Removal & Installation - A/t (01l) Audi A6 C5

APPLICATION

AUTOMATIC TRANSAXLE APPLICATIONS

Scheme 1

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Scheme 3

BATTERY DISCONNECT PROCEDURES

Note. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

Before beginning repairs on the electrical system

1. Obtain the anti-theft radio security code.
2. Switch off all electrical consumers.
3. Switch ignition off and remove ignition key.
4. On vehicles equipped with Audi Telematics by OnStar, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery. See «Back-Up Battery For Telematic/Telephone Control Module»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__back-up-battery-for-telematictelephone-control-module) .
5. Disconnect negative ( - ) battery terminal.

After reconnecting vehicle battery

1. Re-code and check operation of anti-theft radio
2. Check operation of clock and power windows. See «Power Window Control Module»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__power-window-control-module) .
3. On vehicles equipped with Audi Telematics by OnStar, switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module. See «Back-Up Battery For Telematic/Telephone Control Module»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__back-up-battery-for-telematictelephone-control-module) .

Power Window Control Module

If the battery is disconnected, the window control module loses its memory of current position and the automatic up/down function. To reset

1. Switch ignition on.
2. Lift window switch up to run power windows up to stop.
3. Operate all window lifters again for at least 1 second in "close" position to activate automatic up/down function.
4. Press window switch briefly.
5. The selected side window must automatically run to the bottom stop.

Back-Up Battery For Telematic/Telephone Control Module

Switching back-up battery on or off requires using factor scan tool VAG 1551 or VAS 5051 Scan Tool (ST), or equivalent aftermarket scan tool.

Under "Rapid data transfer" operating mode 1, select "Telematics" address word 75. Then select function "10 - Adaptation".

Emergency (back-up) battery, switch on/off, reset time register can be selected from this mode. Consult scan tool operator's manual for instructions.

Hold crankshaft in position using 3242 crankshaft holder. Mark positions of shim -1- (in front of drive plate) and washer -2- (behind drive plate). (Scheme 4)

Scheme 4

Install drive plate together with washer -2- and shim -1-. Always replace drive plate mounting bolts. Drive plate to crankshaft bolts tightening torque: 60 Nm (44 ft lb) + 1/4 -turn (90°).

Note. Short engines and exchange engines are supplied without a bushing in the crankshaft. For vehicles equipped with an automatic transmission, install the bushing before installing the drive plate.

Measure distance -a- at three points and calculate average value. (Scheme 5) Dimension -a-: approx. 12.3 mm (0.484 in.). If necessary, install different shim.

Scheme 5

Note. Before installing the engine, make sure the engine to transmission centering sleeves are installed in the engine block.

Scheme 6

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Scheme 9

1. Support engine with supporting device. (Scheme 6) Remove hubcap. On vehicles equipped with light alloy wheels, use pulling hook in vehicle tools to pull off center cap. On all vehicles, remove wheels. Remove sound insulation. (Scheme 7)
2. Prior to loosening subframe, use special tool (3393) to ensure holes (1 and 2) align. (Scheme 8) If holes are not aligned, an axle alignment must be performed after subframe is installed.
3. Unscrew hex nuts (3). (Scheme 9) Remove hex bolt (1) and guide link to subframe. Unscrew hex bolts (1). (Scheme 10) Remove hex bolts (2), and lower subframe in back. Pull out hex bolts of guide links. Pull guide links out of subframe. Unscrew hex bolt (5). (Scheme 9)
4. Position marks for vehicle level sensor are located on left control arm for installation reference. During transaxle support with bonded rubber mount removal and subframe lowering procedure, ensure coupling rod is disconnected from vehicle level sensor to prevent sensor damage. Replace self-locking nut during sensor installation. (Scheme 11)
5. Remove hex nut (2), track control link to subframe and remove hex bolt. (Scheme 9) Pull ABS wheel speed sensor cable out of bracket on brake caliper. Pull track control links out of carrier. (Scheme 12)
6. Unscrew hex nuts (3 and 4). (Scheme 10) Remove hex bolts (5). Loosen hex bolt (6) until subframe can be removed. Remove subframe.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. To install subframe, insert subframe and partially thread NEW hex bolts (5 and 6). (Scheme 10) Guide bearing and guide links into subframe. Insert bolts in outside holes (arrows). (Scheme 13)
2. Holes (1) and (2) of subframe and hole (3) of aluminum bracket must line up on both sides. (Scheme 8) Fixing subframe in this way is a substitute for a subsequent axle alignment only when: Subframe has been removed and reinstalled; holes (1) and (2) line up before repair.
3. Start hex bolts (1) and (2). (Scheme 10) Start hex nuts (3) and (4). Protect drilled hole in body for special tool 3393 against corrosion.
4. Turn NEW hex bolts (2) and (5) to 81 ft. lbs. (110 N.m) plus an additional 1/4 turn. (Scheme 10) Tighten hex bolts (6) to 52 ft. lbs. (70 N.m). Tighten hex bolt (1). Note different bolt versions. See «BOLT VERSIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__bolt-versions) under TORQUE SPECIFICATIONS. Tighten hex nuts (3) and (4) to 30 ft. lbs. (40 N.m). (Scheme 10)
5. Install guide link to subframe and HAND tighten NEW hex bolts and nuts. Install track control link to subframe and HAND tighten NEW hex bolts and nuts. Tighten coupling bolts to stabilizer bar using NEW ribbed nuts. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__torque-specifications).
6. Install coupling to stabilizer bar. Note change in coupling and in tightening torques. (Scheme 14)- (Scheme 16). Use NEW ribbed nuts, and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__torque-specifications).
7. Install suspension strut to track control link. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__torque-specifications). Insert ABS wheel speed sensor cable into bracket on brake caliper. Install wheels, and tighten lug nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__torque-specifications).

Scheme 14

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Scheme 16

Scheme 17

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Scheme 19

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Scheme 23

Scheme 24

Scheme 25

Scheme 26

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Scheme 28

1. Obtain radio code for theft-protection radio. Disconnect Negative battery cable. See «BATTERY DISCONNECT PROCEDURES»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__battery-disconnect-procedures). Remove engine covers. (Scheme 17)
2. Remove intake air duct (1) to air cleaner (arrows). (Scheme 18) Remove hose (1). (Scheme 19) Disconnect intake air duct (2) to throttle valve unit.
3. Remove hose (1) from air cleaner by turning it in direction of arrow. (Scheme 20) Remove bracket for frequency valve (2) from air cleaner body. Remove connector for mass air flow Meter (3). Remove bolt (arrow), and remove air cleaner with mass air flow meter and intake air duct. Disconnect connectors for left and right oxygen sensors next to throttle valve unit.
4. Remove bolts for engine coolant reservoir and set aside. Remove bolts for left and right upper exhaust system connection. Remove all connecting bolts for engine and transmission that can be reached from above. Install engine/transmission sling (10-222 A) with brackets (10-222 A/1). (Scheme 6) Insert hook of spindle in eyelet (A) at rear of engine.
5. Slightly pre-tension engine and transmission unit with spindles. Raise and support vehicle. Remove front wheels. Remove noise insulation tray. (Scheme 7)
6. Remove rear noise insulation bracket (1). (Scheme 21) Turn securing lever (4), and remove connector for transmission harness. Remove connector for multi-function transmission range switch (2), and remove connector (3) bracket.
7. Remove heat shields for left and right axle shafts (arrows). (Scheme 22) Remove axle shafts from transmission flanges.
8. Remove engine speed sensor I (G28) (arrow "B") at left front of transmission. (Scheme 23) Remove connector (arrow "A") from speedometer vehicle speed sensor (G22). Remove heat shield for shift lever cable. Remove lower nuts for exhaust pipes from exhaust manifold. Remove left and right oxygen sensors behind catalytic converters, and mark which one was installed on right and which on left.
9. Loosen dual clamp and remove front exhaust pipes with catalytic converters and upper oxygen sensors. Remove heat shield (A) above drive shaft. (Scheme 24) Remove heat shield (B) for drive shaft from cover for Torsen differential (arrows).
10. Remove transmission output RPM (G195) sender connector together with heat shield foil (A). (Scheme 25)
11. Check whether there is a factory marking (colored marking) on driveshaft and at transmission flange. If not, place mating marks on driveshaft and transmission flange with color. Remove drive shaft at transmission and either support or wire aside. Remove starter.
12. Counterhold center bolt of vibration damper, and remove torque converter from clutch disk by turning crank shaft an additional 1/3 turn each time until bolts are removed. (Scheme 26)
13. Remove multi-function transmission range switch. Remove socket for selector lever cable (1) from selector lever (2). (Scheme 27) If necessary, mark position of bracket for selector lever cable on transmission case for re-installation. Remove bracket (arrows). (Scheme 28)
14. Remove clamp for ATF line at connecting bolt for engine and transmission. Place oil drip pan (V.A.G. 1306) below transmission. Remove ATF lines at transmission, pull out and set aside. Cap lines and transmission connections with clean caps to prevent ATF from running out.
15. Install transmission support 3282 with adjustment plate (3282/25) and install on engine/transmission jack (V.A.G. 1383 A). Support transmission with jack (V.A.G. 1383 A) and transmission support (3282) from below. (Scheme 29) Secure left support (arrow) with bolt M10.
16. Remove left and right side transmission support, complete with transmission mounts. (Scheme 30) Lower subframe front and rear. See «SUBFRAME»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l).
17. Remove both engine mounts from engine/transmission carrier. If necessary, lift engine a little more using spindles. Remove remaining bolts between engine and transmission. If necessary, lower engine again using spindles. Lower transmission carefully by adjusting transmission support plate (3282) at rear.
18. Press off torque converter with lever from drive plate. (Scheme 31) Separate transmission from engine.
19. Secure torque converter to prevent it falling out. Lower transmission by adjusting transmission support (3282) at rear. see scheme 32 Guide transmission out tilted toward rear and down.

Note. Before installing a replacement transaxle, first clean ATF cooler and ATF lines. See SERVICING - A/T (01L, AWD) article.

Scheme 29

1. Installation is reverse of removal procedure. Not the following: Before installing transmission, ensure torque converter is properly inserted in transmission. See step 2. Before installing transmission, ensure dowels (A and B) are properly installed in engine flange. see scheme 33 Take care not to catch any loose wiring between engine and transmission. Fasten torque converter to drive plate using NEW bolts (M10x1x17). Always replace self locking bolts and nuts. Always replace gaskets and "O" rings. Always replace M14 bolts and lock washers at engine and transmission carrier (subframe).
2. Insert torque converter through seal to first stop on transmission shaft. Push converter by hand into bell housing while turning converter until notches on converter hub engage with corresponding driver notches of pump wheel and converter slides noticeably toward inside.
3. Torque converter is correctly installed when distance between flange of bell housing and threaded plates at converter is approximately 22 mm. see scheme 34 If converter was not properly installed, dimension is approximately 10 mm.
4. Install subframe. See «SUBFRAME»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l).
5. Adjust selector lever. See «SERVICING - A/T (01L, AWD)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd) article.
6. Install driveshaft to transmission flange, aligning mating marks made during removal. Replace gaskets on drive flanges (remove protective film and attach gasket to drive flanges). Always remove any remaining locking fluid from thread bores in the transmission drive flanges and the rear final drive. Otherwise there is a possibility that the new bolts may get jammed when installed and shear when removed. Cleaning can be performed with a thread cutter. Install NEW driveshaft flange bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__torque-specifications).
7. Reconnect transmission output RPM (G195) sender connector, and ensure heat shield foil (A) above transmission is properly fastened. (Scheme 25)
8. Install exhaust system. Check gear oil in final drive, and check ATF. See «SERVICING - A/T (01L, AWD)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd) article.
9. Install axle shafts to transmission flanges on both sides.
10. After connecting battery, enter anti-theft code for radio. Fully close power windows to stop. Activate all power window switches for at least one second to activate automatic window raising/lowering. Set clock to correct time. See «BATTERY DISCONNECT PROCEDURSE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01l__battery-disconnect-procedures).

Note. Lower vehicle and final tighten bolts/nuts on suspension components with bonded rubber bushings.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Note. Engine-to-transaxle tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened. Other lubricants are permitted (e.g. engine oil or transaxle fluid); however, they may not contain graphite. Do not use any degreased parts.

TRANSAXLE-TO-ENGINE BOLT TORQUE SPECIFICATIONS

Scheme 30

BOLT VERSIONS

Three different 8 mm bolt versions are used on Audi suspensions. see scheme 36 All bolts should only be used once. Bolts are as follows

1. Bolt "A" without ribbing. Tightening torque 18 ft. lbs. (25 N. m).
2. Bolt "B" with ribbing. Tightening torque 55 ft. lbs. (75 N. m).
3. Bolt "C" with screw head and washer ribbing. Tightening torque 22 ft. lbs. (30 N.m) plus an additional 90°.

Scheme 31

See also:
• SERVICING - A/T (01L, AWD)
• Back-Up Battery For Telematic/Telephone Control Module
• Power Window Control Module
• BOLT VERSIONS
• TORQUE SPECIFICATIONS
• BATTERY DISCONNECT PROCEDURES
• SUBFRAME