Servicing - A/t (01l, Awd) Audi A6 C5

APPLICATION

TRANSAXLE APPLICATION

Scheme 103

Scheme 104

Scheme 105

Transaxle

Check fluid level at 15,000 mile intervals. Fluid is filled for life. No changing is required.

Center Differential & Final Drives

Check fluid level at 15,000 mile intervals. Fluid is filled for life. No changing is required.

CHECKING FLUID LEVELS

Note. ATF level is affected by ATF temperature. Checking ATF level at too low a temperature leads to overfilling. Checking ATF level at too high a temperature leads to under filling. Overfilling or under filling transaxle can lead to transaxle malfunction. ATF temperature can be read with Vehicle Diagnostic, Test and Information System or at display of VAG (1551) Scan Tool.

Note. VAS Scan Tool (5051) is required to check ATF level. Scan tool is used to measure ATF temperature. Follow aftermarket scan tool manufacturer instructions (if applicable) to check ATF temperature.

Scheme 106

Scheme 107

Scheme 108

Scheme 109

1. Ensure transmission is not in "emergency running" mode. Park vehicle on level surface. Set selector lever to "P" position. Run engine at idle. Turn A/C and heater off. ATF temperature must not be higher than 86° F (30° C). If necessary let transmission cool down.
2. Connect Vehicle Diagnostic, Test and Information System VAS 5051 with adapter cable VAS 5051/1, or connect VAG 1551 Scan Tool with adapter cable VAG 1551/3 to Data Link Connector (DLC) under knee bar under steering wheel according to manufacturer instructions. (Scheme 106)or (Scheme 107).
3. Start engine. On screen 1, enter "08" for function "Reading Measuring value block and confirm input by pressing "Q" button. (Scheme 108) On screen 2, enter "004" for display group "004", and confirm input by pressing "Q" button. Read ATF temperature in display field 1 on screen 3. For moderate climates, ATF temperature must be
4. Hang up container for ATF filling device (VAG 1924) as high as possible on vehicle. Raise and support vehicle. Place drip tray (VAG 1306) under transmission. When ATF temperature is 86° F (30° C), remove ATF plug (2). (Scheme 109) ATF level is correct when a small amount of ATF runs out while temperature is between 86° F (30° C) and 113° F (45° C). For warmer climates, ATF temperature must be between 86° F (30° C) and 122° F (50° C).
5. If no ATF drains when at specified temperature range, insert filling hook of filling device (VAG 1924) into ATF plug hole (2). (Scheme 109) Add ATF with filling device (arrow) until ATF flows from plug opening. (Scheme 110)
6. Always replace ATF plug gasket. Insert plug, and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications). Press "arrow" button on Scan Tool (VAG 1551) Enter "06" for function "End output" and confirm entry by pressing "Q".

Scheme 110

1. Drive vehicle a short distance to warm up gear oil to about 140°F (60°C). Position vehicle on level surface (4-post hoist or over pit). Turn engine off and let gear oil settle to bottom of case for 2 minutes.
2. Place drain pan under final drive. Remove fill plug (arrow) on side of final drive. (Scheme 111)
3. If necessary, remove heat shield and input shaft from transmission, to gain access to bolt. Gear oil level should be at lower edge of fill hole. Add appropriate fluid as required. See «RECOMMENDED FLUIDS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__recommended-fluids). Install fill plug with NEW sealing ring. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

Rear Final Drive

Position vehicle on level surface (4-post hoist or over pit). Place drain pan under rear final drive. Remove fill plug (arrow) to check gear oil. (Scheme 112) Oil level is correct when rear final drive is filled to lower edge of fill hole. Install plug and tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 111

Scheme 112

1. Position vehicle on level surface (4-post hoist or over pit). Remove right catalytic converter from rear exhaust system and press rear of catalytic converter toward right. Place drain pan under center differential. Remove fill plug (B) and check gear oil level. (Scheme 113)
2. Gear oil level should be at lower edge of fill hole. Add appropriate fluid as required. See «RECOMMENDED FLUIDS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__recommended-fluids). Install NEW fill plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications). Install right catalytic converter on rear exhaust system.

RECOMMENDED FLUIDS

Note. Transfer case may also be known as a distributor gear.

RECOMMENDED FLUIDS

FLUID CAPACITIES

TRANSAXLE FLUID CAPACITIES

FINAL DRIVE & TRANSFER CASE FLUID CAPACITIES

Note. Transfer case may also be known as a distributor gear.

DRAINING & REFILLING

01L Transaxle

1. Turn engine off. Hang up container of ATF filling device (VAG 1924) on vehicle as high as possible. Raise and support vehicle. Place drain pan under transaxle. Remove drain plug (1). (Scheme 109)
2. Drain ATF. Install NEW seal on NEW drain plug. Install NEW drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).
3. Remove ATF inspection plug (2). (Scheme 109) Hang filling hook (arrow) of Filling System (VAG 1924) into inspection hole (2). (Scheme 110) Fill until ATF runs out of inspection hole.
4. Shift selector lever into "P" position. Start engine. Press and hold brake pedal. Shift through all selector lever positions with vehicle stationary, leaving selector lever in each position for about 10 seconds, and ending in "P" position. Check fluid level. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION. Add ATF as necessary.
5. Replace seal on ATF inspection plug. Tighten inspection plug to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

ATF LINES & ATF COOLER FLUSHING

Scheme 113

1. Remove bolts (2, 3 and 5). (Scheme 114) Remove ATF lines (6 and 7) from transmission.
2. Attach hose to ATF line (6) and secure with hose clamp. Insert other end into suitable container. Apply air pressure several times into ATF line (7). Position hose from ATF line (6) to ATF line (7) and repeat. Tighten ATF lines to specification. (Scheme 114)
3. Check ATF level and add ATF as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION.

IGNITION KEY REMOVAL LOCK

Turn ignition key to driving position (ignition on), and depress brake pedal and hold. Shifting from "P" position must be possible without snagging when button on selector lever is depressed. Key must not be able to be removed unless selector lever is in "P" position. Move selector lever to "P" position. Ignition key must be able to be turned to removing position without binding. Remove ignition key. Selector lever must not be able to move from "P" position with depressed button in handle and depressed brake pedal.

SHIFT MECHANISM

Note. Ensure motor CANNOT be started in driving ranges "2", "3", "4", "D" and "R".

Note. During vehicle speeds above 3 MPH (5 km/h) and shifting into "N", shift lock solenoid must not engage and lock selector lever. Selector lever can be shifted into a driving range. When driving slower than 1.2 MPH (2 km/h) and shifting into "N", shift lock solenoid must only engage after approximately one second. Selector lever can only be shifted out of "N" when brake pedal is depressed.

1. Place selector lever in "P" position and turn ignition on. With brake pedal depressed, selector lever should be locked and not able to be moved from "P" position with depressed button in lever. Shift lock solenoid switch locks selector lever. With brake pedal not depressed, shift lock solenoid releases selector lever. Selecting driving range must be possible without binding or snagging with button in handle depressed. Move selector lever slowly from "P" to "R, N, D, 4, 3, 2" and check whether driving range position in display of instrument cluster are same.
2. Place selector lever in "N" position and turn ignition on. With brake pedal not depressed, selector lever should be locked and not able to be moved from "N" position with depressed button in lever. Shift lock solenoid switch should lock selector lever. With brake pedal depressed, shift lock solenoid should release selector lever. Selecting a driving range should be possible without binding or snagging with button in handle depressed.
3. Place selector lever in "D" position, turn ignition on, and turn light switch on. Move selector lever out of driving range "D" position, and into Tiptronic gate. Illumination of "D" symbol on cover of shift mechanism should dim and "+" and "-" symbols should illuminate. Start engine and idle. Engage parking brake and depress brake pedal. Display of selector lever position in instrument cluster should change during shifting into Tiptronic gate from "PRND432" to "54321".

ON-VEHICLE REPAIRS

Note. Various components may be serviced without transaxle removal. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION .

DRIVE SHAFT

Note. Do not bend driveshaft, maximum permissible bending angle is 25 degrees. Otherwise, universal joint may be damaged. Only store and move driveshaft fully extended.

Note. No repair work can be performed on driveshaft, with exception of removing and installing and adjustment work. If driveshaft is only detached at transmission or from rear final drive, it must be tied up or supported at constant velocity joints.

Note. After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and bolt head may not be reinstalled.

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

1. Remove crossmember below exhaust system, if installed. Remove rear part of exhaust system behind clamping sleeve(s). Remove heat shields for driveshaft from body (arrows). (Scheme 115)
2. Attach 3213 alignment fixture with 3139/3 spacing devices and tighten plastic nuts. (Scheme 116)
3. Remove securing nuts (arrows) for intermediate bearing. (Scheme 117) Do not remove stud bolt. Align intermediate bearing of drive shaft so that distance ("A", left side) is equal to distance ("A", right side). (Scheme 118)
4. Determine adjustment shims necessary. See «ADJUSTMENT SHIM THICKNESS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd). Loosen plastic nuts of installation device (arrows "A") far enough so that bracket for intermediate bearing (1) has clearance (a) to stud (2). (Scheme 119) Insert determined adjustment shim (1) and swing bracket for intermediate bearing (2) to other side. (Scheme 120) Place second adjustment shim (4) onto stud (3). Tighten both plastic nuts of installation device (arrow "A") again.
5. To center drive shaft lengthwise, slide drive shaft with alignment fixture toward rear to stop. Mark location of intermediate bearing assembly (arrow "A"). (Scheme 121) Slide drive shaft with alignment fixture toward front to stop. Mark location of intermediate bearing to assembly (arrow "B"). Center drive shaft (arrow "C"). Intermediate bearing must be centered between markings (A and B). Tighten intermediate bearing in centered position to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).
6. Remove mounting fixture. To install, reverse removal procedure. Install exhaust system free of stress. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

ADJUSTMENT SHIM THICKNESS

LOCKING CABLE

Note. Locking cable must always be adjusted in installation position.

Scheme 119

1. Remove selector lever handle. See «SELECTOR LEVER HANDLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
2. Shift selector lever to "P" position. Loosen bolt (6). (Scheme 122) Clamp (3) must be movable by hand in direction of arrow (5).
3. Move steering column to lowest position. Insert gage (3352 A) between lever for lock cable and lock cable eye. Pull lock cable in direction of arrow (5), and tighten bolt (6) with 89 INCH lbs (10 N.m). Remove adjustment gage (4). Check ignition key removal lock after every adjustment of lock cable. See «IGNITION KEY REMOVAL LOCK»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__ignition-key-removal-lock) under INSPECTION.
4. Reinstall all components. See «SELECTOR LEVER HANDLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd). Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

Scheme 120

Scheme 121

Scheme 122

1. Shift selector lever to "P" position. Raise and support vehicle. Remove heat shield at selector lever cable. Pry off selector lever cable using lever (80-200) from lever and selector shaft (arrow). (Scheme 123)
2. Move selector lever from "P" to "2" position. Shift mechanism and selector lever cable must move easily. If necessary, replace selector lever cable or repair shift mechanism. Shift selector lever to "P" position. When moving shift lever and selector shaft to "P" position, parking lock must engage. Both front wheels must not turn in one direction. If selector lever cable is not able to attach selector lever cable to selector shaft, adjust selector lever cable.
3. Remove selector lever cable from lever/selector shaft. Shift selector lever to "P" position. When selector lever and selector shaft are moved to "P" position, parking lock must be engaged and front wheels must not turn in one direction. Loosen bracket nuts (arrows) on transmission. (Scheme 124)
4. Attach selector lever cable on lever/selector shaft. Straighten selector lever cable at bracket (B). (Scheme 125) Install heat shield (A). Tighten bolts (2 and 3) at bracket. Check shift mechanism. See «SHIFT MECHANISM»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__shift-mechanism) under INSPECTION. Install all components. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

REMOVAL & INSTALLATION

Scheme 123

Scheme 124

1. Remove radio. See «RADIO (CHORUS/SYMPHONY)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__radio-chorussymphony) or «RADIO (CONCERT)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__radio-concert).
2. Remove center trim section of instrument panel. See «A/C CONTROL HEAD & RADIO TRIM SECTION»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
3. After removing the two lower screws (A), the clips located in front of the fastening straps on A/C Control Head should be tipped forward and removed using a screwdriver. (Scheme 126) Remove A/C control head (B).
4. Press back harness connector release catches (F) and disconnect harness connectors (A) through (D). (Scheme 127) Press back harness connector releases catches (G) and disconnect harness connector (E) for rear window heating.
5. To install, reverse removal procedure.

Note. The display panel on A/C Control Head changed from C° to F° and back by pressing and holding the "Recirculate air" button, then pressing the temperature "+" button for the driver's side.

Scheme 125

1. Remove radio. See «RADIO (CHORUS/SYMPHONY)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__radio-chorussymphony) or «RADIO (CONCERT)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__radio-concert).
2. Remove bolts (A). (Scheme 128) Lift A/C control head (B) up slightly and remove in direction of arrow. In these vehicles, A/C control head is held underneath by latching tabs (C) and (D).
3. Press back harness connector release catches (F) and disconnect harness connectors (A) through (D). (Scheme 127) Press back harness connector releases catches (G) and disconnect harness connector (E) for rear window heating.
4. To install, reverse removal procedure.

(Scheme 129)for procedures.

Scheme 126

For procedures (Scheme 130)and (Scheme 131).

Scheme 127

Scheme 128

1. Remove rear section of center console. See «CENTER CONSOLE, REAR SECTION»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
2. Only for "Chorus and Concert" radios, open front ashtray. Unclip trim section (2) at fasteners (3). There are 6 clips. (Scheme 132)
3. Remove radio. See «RADIO (CHORUS/SYMPHONY)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__radio-chorussymphony) or «RADIO (CONCERT)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__radio-concert). For "plus" radio navigation system, remove operating electronics and telephone control module.
4. Remove front ashtray for vehicles with "Symphony" radio systems and "radio-navigation plus".
5. Remove A/C control panel. See «A/C CONTROL PANEL»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
6. Remove front ashtray for vehicles with "Chorus and Concert" radio systems. See «FRONT ASH TRAY (CHORUS & CONCERT RADIOS)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd). Remove front ashtray for vehicles with "Symphony" radio systems and "radio-navigation plus".
7. Unclip switch-panel trim (5) at fasteners (4). (Scheme 132) Remove bolts (6). Pry off trim cap (7). Remove nut (8).
8. Pull center console over securing pin on driver's side. Pull out center console to rear.
9. Installation is reverse of removal procedure. When inserting center console, install retainer (9) in fastener. (Scheme 132)

Scheme 129

Scheme 130

Scheme 131

1. Remove rear air vent and rear air-duct connecting piece from center console, rear section.
2. If necessary, remove center armrest. (Scheme 133)
3. Remove nut (3). Remove mat lining (2) upward. Remove bolt (8). (Scheme 135)
4. Twist off shifter knob (4). Unclip center console insert (6) upward. Remove bolts (7). (Scheme 135)
5. Remove parking brake pry trim. (Scheme 134)
6. Raise rear section of center console (1) at front and detach connector for mirror adjustment switch (9). (Scheme 134)
7. Pull parking brake pry up as far as it will go. Unfasten trim (10) from retainer (11) on parking brake pry. (Scheme 134) Raise rear section of center console (1) over stud (12) and pull center console to rear. Lift out rear section of center console (1) forward over parking brake pry.
8. To install, reverse removal procedure. Install trim (10) at retainer (11) on parking brake pry. (Scheme 134) Make sure air ducts are properly installed when installing rear section of center console (1).

Scheme 132

Scheme 133

1. Unclip trim section. (Scheme 129)
2. Unclip center console insert (2). (Scheme 136) Open front ashtray. Remove bolts (1).
3. Using a screwdriver (2), pull out retainers (1) on left and right in direction of arrow. (Scheme 137) Carefully pull A/C control head out slightly toward the rear, and pull out ashtray downward and toward the rear. Pull ashtray toward the rear and disconnect wires for cigarette lighter and ashtray light.
4. When installing, make sure that guides engage in center console on left and right sides.

Scheme 134

Scheme 135

Scheme 136

Scheme 137

1. On vehicles with light-alloy wheels, use pulling hook, from in-vehicle tool, to pull off center cap. On all other vehicles remove hubcap. Ensure vehicle is standing on its wheels, and loosen hex bolt for outer joint of right side axle shaft a maximum of 90 degrees.
2. Raise and support vehicle. Remove right front wheel. Remove heat shield for right drive axle.
3. Remove right drive axle and wire aside. See «AXLE SHAFTS - FRONT & REAR»(/audi/a6/c5-1997-2001/remont/axle-shafts/#axle-shafts-front-rear) in AXLE SHAFTS. Remove front left and front right exhaust pipes with de-coupling element.
4. Support engine and transmission assembly with a jack. Remove right transaxle support. (Scheme 138)
5. Prevent drive flange from turning using mandrel and remove center bolt from right drive flange (arrow). (Scheme 139) Place oil pan underneath transaxle to catch spilled fluid. Pull out right drive flange.
6. Loosen bolts for differential cover in reverse order of tightening sequence shown in illustration (start at 12, finish at 1), and remove differential cover. (Scheme 140)
7. Replace "O" ring (arrow). (Scheme 141)
8. To install, reverse removal procedure. Tighten differential cover bolts in sequence in 2 stages. For first stage, tighten bolts (1, 2 and 3) by hand. (Scheme 140) For second stage, tighten bolts (1 through 12) to 17 ft. lbs. (23 N.m). Check final drive fluid level and correct as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION.
9. Install right axle shaft. See «AXLE SHAFTS - FRONT & REAR»(/audi/a6/c5-1997-2001/remont/axle-shafts/#axle-shafts-front-rear) in AXLE SHAFTS. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

Note. Do not bend driveshaft, maximum permissible bending angle is 25 degrees. Otherwise universal joint may be damaged. Only store and move driveshaft fully extended.

Note. No repair work can be performed on driveshaft with exception of removing and installing and adjustment work. If driveshaft is only detached at transmission or from rear final drive, it must be tied up or supported at constant velocity joints.

Note. After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and bolt head may not be reinstalled.

Scheme 138

Scheme 139

Scheme 140

1. Remove crossmember below exhaust system if installed. Remove rear part of exhaust system behind clamping sleeve(s). Remove heat shields for driveshaft from body (arrows). (Scheme 115)
2. Remove heat shield for drive shaft from cover for Torsen differential (arrows). (Scheme 142)
3. Check whether there is factory marking (colored marking) on drive shaft and at flange/drive shaft at rear final drive. If not, mark location of drive shaft flange (arrow "A") to rear final drive (arrow "B") with color. (Scheme 143)
4. Remove upper three mounting bolts for each drive shaft constant velocity joint. Attach alignment fixture (3139) with spacing devices (3139/3) and tighten plastic nuts. (Scheme 116) Remove remaining three mounting bolts at front and rear constant velocity joints. Remove securing nuts (arrows) for intermediate bearing and remove drive shaft with alignment fixture. (Scheme 117)
5. To install, reverse removal procedure. For proper balance, drive shaft flanges (arrow A) and rear final drive (arrow B) must be installed so that factory color markings or markings which were made afterward are aligned. (Scheme 143) If new drive shaft is installed and factory color markings on rear final drive flange is no longer visible, check radial run out at flange/drive shaft. Mark largest radial run-out on outer edge of rear final drive flange with colored marking (equivalent to largest distance from turning axis). Align color marking on drive shaft to new marking on final drive flange. (Scheme 144)
6. Degrease drive flange. Replace gaskets on drive flanges (remove protective film and attach gasket to drive flanges).
7. After disconnecting driveshaft from rear final drive, an additional balance washer (thick washer) that may be located between shim and bolt head may not be reinstalled. After removing drive shaft, always remove any remaining locking fluid from thread bores in transmission drive flanges and rear final drive. Otherwise there is a possibility that new bolts may get jammed when installed and shear when removed. Cleaning can be performed with a thread cutter. Replace drive shaft bolts (self-locking).
8. Adjust drive shaft after installing. See «DRIVE SHAFT»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__drive-shaft) under ADJUSTMENTS. Install exhaust system free of stress. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

LEFT DRIVE FLANGE

Scheme 141

Scheme 142

1. On vehicles with light-alloy wheels, use pulling hook, from in-vehicle tool, to pull off center cap. On all other vehicles remove hubcap. Ensure vehicle is standing on its wheels, and loosen hex bolt for outer joint of left side axle shaft a maximum of 90 degrees.
2. Remove fill plug (arrow) on side of final drive. (Scheme 111) Remove about 1/2 quart of gear oil from final drive using Suction Device (VAG 1358A).
3. Remove left front wheel. Remove heat shield for left drive axle. Remove left drive axle. See «AXLE SHAFTS - FRONT & REAR»(/audi/a6/c5-1997-2001/remont/axle-shafts/#axle-shafts-front-rear) in AXLE SHAFTS.
4. Remove vehicle speed sensor. (Scheme 145) Remove bracket for connector from drive flange bracket.
5. Remove bracket for left drive flange (arrows). (Scheme 146) Pull out left drive flange.
6. To install flange, reverse removal procedure. Replace "O" ring (arrow B) for left drive flange bracket. (Scheme 147)
7. Check end of left drive flange (arrow) for burrs and sharp edges and deburr if necessary. (Scheme 148)
8. Install left drive flange in transaxle. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).
9. Install left drive axle shaft. See «AXLE SHAFTS - FRONT & REAR»(/audi/a6/c5-1997-2001/remont/axle-shafts/#axle-shafts-front-rear) in AXLE SHAFTS.
10. Install vehicle speedometer vehicle speed sensor. (Scheme 145)
11. Check final drive fluid level and correct as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION.

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

1. Remove left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__left-drive-flange).
2. Remove circlip (arrow "A") from ball bearing. (Scheme 149)
3. Set mounting bracket onto thrust plates (VW 401 and VW402). (Scheme 150) Hold drive flange with one hand to keep it from falling out toward bottom. Pull off magnetic rig for speedometer vehicle speed sensor from drive flange and remove mounting bracket.
4. Using thrust plates (VW 401 and VW 402) and punch (VW 407), press ball bearing out of mounting bracket. (Scheme 151)
5. Set drive gear for speedometer vehicle speed sensor (arrow) onto drive flange, and check installation position, if necessary. (Scheme 152) Followers at magnetic ring must engage in grooves of drive flange. If necessary, coat contact surface with petroleum jelly to affix magnetic ring in installation position.
6. Using thrust plates (VW 401 and 402), thrust disc (VW 412) and driving sleeve (32-109), press NEW ball bearing into mounting bracket. (Scheme 153)
7. Using thrust plate (VW 401 and VW 412), tube (VW 415) and driving sleeve (32-109), press mounting bracket with ball bearing onto left drive flange. (Scheme 154)
8. Insert circlip (arrow "A"). (Scheme 149)
9. Install left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__left-drive-flange).
10. Check and top off transmission fluid in rear final drive. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION.

Scheme 149

1. Remove left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__left-drive-flange).
2. Remove circlip (arrow "A") from ball bearing. (Scheme 149) Set mounting bracket onto thrust plates (VW 401 and VW402). (Scheme 150) Hold drive flange with one hand to keep it from falling out toward bottom. Press out drive flange from mounting bracket for left drive flange using thrust disc (VW 412). Pry out sealing ring from left drive flange mounting bracket using extractor lever (VW681).
3. To install, use assembly mandrel (3384) to push in "O" ring to pressure piece stop. (Scheme 155)
4. Set drive gear for speedometer vehicle speed sensor (arrow) onto drive flange, and check installation position, if necessary. (Scheme 152) Followers at magnetic ring must engage in grooves of drive flange. If necessary, coat contact surface with petroleum jelly to affix magnetic ring in installation position.
5. Set drive flange onto thrust plate (VW 401). Press on mounting bracket with thrust plate (VW 412), tube (VW 415) and driving sleeve (32-109). (Scheme 154)
6. Press mounting bracket with ball bearing onto left drive flange. Insert circlip (arrow "A"). (Scheme 149)
7. Install left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__left-drive-flange).
8. Check and top off ATF in rear final drive. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

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.

Scheme 150

1. Shift selector lever into "2" position. Disconnect battery ground connection.
2. Remove selector lever handle. See «SELECTOR LEVER HANDLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
3. Remove center console, front section. See «CENTER CONSOLE, FRONT SECTION»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
4. Remove steering wheel. Turn ignition key to driving position (ignition on).
5. Move selector lever to "P" position. Lift retaining clip (1) from interlock lever and pull locking cable out from ignition switch. (Scheme 122) Unlock holding tabs from selector lever cover mounting bracket with screwdriver. Disconnect transmission ranges and Tiptronic harness connectors. Remove selector lever cover.
6. Unclip lock cable from securing spring (A) at mounting bracket, while slightly lifting securing spring. (Scheme 156) Free lock cable from cable tie (2) and remove. (Scheme 122)
7. To install, route lock cable without kinks. Turn ignition key to driving position (ignition on). Insert lock cable in ignition/starter switch. Check locking device (1). for proper engagement. (Scheme 122) Attach lock cable with cable tie (2) to airbag sensor. Turn ignition/starter key to lock position. (ignition off). Sift selector lever to "P" position. Slip in lock cable in securing spring (A) of mounting bracket. (Scheme 156) Insert lock cable bracket (3) in shift mechanism and lock cable eye in lever for lock cable. (Scheme 122) Adjust lock cable as necessary. See «LOCKING CABLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__locking-cable) under ADJUSTMENTS.

To remove securing spring, slightly lift spring at top (arrow "B"). Remove locking cable from shift mechanism. (Scheme 156) To install securing spring, insert spring (arrow "B") from top and hook in at retaining clip (arrow "C"). Align spring so that it is seated evenly in groove (arrow "A"). Slightly lift spring at top (arrow "B") and insert locking cable into shift mechanism. (Scheme 156)

Scheme 151

1. On vehicles with light-alloy wheels, use pulling hook, from in-vehicle tool, to pull off center cap. On all other vehicles remove hubcap. Ensure vehicle is standing on its wheels, and loosen hex bolt for outer joint of right side axle shaft a maximum of 90 degrees.
2. Remove right front wheel. Remove heat shield for right drive axle. Remove right drive axle. See «AXLE SHAFTS - FRONT & REAR»(/audi/a6/c5-1997-2001/remont/axle-shafts/#axle-shafts-front-rear) in AXLE SHAFTS.
3. Prevent drive flange from turning using mandrel and remove center bolt from right drive flange (arrow). (Scheme 139)
4. Place drain pan underneath transaxle to catch spilled fluid. Pull out right drive flange. Remove sealing ring for right drive flange with extractor lever (VW 681). (Scheme 157)
5. Drive sealing ring for right drive flange in to stop using pressure piece (3382). (Scheme 158) Sealing ring must sit equally deep in housing at circumference. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).
6. Install right drive axle. See «AXLE SHAFTS - FRONT & REAR»(/audi/a6/c5-1997-2001/remont/axle-shafts/#axle-shafts-front-rear) in AXLE SHAFTS. Check final drive fluid level and correct as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION.

Scheme 152

Scheme 153

Scheme 154

Scheme 155

1. To remove cable, shift selector lever into "P" position. Raise and support vehicle. Remove front exhaust system with catalytic converter. Remove heat shield (A) above driveshaft. (Scheme 159)
2. Remove heat shield (B) for drive shaft from cover for Torsen differential (arrows). Place mating marks on drive shaft and transaxle drive flange and unbolt driveshaft from transaxle and support to side. See «DRIVE SHAFT»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
3. Remove rubber sleeve of selector lever cable and push back. Remove cover from mounting bracket (arrows). (Scheme 160)
4. Press together ends of spring clip (B) and remove. (Scheme 161) Pull out lock plate (A) for selector lever cable at mounting bracket downward. Remove selector lever cable from selector lever.
5. Remove bolts (1, 3 and 4). (Scheme 125) Remove heat shield (A) for selector lever cable.
6. Pry off selector lever cable with special tool (80-200) from lever and selector shaft (arrow). (Scheme 123)
7. Remove bracket (B) from transmission. (Scheme 125) Remove nuts (5) and remove bracket (B) from selector lever cable. Pull out selector lever cable from mounting bracket without kinking cable.
8. To install cable, move selector lever, lever and selector shaft in "P" position. Ensure parking lock engages. Slightly lubricate eye and socket before installing. Do not bend or kink selector lever cable.
9. Guide selector lever cable into mounting bracket. Attach selector lever cable on selector lever. Press ends of spring clamp (B) together and secure selector lever cable. (Scheme 161) Install lock plate (A) for selector lever cable at mounting bracket. Ensure angled ends of lock plate point toward end of selector lever cable.
10. Attach selector lever cable hand-tight to bracket (B). (Scheme 125) Attach selector lever cable to lever and selector shaft. straighten selector lever cable in bracket (B).
11. Install bracket to transmission (1) and selector lever cable to bracket (2). (Scheme 162) Counter hold hex head (3), and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).
12. Install heat shield (A). (Scheme 125)
13. Install nuts (arrows). (Scheme 160) Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications). Check selector lever cable, and adjust as necessary. See «SELECTOR LEVER CABLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd) under ADJUSTMENTS.
14. Reconnect drive shaft to transmission flange. See «DRIVE SHAFT»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
15. Reconnect front and rear exhaust systems, free of stress.

Scheme 156

1. Move selector lever to position "3". Push sleeve (1) down to stop. (Scheme 163) Pull button (2) to stop (dimension "a") out of selector lever handle (3) and pull handle upward. Dimension "a" = 3 mm.
2. To install, Move selector lever to position "3". Carefully pull out knob (2) to dimension "a" out of selector lever handle (3). (Scheme 163) At the same time attach handle (3) with knob (2) in driving direction on selector lever to stop. Turn handle (3) until knob (2) is pointing to driver. This causes handle to engage into grove of selector lever.
3. Attach handle (3) completely to selector lever. (Scheme 163) It must engage into circular grove of selector lever. Push in knob (2) in handle of selector lever (3). Pull up sleeve (1) until it engages in handle (3).

RADIO (CHORUS/SYMPHONY)

Scheme 157

Scheme 158

Scheme 159

1. Insert radio removal tools (T10057) into release slots (arrows) as shown until they engage. (Scheme 164)and (Scheme 165). Pull radio out of instrument panel using grip rings on release tool. Unlock and disconnect electrical harness connections.
2. Remove radio removal tools before installing radio. Press locking latch (arrow) and remove radio release tools toward front. (Scheme 166)
3. Connect electrical connections to radio. Slide radio evenly into instrument panel, until it engages in assembly frame.

RADIO (CONCERT)

Scheme 160

Scheme 161

1. Insert removal tools (3344) into front of radio. (Scheme 167)and (Scheme 168). Remove radio from instrument panel. Disconnect electrical connections and antenna wire.
2. Remove radio removal tools before installing radio. Connect electrical connections. Carefully slide radio into instrument panel and engage in mounting frame. Activate anti-theft coding radio operating instructions.

Scheme 162

Scheme 163

1. Raise and support vehicle. Support engine/transaxle assembly with jack. Remove left transmission support. (Scheme 138)
2. Remove multifunction TR switch. See «TRANSAXLE RANGE SWITCH»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd). Drive spring pin (1) out of transaxle selector lever (2) in driving direction (arrow) until transaxle selector lever can be removed from selector shaft. (Scheme 169) Using a screwdriver, pierce sealing ring and pry out.
3. To install, lightly lubricate outside of seal and sealing lip with petroleum jelly or equivalent. Open side of seal faces transaxle. Attach NEW seal on installation tool (3454) and push to stop using lever (A). (Scheme 170)
4. Drive back spring pin in transmission selector lever. Install transmission selector lever and drive spring pin through selector shaft. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

Transaxle fluid temperature sensor is integrated in transaxle wiring harness. For temperature sensor replacement, see TRANSAXLE WIRING HARNESS .

Scheme 164

1. Place drain pan under transaxle. Remove drain plug (1). (Scheme 109) Unscrew oil pan bolts in diagonal sequence and remove oil pan. Clean all 4 magnets in recesses of oil pan. Ensure magnets are seated correctly in pan upon installation.
2. Unscrew 2 bolts on ATF screen. (Scheme 171) Pull ATF screen off of valve body. To install ATF screen, lubricate seal on intake neck of ATF screen with petroleum jelly or equivalent. Carefully push intake neck of ATF screen into opening of valve body. Install bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).
3. Install NEW oil pan gasket and oil pan. Install oil pan bolts and tighten in diagonal sequence to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).
4. Install drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications). Fill transaxle with ATF. See «DRAINING & REFILLING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__draining-refilling) under LUBRICATION.

Note. Transaxle range switch may also be referred to as multifunction TR switch.

1. Raise and support vehicle. Support engine/transaxle assembly with jack. Remove left transmission support. (Scheme 138)
2. Remove multi-function Transmission Range (TR) switch (F125) at transmission and pull of selector shaft.
3. To install, center multifunction TR switch on selector shaft. Flat section in splines in switch (3) must coincide with flat section of selector shaft (1). Turn switch until centering opening (4) at switch housing fits into centering dowel (2) at transmission housing. (Scheme 172) Install multi-function TR switch (F125) to transmission.
4. Install left transmission support. (Scheme 138) Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

Scheme 165

Scheme 166

1. Remove valve body. See «VALVE BODY ASSEMBLY»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd). Disconnect harness connector (A) on back side of valve body. see scheme 71 Remove sensor (B) for transmission RPM (G182) at valve body.
2. To install, use spacers (2) and install sensor for transmission RPM (1). Install harness connector on sensor. Install valve body. See «VALVE BODY ASSEMBLY»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
3. Replace or refill ATF after repair. See «DRAINING & REFILLING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__draining-refilling) under LUBRICATION.

Scheme 167

Scheme 168

1. Remove valve body. See «VALVE BODY ASSEMBLY»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
2. Using a small screwdriver, pry out retaining tabs on solenoid valve connectors, and pull off connectors. see scheme 73 Remove harness from side clips of valve body. Remove sensor for transmission RPM (A) on back side of valve body. see scheme 71 Carefully bend out both clips (arrows) with pair of pliers.
3. To install, reverse removal procedure. When installing wiring harness, plug connectors onto respective solenoid valves. Clip wiring harness into retaining clips. If not installed correctly, wiring harness can be trapped when valve body is installed.
4. Replace damaged clamps Install valve body. Fill with ATF and check ATF level. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION.

Scheme 169

Scheme 170

1. Remove oil pan and ATF screen. See «TRANSAXLE OIL PAN & ATF SCREEN»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
2. Remove circlip (arrow) for harness connector. see scheme 74 Remove harness connector by pressing toward inside.
3. Valve body bolts have different lengths. Remove bolts (arrows). see scheme 75 Carefully remove valve body from transmission. Do not place remove valve body on back side, on sender for transmission input RPM.
4. To install, lightly lubricate "O" ring for harness connector with petroleum jelly or equivalent. Install harness connector in transmission. Tabs on connection side must be horizontal. Flattened side of connector must be positioned parallel to oil pan sealing face. Fasten and route harness at valve body. See «TRANSAXLE WIRING HARNESS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd).
5. Attach valve body without force, and insert dowel of indent (1) into groove of selector lever (2). see scheme 76
6. Insert harness connector circlip (arrow). see scheme 74
7. Install valve body bolts (arrows), and hand tighten. see scheme 75 Bolts have different lengths. Ensure correct bolts are used during installation.
8. Tighten valve body bolts and remaining nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

Scheme 171

Remove harness connector for speedometer vehicle speed sensor (G22). Press down clamp for sensor, turn and remove. To install, replace "O" rings (arrows) for sensor. see scheme 78 Insert sensor with petroleum jelly. Snap clamp in place.

Scheme 172

1. Remove left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__left-drive-flange).
2. Remove circlip (arrow "A") from ball bearing. (Scheme 149)
3. Using thrust disc (VW 412) and thrust plates (VW 401 and VW 402), press out drive flange from mounting bracket for left drive flange. (Scheme 150) Hold drive flange with one hand to keep from falling out toward bottom. Pull off drive gear from speedometer vehicle speed sensor from drive flange and remove from mounting bracket.
4. To install, set drive gear for speedometer vehicle speed sensor (arrow) onto drive flange, and check installation position, if necessary. (Scheme 152) Followers at magnetic ring must engage in grooves of drive flange. If necessary, coat contact surface with petroleum jelly to affix magnetic ring in installation position.
5. Set drive flange onto thrust plate (VW 401). Press on mounting bracket with thrust plate (VW 412), tube (VW 415) and driving sleeve (32-109). (Scheme 154)
6. Press mounting bracket with ball bearing onto left drive flange. Insert circlip (arrow "A"). (Scheme 149)
7. Install left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__left-drive-flange). Check and top off ATF in rear final drive. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__checking-fluid-levels) under LUBRICATION. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01l-awd__torque-specifications).

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• AXLE SHAFTS - FRONT & REAR
• TORQUE SPECIFICATIONS
• RECOMMENDED FLUIDS
• CHECKING FLUID LEVELS
• ADJUSTMENTS
• REMOVAL & INSTALLATION
• IGNITION KEY REMOVAL LOCK
• SHIFT MECHANISM
• RADIO (CHORUS/SYMPHONY)
• RADIO (CONCERT)
• DRIVE SHAFT
• LEFT DRIVE FLANGE
• LOCKING CABLE
• DRAINING & REFILLING