Servicing - A/t Audi A6 C4

IDENTIFICATION

AUTOMATIC TRANSAXLE APPLICATIONS

SERVICE INTERVALS

Check fluid level every 15,000 miles. Change transaxle fluid and filter every 30,000 miles under severe driving conditions.

Final Drive

Place vehicle on level surface. Fluid level should be to edge of fill hole on side of case. If level is too high, this may be caused be leaking seals between transaxle and final drive.

Note. If using VAG Scan Tool (1551) and VAG ATF Filling System (1924), follow manufacturer's instructions.

Transaxle With Fill Tube

With transaxle at normal operating temperature, park vehicle on level surface. Place selector lever in "P" or "N" position and apply parking brake. Allow engine to idle. Ensure fluid level is between marks on dipstick.

Transaxle Without Fill Tube

1. Ensure transaxle is not in "emergency running" mode. ATF temperature must be 95°F (35°C) or less. Ensure vehicle is level and idling in Park. Raise vehicle, remove ATF level checking plug from bottom of oil pan (level checking plug is at rear of oil pan).
2. Allow vehicle to idle until ATF reaches test temperature of 95-104°F (35-40°C). If ATF drips out of open level checking plug hole, level is correct. If not, add ATF to filler plug. Filler plug is located above front of oil pan. Use a screwdriver to pry off locking cap. Remove plug from filler pipe.
3. With engine still at idle, add ATF until fluid runs out of level checking plug hole. Use a NEW sealing washer and install plug. Tighten plug to 11 ft. lbs. (15 N.m).

RECOMMENDED FLUID

RECOMMENDED FLUIDS

FLUID CAPACITIES

TRANSAXLE REFILL CAPACITIES

DRAINING & REFILLING

Note. Fluid level should be check with vehicle on level ground, idling and at normal operating temperature.

1. Remove oil pan and clean. Remove filter and allow oil to drain. Install NEW filter and replace oil pan gasket. Install oil pan. On vehicles with dipstick tube, add appropriate amount of fluid through dipstick tube. See «FLUID CAPACITIES»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__fluid-capacities) . On vehicles without dipstick tube, add appropriate amount of fluid through filler plug on side of oil pan. See «FLUID CAPACITIES»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__fluid-capacities) .
2. Ensure vehicle is on level ground. Start vehicle and let idle. Apply brake and move gear selector through all positions. Place gear selector in neutral. Allow engine to warm-up to normal operating temperature. On vehicles with dipstick tube, check and adjust fluid level as necessary. On vehicle without dipstick tube, ensure fluid level is to bottom of filler hole.

ADJUSTMENTS

Note. Information on neutral safety switch is not available at time of publication.

AUTOMATIC SHIFT LOCK SOLENOID

Remove gear selector lever handle and console cover to access gear selector assembly. See CENTER CONSOLE under REMOVAL & INSTALLATION. Place gear selector lever in Reverse. Clearance between gear selector lever and solenoid switch valve should be.024-.055" (0.6-1.4 mm). (Scheme 4) If clearance is not correct, loosen retaining screws and adjust.

Scheme 4

KICK DOWN SWITCH

Note. Prior to adjusting kick down switch, ensure accelerator pedal cable is properly adjusted. See ACCELERATOR PEDAL CABLE .

1. Remove noise damper. Disconnect 2-pin harness connector for kick down switch. Check continuity by connecting a multi-meter between terminals No. 1 and 2 of kick down switch harness connector. There should be no continuity.
2. Slowly depress accelerator pedal. Kick down switch must close when kick down switch lever is in area "A" and "B" of throttle cam. (Scheme 5) Resistance should be 0 ohms.
3. If specified values are not attained, loosen mounting bolts for kick down switch. Press throttle lever, by hand, to full load stop. (Scheme 6) Adjust kick down switch so lever of kick down switch contacts throttle cam. (Scheme 7) Tighten mounting bolts, and secure with locking fluid.

Scheme 5

Scheme 6

Scheme 7

MULTI-FUNCTION TRANSMISSION RANGE SWITCH

Note. Special tool 3338 adjusting device or installation aid 0 501 311 626 (supplied with multi-function switch as a replacement part) is required. (Scheme 8)

Adjusting Using Installation Aid

1. Remove left-side transmission support. See «LEFT-SIDE TRANSMISSION SUPPORT»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__left-side-transmission-support) under REMOVAL & INSTALLATION.
2. Disconnect selector lever cable from transmission selector lever.
3. Completely unscrew clamping screw (arrow 1) and disconnect transmission selector lever from shaft (1). (Scheme 9)
4. Remove multi-function switch mounting screw (arrows 2) and pull multi-function switch off of shaft. Move selector shaft (1) back out of this position two detents to position "N".
5. Place installation aid on shaft. (Scheme 10)
6. Loosen multi-function switch mounting screws (arrows 2). (Scheme 9)
7. Turn multi-function switch until it aligns with hole in installation aid and secure using pin or 4 mm drill bit. (Scheme 10)
8. Tighten multi-function switch mounting screws to specifications. See «TORQUE SPECIFICATIONS»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__torque-specifications).
9. Remove installation aid and pin or drill bit.

Scheme 8

Scheme 9

Scheme 10

Adjusting Using 3338 Device

1. Remove left-side transmission support. See «LEFT-SIDE TRANSMISSION SUPPORT»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__left-side-transmission-support) under REMOVAL & INSTALLATION.
2. Disconnect selector lever cable from transmission selector lever.
3. Completely unscrew clamping screw (arrow 1) and disconnect transmission selector lever from shaft (1). (Scheme 9)
4. Remove multi-function switch mounting screw (arrows 2) and pull multi-function switch off of shaft. Move selector shaft (1) back out of this position two detents to position "N".
5. Place 3338 adjusting device on shaft and tighten its set screw using small screwdriver. (Scheme 11)
6. Loosen multi-function switch mounting screws (arrows).
7. Turn multi-function switch so that hole in adjusting Device (3338) and multi-function switch align and can be secured using pin from Adjusting Device (3338). (Scheme 12)
8. Tighten multi-function switch mounting screws to specifications. See «TORQUE SPECIFICATIONS»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__torque-specifications).
9. Remove installation aid and pin or drill bit.

Scheme 11

Scheme 12

Selector Lever In Position "P"

1. If brake pedal is not depressed, selector lever is blocked and cannot be moved out of position P. Shift lock solenoid blocks selector lever.
2. If brake pedal is depressed, shift lock solenoid releases selector lever. It is possible to engage a driving mode. Turn ignition on, with engine off. Slowly move selector lever from position "P" through "R", "N", "D", "3", "2" and "1".

Selector Lever In Position "N"

Starter must not be able to be operated in selector lever positions "1", "2", "3", "D" and "R". At speeds over 3 MPH and selector lever moved into position "N", shift lock solenoid must not engage and block selector lever. Selector lever can be shifted into a driving mode.

At speed under 3 MPH, and selector lever moved into position "N", shift lock solenoid must not engage until after approximately 1 second. Selector lever cannot be moved out of position "N" until after brake pedal is depressed.

Note. Ignition must be on, with engine off.

1. If brake pedal is not depressed, selector lever is blocked and cannot be moved out of position "N". Shift lock solenoid blocks selector lever.
2. If brake pedal is depressed, shift lock solenoid releases selector lever. It is possible to engage a driving mode.

Adjustment A

1. Remove center console. See «CENTER CONSOLE»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at) under REMOVAL & INSTALLATION.
2. Move selector lever into position "P".
3. Loosen bolts (arrows) on bracket for selector level cable until bracket can be moved. (Scheme 13)
4. Pull selector lever cable back (arrow) to move transmission selector lever into position "P". (Scheme 14) Check if selector lever cable is routed free of tension.
5. Tighten bolts on bracket for selector lever to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__torque-specifications).
6. Check selector lever function. See «SELECTOR LEVER FUNCTION CHECK»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at).

Scheme 13

Scheme 14

Adjustment B

Note. If Transmission Range (TR) selector lever display in instrument cluster does not match selector lever position, repeat adjustment procedure and/or adjust multi-function TR switch. See MULTI-FUNCTION TRANSMISSION RANGE SWITCH .

1. Remove front center console. See «CENTER CONSOLE»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at) under REMOVAL & INSTALLATION.
2. Remove footwell vent. See «HEATER & VENTILATION AIR DUCTS»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at) under REMOVAL & INSTALLATION.
3. Move selector lever into position "P".
4. Loosen nut (arrow) on clamping pin for selector level cable. (Scheme 15)
5. Pull selector lever cable back to move transmission selector lever into position "P". (Scheme 14)
6. Check if selector lever cable is routed free of tension.
7. Check if markings on bracket for selector lever cable (arrows) are aligned to center of mounting bolts. (Scheme 13) If necessary, align
8. Tighten nut (arrow) on clamping pin for selector lever cable. (Scheme 15) Tighten to specification, see «TORQUE SPECIFICATIONS»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__torque-specifications).
9. Check selector lever function. See «SELECTOR LEVER FUNCTION CHECK»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at).

Scheme 15

PARK LOCK CABLE

Note. Lock cable must be adjusted in installation position

Scheme 16

1. Loosen lock bolt. (Scheme 16)
2. Turn ignition switch to "ON" position.
3. Secure lock cable bracket in installation position at front of selector lever housing.
4. Place feeler gauge between locking flap and locking pin. (Scheme 16)
5. Adjust lock cable by sliding in direction of arrow until locking pin is lightly pressed against feeler gauge.
6. Tighten bolt to specifications. See «TORQUE SPECIFICATIONS»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at__torque-specifications).
7. Turn ignition switch to "OFF" and "ON" positions several times.
8. Check dimension between locking pin and locking flap again. Specified dimension between locking pin and locking flap is.047-.067" (1.2-1.7 mm).
9. Move selector lever into position "N". Install locking cable at selector lever housing.
10. Ensure lock cable is routed without kinks.
11. Fasten lock cable to heater housing using cable clip (arrow). (Scheme 17)

Scheme 17

ACCELERATOR PEDAL CABLE

2.2L 5-Cyl.

Note. When installing, ensure accelerator pedal cable aligns between support bracket and fast idle cam.

1. Ensure accelerator pedal cable is connected to accelerator pedal and fast idle cam.
2. Ensure securing clip is pulled off accelerator pedal cable sleeve.
3. Depress accelerator pedal to Wide Open Throttle (WOT) position.
4. Pull back accelerator pedal cable sleeve until throttle valve lever contacts WOT stop.
5. Insert securing clip behind support bracket at locking segment of accelerator pedal cable sleeve.

Scheme 18

2.8L V6

Note. When installing, ensure accelerator pedal cable aligns between support bracket and throttle valve lever. Accelerator pedal cable is fixed to accelerator pedal and fast idle cam. Longitudinal adjustment of accelerator pedal cable sleeve is not determined by securing clip.

Scheme 19

Scheme 20

1. Insert spacer between accelerator pedal and stop, and secure in place. (Scheme 19)
2. Pull accelerator pedal cable sleeve back until throttle valve lever contacts wide open throttle stop. (Scheme 20)
3. Insert securing clip behind support bracket, to lock accelerator pedal cable sleeve in place. (Scheme 20)
4. To check accelerator pedal cable: Depress accelerator pedal. Throttle valve lever must contact wide open throttle stop. When accelerator pedal is release, throttle valve lever must contact closed throttle position stop (arrow). (Scheme 21) If throttle valve lever does not contact closed throttle position stop, repeat cable adjustment until checking conditions described above are met.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

LEFT-SIDE TRANSMISSION SUPPORT

The following special tools and equipment must be available for removal process

1. 10-22A engine support bridge with 10-22A/1 bracket for engine. (Scheme 25)
2. 2024A/2 special tool. (Scheme 26)

Scheme 25

Scheme 26

Removal (5-Cylinder)

1. Remove fuel distributor cover.
2. Place 10-222A engine support bridge with 10-222A1 bracket for engine on bumper bolting edge. (Scheme 27)
3. Tension engine using spindle.
4. Remove catalytic converters.
5. Loosen mounting nuts for left bonded rubber bushing (arrow 1). (Scheme 28)
6. Disconnect transmission support, left, at bonded rubber bushing (arrows 2).
7. Disconnect plug connector for multi-function switch.
8. Disconnect bracket for multi-function switch plug connector (1). (Scheme 29)
9. Remove mounting screws for transmission support (arrows) and remove transmission support.

Scheme 27

Scheme 28

Scheme 29

Removal (6-Cylinder)

1. Pull off spark plug connectors in front of left rear engine mount.
2. Fasten 2024A/2 bracket with bolt on left rear engine mount. (Scheme 30)
3. Place 10-222A engine support bridge with 10-222A1 bracket for engine on bumper bolting edge.
4. Tension engine using spindle.
5. Remove catalytic converters.
6. Loosen mounting nuts for left bonded rubber bushing (arrow 1). (Scheme 28)
7. Disconnect transmission support, left, at bonded rubber bushing (arrows 2).
8. Disconnect plug connector for multi-function switch.
9. Disconnect bracket for multi-function switch plug connector (1). (Scheme 29)
10. Remove mounting screws for transmission support (arrows) and remove transmission support.

Scheme 30

Installation (5 & 6-Cylinder)

Installation is the reverse of removal, noting the following

1. Lift transmission to install transmission support, if necessary.
2. Align exhaust system free of stress.

Removal

1. Remove front center console. See «CENTER CONSOLE»(/audi/a6/c4-1994-1997/remont/automatic-trans/#servicing-at).
2. Remove steering wheel. See «STEERING COLUMN»(/audi/a6/c4-1994-1997/remont/steering-column/#steering-column) article in STEERING.
3. Remove instrument cluster. See «1995 INSTRUMENT PANELS»(/audi/a6/c4-1994-1997/remont/gauges-instrument-panels/#instrument-panels) or «INSTRUMENT PANELS»(ref-12985) article in ACCESSORIES & EQUIPMENT.
4. Move selector lever into position "N".
5. Loosen hex bolts (arrows). (Scheme 31)
6. Remove cap (1). (Scheme 32)
7. Unclip cable clip (2).
8. Swing lock cable (3) upward approximately 90° and pull upward and out of bracket on ignition switch.
9. Remove cable clip from lock cable on air duct and remove lock cable.

Scheme 31

Scheme 32

Installation

Note. Flat surface of lock cable and mounting eye must line up.

1. Install lock cable onto bracket on ignition switch and turn locking cable downward approximately 90°.
2. Clip in cable clip
3. Place cap on ignition switch.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• STEERING COLUMN
• 1995 INSTRUMENT PANELS
• FLUID CAPACITIES
• CENTER CONSOLE
• ACCELERATOR PEDAL CABLE
• LEFT-SIDE TRANSMISSION SUPPORT
• TORQUE SPECIFICATIONS
• ADJUSTMENT B
• MULTI-FUNCTION TRANSMISSION RANGE SWITCH