Removal & Installation - A/t (01v - with 2.8l) Audi A6 C5

APPLICATION

TRANSAXLE APPLICATION

Scheme 173

Scheme 174

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-01v-with-28l__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-01v-with-28l__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-01v-with-28l__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.

DRIVE PLATE

Note. The following procedure is given assuming the transmission has been removed or the engine has been removed for servicing.

Scheme 175

1. Holding drive plate stationary, remove drive plate bolts. Manufacturer requires using NEW drive plate bolts on installation.
2. BEFORE removing shims and drive plate, note installed position for reassembly reference. (Scheme 175) Mark drive plate and shims for reference.

Scheme 176

1. Install drive plate and shims in original locations. Install OLD bolts into flange. Check dimension "A" at 3 evenly space points. Find average of readings. Specification should be approximately 12.3 mm (0.484". (Scheme 176) If specification is not correct, different size shims are available from manufacturer to obtain correct clearance.
2. When correct shim size is installed, install NEW drive plate bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01v-with-28l__torque-specifications).

Scheme 177

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Scheme 179

Scheme 180

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Scheme 182

Scheme 183

Scheme 184

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Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

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Scheme 193

Scheme 194

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Scheme 198

Scheme 199

1. Disconnect negative battery cable. See «BATTERY DISCONNECT PROCEDURES»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01v-with-28l__battery-disconnect-procedures).
2. Remove bolts (arrows) and remove engine cover. (Scheme 177)
3. Remove cover above air filter. Remove air guide (1) between air filter housing and lock carrier. (Scheme 178) Disconnect connector for EVAP canister purge regulator valve (2), and remove valve from bracket. Disconnect connector (3) at Mass Air Flow sensor. Remove intake air duct (44) from intake manifold. Remove upper part of air filter housing (5).
4. Unbolt engine coolant expansion tank and lay aside. Remove heated oxygen sensor from front exhaust pipes (left and right). Remove upper securing nuts from front exhaust pipes (left and right).
5. Assemble both Engine Support Adapters (10-222A/3) for front and rear spindles on support bar. Set Engine Support Bridge (10-222A) onto the fender mounting flanges using Brackets (10-222A/1). (Scheme 179) Hang both spindles on the adapters. Secure engine to spindles. To do so, additionally use a shackle (1) at the rear side of the engine to avoid damage.
6. Take up weight of engine/transaxle assembly on spindles. Tighten the rear spindle less, to enable later lowering at rear. Raise and support vehicle. Remove front wheels.
7. Remove noise insulation tray (arrows). (Scheme 180) Remove bracket for noise insulation tray. Remove left and right heat shields for drive axles (arrows). (Scheme 181)
8. Disconnect drive axles from transaxle drive flanges. Unbolt engine speed (RPM) sensor (arrow B) from transaxle at front left. (Scheme 182) Remove connector for speedometer (arrow A) from transaxle.
9. Disconnect connector (1) from wire for multifunction switch. Swing securing lever (2), and disconnect connector for transaxle wiring harness. (Scheme 183) Remove starter.
10. Using special tool (V175), remove torque converter from clutch disk by turning crank shaft an additional 1/3 turn each time until bolts are removed. (Scheme 184)
11. Unclip alternator vent hose (1). (Scheme 185)
12. Unbolt ATF line bracket (2) at oil pan. Separate ATF lines (1) to ATF cooler. (Scheme 186) Plug ATF lines with clean plug. Unbolt ATF line bracket (3). Remove transmission side starter bolt (2).
13. On vehicles equipped with All Wheel Drive (AWD), remove heat shield (A) above drive shaft. (Scheme 187)
14. If necessary, remove rear portion of exhaust system.
15. Remove heat shield (2) for drive shaft from cover for Torsen differential (arrows). (Scheme 188)
16. Check whether there is a factory marking (colored marking) on driveshaft and at transaxle flange. If not, place mating marks driveshaft and transmission flange for reassembly reference. This is essential to prevent driveline vibration after driveshaft is installed. Unbolt drive shaft from transaxle and hang or support.
17. On all models, position Transaxle Support (3282). Use Adjusting Plate (3282/19) to position the transaxle support on transaxle. (Scheme 189) The symbols on the adjusting plate indicate the necessary mounts and the arrow points toward front of vehicle.
18. Roll VAG 1383A engine/transmission hoist with 3238 transmission support under transmission and support transmission. Align adjustment plate parallel to transmission. Secure transmission on transmission support using bolt (A). (Scheme 190) AWD transaxle is supported at the same positions as the FWD transaxle.
19. On both sides of transmission, remove heat shield (C). (Scheme 191)and (Scheme 192).
20. Remove bolts (A), and remove heat shield (D). Remove transmission supports (E). (Scheme 193) Items (C and B) are not installed on vehicles with hydraulic transmission bearing (H), because bolt (G) is threaded directly into transmission bearing (mount).
21. Unbolt multi-function Transmission Range (TR) switch (F125) for protection against damage (arrows) and expose wiring harness. (Scheme 194)
22. Mark position of mounting bracket for selector lever cable to transmission housing for re-installation. Unbolt mounting bracket (arrows). (Scheme 195) Pry off selector lever cable from lever/shift rod using 80-200 (arrows). (Scheme 196)
23. Prior to loosening subframe, ensure holes, (1 and 2) align using testing mandrel (3393). (Scheme 197) If holes are unable to align, axle alignment must be performed after unit support is installed.
24. Remove bolts (1 and 2) at rear of subframe on both sides of vehicle. (Scheme 198) Unscrew hex nuts (3) and (4). Remove hex bolts (5). Loosen hex bolt (6) until subframe can be removed. Slightly lower engine/transmission subframe at rear above hoist (VAG 1383A). Remove exhaust pipes.
25. Remove remaining connection bolts for engine/transmission. Press torque converter out of clutch disc while pressing transmission from engine. Press torque converter against ATF pump (arrow). (Scheme 199)
26. Rotate transmission (arrow) and carefully move into position between subframe and vehicle floor. (Scheme 200) Lower transmission. Secure converter so it does not fall out.

Note. Prior to installing transaxle, ensure dowel sleeves are seated correctly on the engine housing. Item A in see scheme 34. If the dowel sleeves get stuck in the transaxle housing, they must be removed and NEW dowel sleeves must be installed on the engine.

Scheme 200

Scheme 201

Scheme 202

1. Before installing a replacement transaxle, first clean the ATF cooler and ATF lines. See appropriate A/T SERVICING article.
2. Press and rotate torque converter by hand until recess of torque converter hub engages in coupling plate of pump gear and torque converter is felt to slip in to proper position. Using depth gauge, measure converter installed distance. If the converter is correctly positioned, the distance between the faces of the threaded hole at torque converter and contact surface of the converter housing of transaxle is about 0.91" (23 mm). If the converter is not correctly positioned, the distance is about 0.43" (11 mm). (Scheme 201)
3. Position transmission support (3282). (Scheme 189) Use adjustment plate (3282/19) to position transmission support (3282) for transmission. Symbols on adjustment plate indicate necessary mounts and arrow points toward front of vehicle.
4. Place transmission onto transmission support. Secure transmission on transmission support (3282) using bolt (A). (Scheme 190)
5. Move transmission into position between lowered subframe and vehicle floor. Subframe is lowered approximately 150 mm at rear. Align transmission properly to engine.
6. Press lever/shift rod (2) at transmission completely toward rear (opposite direction of arrow) until park position is engage. (Scheme 202) Shift selector lever into "P" position, and carefully press up ball head of selector lever cable on lever/shift rod (2) using pair of pliers.
7. Place intermediate plate onto bushings. Ensure wires do not get pinched as transmission is docked at engine. Install connecting bolts for engine/transmission.
8. Install multi-function Transmission Range (TR) switch (F125). (Scheme 194) Slightly raise engine/transmission subframe at rear via hoist (V.A.G. 1383A). Install remaining connecting bolts for engine/transmission.
9. Turn NEW hex bolts (2) and (5) to 81 ft. lbs. (110 N.m) plus an additional 1/4 turn. (Scheme 198) 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-01v-with-28l__bolt-versions). Tighten hex nuts (3) and (4) to 30 ft. lbs. (40 N.m). (Scheme 198)
10. If any suspension components were disconnected from the subframe, install NEW guide link bolt to subframe. Hand tighten bolt.
11. Install coupling to stabilizer bar. Note change in coupling and in tightening torques. (Scheme 203)- see scheme 33.
12. Install transmission supports at left and right with transmission bearing. (Scheme 191)- (Scheme 193). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01v-with-28l__torque-specifications).
13. Remove bolt (A) after transmission is bolted to engine. (Scheme 190) Apply corrosion protection to contact surface between bolt (A) and oil pan.
14. Using special tool (V175), bolt torque converter and clutch disc (flywheel) together. (Scheme 184) Install starter. Install ATF lines to engine/transmission subframe. Install bracket for ATF line. Slightly raise engine/transmission subframe at rear via hoist (V.A.G. 1383A).
15. If equipped, bolt in engine speed (RPM) sensor (arrow B) at front left of transmission. (Scheme 182) Connect speedometer Vehicle Speed Sensor (VSS) connector. Bolt drive axle shafts to transmission flanges. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01v-with-28l__torque-specifications).
16. Bolt selector lever cable mounting bracket. Install selector lever cable, and if necessary, adjust selector lever. See «SERVICING - A/T (01V WITH 2.7L & 2.8L)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v).
17. Connect multi-function transmission range switch connector (1). (Scheme 183) Connect transmission wiring harness connector and secure using securing lever (2). Install heat shield/selector lever cable.
18. On all wheel drive vehicles, replace gaskets on drive shaft flanges (remove protective film and attach gasket to drive flanges). Install drive shaft to transaxle flange, aligning mating marks made during removal. Install and tighten NEW bolts. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01v-with-28l__torque-specifications). If equipped, bolt in heat shield for drive shaft on cover for Torsen differential (B). (Scheme 187)
19. Install bracket for noise insulation panel. Install noise insulation panel. Install front wheels. Remove engine support bridge (10-222A). Insert upper securing nuts for right and left front exhaust pipes. Install heated oxygen sensor in front exhaust pipe (left and right).
20. Install upper part of air filter housing (5). (Scheme 178) Install intake air duct (4) on intake manifold. Connect EVAP canister purge regulator valve (2). Install valve on bracket. Connect connector (3) at mass air flow sensor. Install air guide (1) between air filter housing and lock carrier.
21. Install covers above strut tower and air filter housing. Bolt in coolant expansion tank. Install engine cover. After connecting battery, enter anti-theft code for radio. See «BATTERY DISCONNECT PROCEDURES»(/audi/a6/c5-1997-2001/remont/automatic-trans/#removal-installation-at-01v-with-28l__battery-disconnect-procedures).
22. Final tighten any suspension component bolts and nuts with vehicle resting on ground (normal ride height).
23. Check selector lever cable adjustments and ATF in final drive. See «SERVICING - A/T (01V WITH 2.7L & 2.8L)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Check ATF levels and top off as necessary. Fully close power windows to stop. Activate all power window switches "up" for at least one second to activate automatic window raising/lowering. Set clock to correct time. Ensure all cable ties opened or cut during engine removal are reinstalled at same locations.
24. If necessary, perform wheel alignment. See «SPECIFICATIONS & PROCEDURES»(/audi/a6/c5-1997-2001/remont/wheel-alignment/#specifications-procedures) in SUSPENSION.

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 (2.8L ENGINE)

Scheme 203

BOLT VERSIONS

Three different 8 mm bolt versions are used on Audi suspensions. see scheme 35 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 204

See also:
• SERVICING - A/T (01V WITH 2.7L & 2.8L)
• SPECIFICATIONS & PROCEDURES
• Back-Up Battery For Telematic/Telephone Control Module
• Power Window Control Module
• TORQUE SPECIFICATIONS
• BATTERY DISCONNECT PROCEDURES
• BOLT VERSIONS
• Installation