
2. If installed, disconnect hose - 1 - from air duct.

Note. For sake of illustration, air guide is shown from the rear with engine removed.

Scheme 368

1. Clamp off coolant hose - 2 - with a Hose Clamps Up to 25 mm dia. 3094.
2. Remove coolant hose at coolant reservoir and seal opening.
3. Remove coolant reservoir - arrow - disconnect electrical connector at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir.
4. Lay aside coolant expansion tank with connected coolant hoses - 1 - and - 3 -.

Scheme 369

1. Remove electrical connectors - 1 - and - 3 - at left of bulkhead from bracket and disconnect.
2. Guide electrical wiring to oxygen sensors downward.

Note. Disregard - 2 -.

Scheme 370

1. Remove nut - 2 - which is accessible from top for left exhaust pipe/exhaust manifold.

Note. Shown from rear with engine removed to provide a better illustration.

Scheme 371

1. Remove electrical connectors - 1 - and - 3 - at right of bulkhead from bracket and disconnect.
2. Guide electrical wiring to oxygen sensors downward.

Note. Disregard - 2 -.

Scheme 372

1. Remove nut - 2 - which is accessible from top for right exhaust pipe/exhaust manifold.

Note. Shown from rear with engine removed to provide a better illustration.

Scheme 373

1. Remove screws - 5 - and - 6 - accessible from top at engine/transmission flange.

1. Remove both front wheels.

Note. Secure brake discs with wheel bolts.

1. Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.

Scheme 374

1. Remove left and right drive axle heat shield - 1 -.
2. Remove left and right drive axles from transmission flange shaft.

Scheme 375

1. Remove crossmember from subframe - arrows -.

1. Remove front crossmember - arrows -.

1. Loosen clamping sleeves - 1 - and - 2 -.

Note. To stabilize exhaust system, clamping sleeves remain in installation location and front exhaust pipes remain inserted in clamping sleeves.

Note. Flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.

1. Remove bolts - 1 - and - 2 - at front exhaust pipe rear bracket.

Note. Disregard - 3 -.

Scheme 376

1. Remove bolts - 1 - and - 2 -.
2. Remove front exhaust pipe left bracket.

1. Free up oxygen sensor wiring.
2. Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/left exhaust manifold.

Note. For the sake of illustration, shown with engine removed.

1. Remove front exhaust pipe with catalytic converter.

Scheme 377

1. Remove bolts - 1 - and - 2
2. Remove front exhaust pipe right bracket.

1. Free up oxygen sensor wiring.
2. Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/right exhaust manifold.

Note. For the sake of illustration, shown with engine removed.

1. Remove front exhaust pipe with catalytic converter.

Scheme 378

1. Disconnect Engine Speed (RPM) Sensor G28 electrical connector - arrow -.

Scheme 379

1. Disengage electrical harness connector - 1 - and disconnect from transmission.
2. Move wiring harness clear - arrows -.

Scheme 380

1. Remove right ATF line bracket at lower part of oil pan - arrow -.

Note. Observe the rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission .

Scheme 381

1. Remove bolt - arrow - and ATF lines from transmission.
2. Tie ATF lines clear up to side.

Scheme 382

1. Place plunger of engine/transmission jack V.A.G 1383 A with a block of wood inserted in between - 1 - on transmission at bottom.
2. Raise transmission slightly using engine/transmission jack V.A.G 1383 A.

Scheme 383

1. Remove bolts - arrows - and remove tunnel crossmember.
2. Lower transmission carefully.

Scheme 384

1. Remove bolts - 2 - and remove transmission support - 1 - from transmission.

Scheme 385

1. Mount transmission support 3282 on engine/transmission jack V.A.G 1383 A.
2. Place adjustment plate 3282/30 on the transmission support 3282 , as shown in the illustration.

Note. Adjusting plate only fits in one position.

1. Align arms of transmission support to correspond with holes in the adjustment plate.
2. Attach support elements on adjustment plate, as illustrated.

Scheme 386

1. Guide engine and transmission jack V.A.G 1383 A with transmission support 3282 under transmission.

Note. The arrow symbol on the adjusting plate points in the direction of travel.

1. Align adjusting plate parallel to transmission and secure support to transmission with bolt M10x20 - arrow -.
2. Raise transmission slightly using engine/transmission jack V.A.G 1383 A.

Scheme 387

1. Loosen bolts - arrow - on torque support stop.
2. Press torque support stop upward and retighten bolts to 23 Nm.

Note. Adjusting torque support stop prevents engine from sinking down after removing the front transmission.

1. Remove bolts - 1 to 4 - and - 7 to 11 -.
2. Press transmission off bushings - A - and carefully lower it far enough until selector lever cable is accessible.

1. Mark installation position of support bracket for selector lever cable.
2. Remove bolt - 1 - support bracket for selector lever cable.
3. Press selector lever cable ball joint - 2 - off from selector shaft lever.

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

1. Slowly lower transmission.
2. Pay attention to clearance of drive axles when lowering transmission.

Transmission, installing

Installation is in reverse order of removal. Note the following

Note. Before installing an exchanged transmission, clean ATF lines and ATF cooler --> ATF lines and ATF cooler, cleaning and replace ATF auxiliary filter --> ATF additional filter, removing and installing . When performing repairs, replace self-locking nuts and bolts. Always replace bolts that are secured with tightening torque as well as sealing rings, gaskets and O-rings. Clean input shaft splines of transmission and damper unit splines on flywheel, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Excess grease must be removed. Secure all hose connections with hose clamps of the same type as those equipped by the factory. When installing, bring all cable ties back to original positions.

1. Check if alignment sleeves for centering engine/transmission are in the cylinder block, and install if necessary.
2. Before installing transmission, tie electrical wiring to one side so that it cannot be trapped between engine and transmission.
3. Raise engine far enough until selector lever cable can be installed.

Note. Do not bend or kink the selector lever cable. Lightly grease ball socket of selector lever cable with polycarbamide grease G 052 142 A2 before installing.

1. Install selector lever bracket according to marking on console.

1. Carefully raise transmission and bring into installation position using transmission support 3282.
2. Attach transmission to engine with new bolts.

Note. The torque specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts. Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant. Do not use degreased parts. Tolerance for torque specification ± 15%.

1. Before inserting the lower set of bolts connecting transmission with engine, lift transmission up slightly at rear.

Torque specification, securing engine/transmission (transmission flange pattern)

*Replace engine/transmission securing bolt.

*Bolt strength rating 10.9

1. Install transmission support --> «Transmission mounting and transmission support, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__transmission-mounting-and-transmission-support-removing) .

1. Install tunnel crossmember - arrows -.
2. Install ATF lines with new O-rings --> «ATF lines, ATF cooler and auxiliary ATF filter, component overview, vehicles with 6-cyl. gasoline engine»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .
3. Install front exhaust pipe and align exhaust system free of tension --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Install front crossmember --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Install subframe crossmember --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Fasten drive axles to flange shafts --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Loosen torque support bolts - arrows -.
2. Allow stop for torque support to seat on torque support rubber buffer through its own weight and retighten bolts.
3. Electrical connections and routing.
4. Observe procedures for connecting battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Check adjustment of selector lever cable --> «Selector lever cable, adjusting»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-lever-cable-adjusting) .
2. Check oil level in front final drive --> «Front final drive, checking gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__front-final-drive-checking-gear-oil) .
3. Check ATF level and top off --> «ATF in planetary gear»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Torque specifications

Automatic transmission, transporting

Special tools, testers and auxiliary items required

Scheme 388

1. Attachment and holding rig T40013

Work procedure

Scheme 389

The transmission lift hook T40013 can be used when transporting the transmission and for aligning transmission support 3282.

1. Mount and secure transmission lift hook T40013 on upper rib of transmission housing as shown in the illustration.

Scheme 390

Special tools, testers and auxiliary items required

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

1. Workshop crane VAS 6100
2. Attachment and holding rig T40013

Securing transmission in vertical position

Scheme 391

1. Secure transmission to assembly stand with bolts - 1 - and - 2 -.
2. Screw transmission support VW 353 onto holding plate VW 309.

Scheme 392

1. Using workshop crane VAS 6100 , insert transmission into holding fixture VW 313.

Scheme 393

Securing transmission in horizontal position

1. Bolt transmission onto engine/transmission holder VW 540 - arrows -.
2. Using workshop crane VAS 6100 , insert transmission into holding fixture VW 313.

Transmission mounting and transmission support, removing and installing

Special tools, testers and auxiliary items required

Scheme 394

1. Engine/transmission jack V.A.G 1383 A
2. Wooden block

Removing

1. Loosen quick-release connectors - 2 - and remove rear noise insulation.

1. Remove front exhaust pipe rear bracket by removing bolts - 1 to 3 -.

1. Place plunger of engine/transmission jack V.A.G 1383 A with a block of wood inserted in between - 1 - on transmission at bottom.
2. Raise transmission slightly using engine/transmission jack V.A.G 1383 A.

Scheme 395

1. Remove tunnel crossmember bolts - arrows -.

Scheme 396

1. Remove bolts - 1 - and - 2 - and slide tunnel crossmember back slightly.
2. Remove transmission mounting between transmission and tunnel crossmember.

1. Remove bolts - 2 - and remove transmission support - 1 - from transmission.

Installing

Installation is in reverse order of removal.

Torque specifications

ATF level, checking and topping off

Special tools, testers and auxiliary items required

Scheme 397

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

Scheme 398

1. ATF Filler System F/CVT Gearbox VAS 5162
2. Old oil collecting and extracting device V.A.G 1782
3. Safety glasses

Scheme 399

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

Test conditions

1. Transmission not in emergency operating mode.
2. Move vehicle onto a lifting platform or over a work pit so that it stands absolutely horizontal.
3. Engine idling.
4. Air conditioner and heating must be switched off.

1. Vehicle Diagnostic, Testing and Information System VAS 5051 connected, Vehicle Self-Diagnosis and vehicle system "02 - Transmission electronics" selected.
2. ATF temperature must not be higher than 30 ° C at start of test, allow transmission to cool down if necessary.

Note. The ATF level will vary according to the temperature of the ATF. Checking ATF level at too low ATF temperature leads to overfilling. If the ATF level is checked when the ATF temperature is too high, this will result in underfilling. Over and underfilling lead to impaired functioning of transmission. ATF temperature is read off on the Vehicle Diagnosis, Testing and Information System VAS 5051.

Checking ATF temperature

Display on VAS 5051

Scheme 400

1. In selection - 1 - , click on the diagnostic function "08 - Read measuring value block".

Scheme 401

Display on VAS 5051

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

1. In button field - 2 - , enter "10" for "Display group 10" and confirm input by pressing Q button.

Display on VAS 5051

Scheme 402

1. Read off ATF temperature indicated in display field - 3 -.

Checking ATF level and topping off

Note. Engine keeps running at idle speed. The ATF level is checked at the ATF inspection plug. ATF level is correct if a little bit of fluid still escapes at the ATF check plug between 35 ° and 45 ° C (50 ° C for hot countries) ATF temperature (dependent on the fluid level when warming up).

1. Fill ATF Filler System F/Cvt Gearbox VAS 5162 with ATF for CVT transmissions.

1. ATF specification --> «Capacities»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Scheme 403

1. Secure filled reservoir of ATF Filler System F/Cvt Gearbox VAS 5162 as high as possible on the vehicle.

Note. The shut-off valve on the ATF Filler System F/Cvt Gearbox VAS 5162 must be closed.

1. While brake pedal is depressed, shift through all selector lever positions ( "P" , "R" , "N" , "D" , "S" ) let each position remain shifted at idle for approx. 2 seconds.

1. Loosen quick-release connectors - 2 - and remove rear noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

Scheme 404

1. If an ATF temperature of 35 ° C is reached, remove ATF check plug - B -.

Note. Approx. 5 cl of ATF will always drain initially from the internal oil level tube when the plug is removed.

If ATF continues to flow out of the ATF filler plug hole over the overflow tube before the ATF reaches 40 ° C, the ATF level is OK.

1. Replace and tighten ATF check plug.

1. Tightening torque: 20 Nm.

Note. At the latest at 45 ° C (50 ° C for hot countries) the ATF check plug must be screwed in again. At an ATF temperature above 45 ° C, too much ATF flows out due to heat build-up and the transmission is not filled sufficiently!

The ATF check is now completed.

1. Press <-- button to end function "08 - Read measuring value block".
2. Select "06 - End output".
3. Switch off ignition and disconnect Data Link Connector (DLC).

Add ATF if no ATF has escaped from the ATF check plug hole by 40 ° C Filling ATF .

Filling ATF

Note. Engine keeps running at idle speed.

1. Thread connection on shut-off valve of ATF Filler System F/Cvt Gearbox VAS 5162 into opening of ATF check plug - B -.

Scheme 405

1. Rotate shut-off valve in direction of filler hose - lower arrow -. ATF flows into transmission.
2. Hold a suitable container beneath outlet of ATF Filler System F/Cvt Gearbox VAS 5162.

Scheme 406

1. Check ATF level by rotating shut-off valve in direction of outlet - lower arrow -.

ATF level is correct when ATF drips out only lightly from outlet before 45 ° C is reached.

Note. Approx. 5 cl of ATF will initially drain from the internal oil level tube. This is normal.

1. If no additional ATF flows out, rotate shut-off valve back in direction of filler hose and fill with more ATF; repeat check of ATF level.
2. After reaching correct ATF level, remove shut-off valve again.

Note. After removing shut-off valve, ATF drips out lightly.

1. Replace and tighten ATF check plug.

1. Tightening torque: 20 Nm.

Note. At the latest at 45 ° C (50 ° C for hot countries) the ATF check plug - B - must be screwed in again. At an ATF temperature above 45 ° C, too much ATF flows out due to heat build-up and the transmission is not filled sufficiently!

1. Press <-- button to end function "08 - Read measuring value block".
2. Select "06 - End output".
3. Switch off ignition and unplug diagnostic connector.

ATF, changing or filling after repairs

Special tools, testers and auxiliary items required

1. ATF Filler System F/Cvt Gearbox VAS 5162

Scheme 407

1. Triple square socket driver 3357
2. Old oil collecting and extracting device V.A.G 1782
3. Safety glasses

Work procedure

1. Move vehicle onto a lifting platform or over a work pit so that it stands absolutely horizontal.

Note. Observe disposal regulations! Always blow compressed air through ATF cooler and ATF lines (max. 10 mbar) and replace auxiliary ATF filter before installing a replacement transmission --> ATF additional filter, removing and installing .

1. Fill ATF Filler System F/Cvt Gearbox VAS 5162 with ATF for CVT transmissions.

1. ATF specification --> «Capacities»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

1. Secure filled reservoir of ATF Filler System F/Cvt Gearbox VAS 5162 as high as possible on the vehicle.

Note. The shut-off valve on the ATF Filler System F/Cvt Gearbox VAS 5162 must be closed.

1. Loosen quick-release connectors - 2 - and remove rear noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

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

1. Tightening torque: 24 Nm.

1. Remove ATF check plug - B -.
2. Thread connection on shut-off valve of ATF Filler System F/Cvt Gearbox VAS 5162 into opening of ATF check plug - B -.

1. Rotate shut-off valve in direction of filler hose - lower arrow -. ATF flows into transmission.
2. Fill at least 4.5 to liters ATF into transmission.
3. Selector lever in "P" , start engine and let it run at idle.
4. Automatic transmission fluid (ATF) level, checking and topping off --> «ATF level, checking and topping off»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__atf-level-checking-and-topping-off) .

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

ATF lines, ATF cooler and auxiliary ATF filter, servicing

Note. Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . General repair notes --> Repair instructions . To install, first insert ATF lines into transmission or cooler by hand as far as they will go, then bolt on. Check ATF level after replacing ATF lines --> ATF level, checking and topping off

Scheme 408

1 - 21 Nm

1. First insert ATF lines with new O-ring by hand to stop

2 - ATF lines

3 - O-rings

1. Replace
2. Insert with ATF

4 - ATF cooler

1. Integrated in cooler
2. Removing and installing --> «19 - ENGINE - COOLING SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

5 - O-ring

1. Replace
2. Insert with ATF

6 - Additional ATF filter

1. Removing and installing --> «ATF additional filter, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__atf-additional-filter-removing-and-installing)

7 - 5 Nm

1. First insert ATF lines with new O-ring by hand to stop

8 - O-ring

1. Replace
2. Insert with ATF

9 - Union nuts, 29 Nm

10 - ATF line bracket

11 - 5 Nm

ATF lines and ATF cooler, cleaning

Note. Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission .

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Hose dia. approx. 18 mm
3. Compressed air gun, commercially available
4. Safety glasses

Work procedure

1. Before installing a replacement transmission, always blow into ATF cooler and ATF lines with compressed air (max. 10 bar).
2. Before installing a replacement transmission, always replace auxiliary ATF filter.

Note. If extremely dirty ATF flows out when blowing with compressed air, ATF cooler and ATF lines must also be flushed with clean ATF. ATF lines, removing and installing --> ATF lines, ATF cooler and auxiliary ATF filter, component overview, vehicles with 6-cyl. gasoline engine .

ATF lines, removing and installing

Note. Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission .

Special tools, testers and auxiliary items required

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

Removing

1. Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.

1. Remove right drive axle heat shield - 1 -.

Scheme 409

1. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
2. Loosen union nuts - 2 - and - 3 - and disconnect ATF lines.
3. Remove bracket - 1 -.

1. Remove bolt - arrow - and remove ATF lines from transmission.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace O-rings.

1. Insert ATF lines by hand to stop in transmission, then tighten.

Torque specifications

ATF additional filter, removing and installing

Note. Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . General repair notes --> Repair instructions . Always blow compressed air through ATF cooler and ATF lines (max. 10 mbar) and replace auxiliary ATF filter before installing a replacement transmission --> ATF lines and ATF cooler, cleaning . If extremely dirty ATF flows out when blowing with compressed air, ATF cooler and ATF lines must also be flushed with clean ATF. When installing, insert ATF lines by hand to stop in cooler, then screw in.

Special tools, testers and auxiliary items required

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

Removing

Scheme 410

1. Remove bolts - arrows -.
2. Remove air guide - 1 - and - 2 -.

1. Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.

1. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
2. Loosen union nuts - 2 - and disconnect ATF line.

Note. Ignore - 1 - and - 3 -.

Scheme 411

1. Remove bolts - 1 - and - 2 - and remove ATF additional filter.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace O-rings.

1. Insert ATF additional filter with new O-rings by hand to stop in cooler, then screw in.

Torque specifications

ATF breather pipe, removing and installing

1. If ATF flows out at underside of transmission bell housing, input shaft seal and/or ATF breather tube may be leaking. Before replacing any parts, be sure to find actual cause of malfunction.
2. Input shaft seal must be replaced if leaking --> «Input shaft seal, replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__input-shaft-seal-replacing) .
3. ATF breather tube must be replaced if leaking.

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

Removing

1. Transmission removed.

Scheme 412

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

Installing

Installation is in reverse order of removal. Note the following

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

Torque specification

Transmission, disassembling and assembling

End cover, removing and installing

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

Special tools, testers and auxiliary items required

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

Removing

1. Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.
2. Drain ATF --> «ATF, changing or filling after repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__atf-changing-or-filling-after-repairs) .

1. Remove front crossmember - arrows -.

1. Loosen clamping sleeves - 1 - and - 2 -.

Note. Flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.

1. Remove bolts - 1 - and - 2 - at front exhaust pipe rear bracket.

Note. Disregard - 3 -.

1. Tie left and right exhaust system pipes up to body - arrows -.

1. Place plunger of engine/transmission jack V.A.G 1383 A with a block of wood inserted in between - 1 - on transmission at bottom.
2. Raise transmission slightly using engine/transmission jack V.A.G 1383 A.

1. Remove bolts - arrows - and remove tunnel crossmember.

1. Remove bolts - 2 - and remove transmission support - 1 - from transmission.

1. Disengage electrical harness connector - 1 - and disconnect from transmission.

Note. Ignore - arrows -.

1. Mark installation position of support bracket for selector lever cable.
2. Remove bolt - 1 - support bracket for selector lever cable.

Note. Disregard - 2 -.

Scheme 413

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

Scheme 414

Installing

Installation is in reverse order of removal. Note the following

Note. Replace sealing rings, seals and bolts for end cover.

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

Scheme 415

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

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

1. Put on end cover and make sure seal does not slip.
2. Tighten new bolts - arrows - , first hand-tighten and in diagonal sequence, and then to tightening torque.
3. Check installation position of twin lip oil seal - A

1. Twin lip oil seal must fit flush (sealing lips must not be twisted).

1. Press selector shaft lever in position "D".

Note. To ensure selector shaft lever is in position "D" , shift selector shaft lever on transmission back to stop in "P" and then 3 positions forward (in direction of travel).

1. Install selector lever bracket according to marking on console.
2. Install transmission support --> «Transmission mounting and transmission support, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__transmission-mounting-and-transmission-support-removing) .

1. Install tunnel crossmember - arrows -.
2. Install exhaust system and align free of tension --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Fill with ATF --> «ATF, changing or filling after repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__atf-changing-or-filling-after-repairs) .

Torque specifications

*Replace bolts.

* 90 ° is a quarter turn.

Transmission Control Module (TCM) J217 , removing and installing

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

Removing

1. Remove end cover --> «End cover, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__end-cover-removing-and-installing) .

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

Note. When setting aside Transmission Control Module (TCM) J217 , make sure sensors on control module are not damaged.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace seals and O-rings.

1. If necessary, clean sensors - A - , - C - and - D - of soiling and metal shavings.
2. Clean selector shaft --> «Selector shaft, cleaning»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-shaft-cleaning) .

Scheme 416

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

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

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

1. Tighten bolts - arrows -.
2. Install end cover --> «End cover, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__end-cover-removing-and-installing) .

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

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

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

Torque specification

Selector shaft, cleaning

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

Work procedure

1. Remove Transmission Control Module (TCM) J217 --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__transmission-control-module-tcm-j217) .

Scheme 417

1. Clean selector shaft retainer - arrow - with a lint-free cloth. Clean contact surfaces of magnet especially thoroughly of metal shavings and the like.

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

1. If necessary, clean sensors - A - , - C - and - D - of soiling and metal shavings.
2. Install Transmission Control Module (TCM) J217 --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__transmission-control-module-tcm-j217) .

Hydraulic control module, removing and installing

Note. Rules of cleanliness for working on automatic transmissions --> Rules for cleanliness when working on transmission . General repair notes --> Repair instructions . Always replace hydraulic control assembly if it has collected dirt or if it is faulty.

Removing

1. Remove Transmission Control Module (TCM) J217 --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__transmission-control-module-tcm-j217) .

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

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

Installing

Scheme 418

Installation is in reverse order of removal. Note the following

Note. Replace seals and O-rings.

1. Replace axial sealing elements - A - (qty. 4) and - B -.

Note. Lightly lubricate axial sealing elements with ATF before installing. Axial sealing elements - A - must be inserted into mounts with smaller diameter facing transmission.

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

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

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

Scheme 419

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

Note. When installing control module, make sure that shifting cam (item 1 in (Scheme 418) ) engages into free groove - arrow - on control piston - B -.

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

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

Check function of control piston

Scheme 420

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

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

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

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

1. Tighten bolts - arrows -.

Installing slider for selector lever position

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

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

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

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

1. Clean selector shaft --> «Selector shaft, cleaning»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__selector-shaft-cleaning) .
2. Install Transmission Control Module (TCM) J217 --> «Transmission Control Module (TCM) J217 , removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__transmission-control-module-tcm-j217) .
3. Install end cover --> «End cover, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__end-cover-removing-and-installing) .

Torque specification

Input shaft, removing and installing

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

Special tools, testers and auxiliary items required

Scheme 421

1. Puller T40050

Removing

1. Transmission removed and secured to assembly stand --> «Transmission, attaching to assembly stand»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

1. Drain ATF --> «ATF, changing or filling after repairs»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__atf-changing-or-filling-after-repairs) .

Note. Fill with fresh ATF after repair.

Scheme 422

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

Scheme 423

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

1. Circlip must be pushed all the way down.

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

Scheme 424

1. Do not put down input shaft on its guide bearing - arrow - at bottom end.

Installing

Installation is in reverse order of removal. Note the following

1. Clean sealing surfaces on transmission housing and flange cover.

Scheme 425

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

Scheme 426

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

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

1. Place paper gasket in position.

Scheme 427

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

1. Splines must stand exactly in a row.

1. Insert input shaft in transmission housing together with flange cover and forward clutch.

Scheme 428

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

1. Tighten bolts - arrows - in diagonal sequence and in stages.
2. Fill at least 4.5 to 5 liters of new ATF into transmission.
3. After installing transmission, check ATF level and top off --> «ATF in planetary gear»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Torque specification

Front final drive, gear oil level

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

Front final drive, checking gear oil level

Note. The specified oil level must be maintained exactly; the transmission reacts very sensitively to over-filling.

Test sequence

1. Take vehicle for a short test drive to heat gear oil to approx. 60 ° C.
2. Move vehicle onto a lifting platform or over a work pit so that it is absolutely level.
3. Switch off engine and allow 5 minutes for the gear oil to settle back into transmission case.

1. Loosen quick-release connectors - 2 - and remove rear noise insulation.

Scheme 429

1. Remove inspection plug - arrow -.
2. Check oil level using a tool created in the shop, e.g. an angled section of wire.

1. Specified value: Oil level 8.5 mm below bottom of filler hole.

1. If necessary, top off gear oil level.

1. Axle oil specification --> «Capacities»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Note. When servicing at the shop the oil can also be filled up to the lower edge of the oil filler hole. In this case it is necessary to draw off 0.2 ltr. to attain the correct oil level.

1. Tighten new screw plug.

Torque specification

*Replace screw plug.

Front final drive, servicing

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

Left flange shaft, removing and installing

Special tools, testers and auxiliary items required

Scheme 430

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

Scheme 431

1. Puller T10037

Removing

1. Transmission installed.

1. Remove left front wheel.

Note. Secure brake disc with a wheel bolt.

1. Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.
2. Remove left drive axle --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

Scheme 432

1. Tightly thread lower support of puller T10037 on cover for differential - arrow -.

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

1. Pull left flange shaft using puller T10037 only far enough out until bearing on shaft is pulled out of transmission housing.

Installing

Installation is in reverse order of removal. Note the following

1. Replace securing ring for flange shaft, to do this clamp flange shaft in a vise with protective pads.

Scheme 433

1. Press old securing ring out of groove of flange shaft with new securing ring - A -.
2. Clean flange shaft.
3. A damaged sealing ring must be replaced --> «Left flange shaft oil seal, replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__left-flange-shaft-oil-seal-replacing) .
4. Drive in flange shaft using needle bearing drift VW 295.

1. Install left drive axle --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Check gear oil level in front final drive --> «Front final drive, checking gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__front-final-drive-checking-gear-oil) .

Right flange shaft, removing and installing

Special tools, testers and auxiliary items required

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

Removing

1. Transmission installed.

1. Remove right front wheel.

Note. Secure brake disc with a wheel bolt.

1. Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.
2. Remove right drive axle --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 434

1. Remove mounting bracket for flange shaft - arrows -.
2. Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
3. Pull out right flange shaft together with mounting bracket.

Installing

1. Clean flange shaft.
2. A damaged sealing ring must be replaced --> «Sealing ring for right flange shaft and grooved ball bearing, replacing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

Scheme 435

1. Replace O-ring - arrow A - in mounting bracket for flange shaft.
2. Slide spring - C - with cap outward into hole on end of flange shaft - arrow -.
3. Insert flange shaft - B - into transmission housing.

Note. While sliding in the flange shaft, make sure that spring - C - remains in the flange shaft and does not fall into transmission.

1. Tightly bolt mounting bracket for flange shaft - arrows -.
2. Install right drive axle --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Check gear oil level in front final drive --> «Front final drive, checking gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__front-final-drive-checking-gear-oil) .

Torque specification

Left flange shaft oil seal, replacing

Special tools, testers and auxiliary items required

Scheme 436

1. Extractor lever VW 681

Scheme 437

1. Driver 2062

Work procedure

1. Transmission installed

1. Remove left flange shaft --> «Left flange shaft, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__left-flange-shaft-removing-and-installing) .

Scheme 438

1. Pull out sealing ring for flange shaft using extractor lever VW 681.

Note. Do not damage seating surfaces for oil seal.

Scheme 439

Setup of flange shaft with polygon bearing

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

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

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

1. Installation position: The open side of the sealing ring faces transmission.

Scheme 440

1. Drive in new sealing ring for left flange shaft uniformly using driver 2062 5.5 mm below surface of cover, when doing so do not cant.

Note. If reinstalling an old flange shaft, the seal must be driven in approx. 6.5 mm so that the new seal does not sit on the running surface of the old seal.

1. Install left flange shaft --> «Left flange shaft, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__left-flange-shaft-removing-and-installing) .
2. Check gear oil level in front final drive --> «Front final drive, checking gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__front-final-drive-checking-gear-oil) .

Scheme 441

Special tools, testers and auxiliary items required

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

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

Special tools, testers and auxiliary items required

Scheme 442

1. Tube 2040

1. Driver 2062

Work procedure

1. Remove right flange shaft --> «Right flange shaft, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__right-flange-shaft-removing-and-installing) .

Seal, removing

Scheme 443

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

Scheme 444

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

Removing grooved ball bearing

Scheme 445

1. Press grooved ball bearing out of mounting bracket.

Installing grooved ball bearing

Scheme 446

1. Press new grooved ball bearing into mounting bracket.

Sealing ring, installing

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

1. Installation position: The open side of the sealing ring faces the transmission.

Scheme 447

1. Drive in new sealing ring for right flange shaft uniformly using driver 2062 5.5 mm below surface of mounting bracket, when doing so do not cant.

Note. If reinstalling an old flange shaft, the seal must be driven in approx. 6.5 mm so that the new seal does not sit on the running surface of the old seal.

Scheme 448

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

1. Insert securing ring - arrow A -.
2. Install right flange shaft --> «Right flange shaft, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__right-flange-shaft-removing-and-installing) .
3. Check gear oil level in front final drive --> «Front final drive, checking gear oil level»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j__front-final-drive-checking-gear-oil) .

Input shaft seal, replacing

1. If ATF flows out at underside of transmission bell housing, input shaft seal and/or ATF breather tube may be leaking. Before replacing any parts, be sure to find actual cause of malfunction.
2. Input shaft seal must be replaced if leaking.
3. ATF breather tube must be replaced if leaking --> «ATF breather pipe, removing and installing»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) .

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

Special tools, testers and auxiliary items required

Scheme 449

1. Seal remover T40014

Scheme 450

1. Thrust piece T40015

Work procedure

1. Transmission removed.

Scheme 451

1. Rotate seal ring extractor T40014 by hand into shaft seal until the tool has a good hold in the shaft seal. Then tighten puller with an open-end wrench.
2. You can pull out oil seal a short distance by screwing in rear bolt of puller.
3. Re-tighten extractor using open-end wrench so that extractor again grasps the shaft seal tightly and pull out sealing ring further by screwing in the screw.
4. Repeat procedure until shaft seal has been pulled out completely.

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

1. Coat new shaft seal with ATF.

Scheme 452

1. Slide shaft seal - A - onto input shaft with open side facing transmission.

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

Scheme 453

1. Drive in sealing ring until it stops using thrust piece T40015.

Selector shaft oil seal, replacing

Special tools, testers and auxiliary items required

Scheme 454

1. Tube VW 418 A

Work procedure

1. Transmission removed.

Scheme 455

1. Remove bolt - B - completely and remove lever for selector shaft - A - upward.
2. Carefully pry out sealing ring for selector shaft lying underneath using a screwdriver.

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

1. Coat outer circumference of new sealing ring with ATF.
2. Slide on new sealing ring over selector shaft and press in.
3. Drive in sealing ring until it stops using tube 31.5 mm dia. VW 418 A.
4. Connect lever for selector shaft - A - to selector shaft and tighten bolt - B -.

Torque specification

See also:
• 20 - FUEL SUPPLY SYSTEM
• 94 - LIGHTS, SWITCHES - EXTERIOR
• 68 - INTERIOR EQUIPMENT
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS
• 40 - FRONT SUSPENSION
• 50 - BODY - FRONT
• Code letters, transmission applications, ratios, equipment
• ATF level, checking and topping off
• Front final drive, checking gear oil level
• Transmission Control Module (TCM) J217 , removing and installing
• Hydraulic control module, removing and installing
• Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing
• Shift lock solenoid N110 , removing and installing
• Transmission Park Selector Switch F305 , removing and installing
• Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing
• Selector lever cable, adjusting
• Ignition key lock, checking
• Selector lever cable, removing and installing
• Selector lever handle, removing and installing
• Selector mechanism, removing and installing
• Selector mechanism, checking
• ATF lines and ATF cooler, cleaning
• ATF additional filter, removing and installing
• Transmission mounting and transmission support, removing and installing
• Filling ATF
• Input shaft seal, replacing
• ATF, changing or filling after repairs
• End cover, removing and installing
• Selector shaft, cleaning
• Left flange shaft oil seal, replacing
• Left flange shaft, removing and installing
• Right flange shaft, removing and installing