Servicing - A/t (01v) Audi A6 C5

APPLICATION

TRANSAXLE APPLICATION

Scheme 35

Scheme 36

Transaxle

Check fluid level at 20,000 mile intervals. Fluid is filled for life. No changing is required.

Center Differential & Final Drives

Check fluid level at 20,000 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.

Note. When ATF level is checked, the seal on the level plug must always be replaced. VAG Scan Tool (1551) and Diagnosis Cable (1551/3B) are 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.

01V Transaxle

Note. Some models are equipped with auxiliary ATF cooler. An additional test procedure is required for these vehicles when checking fluid level. Test procedure is performed in step 6 .

Note. In the following procedures, numbers in parenthesis are shown in illustrations.

Scheme 37

1. Ensure transaxle is not in emergency running mode. Ensure all electrical components are switched off. Ensure transaxle ATF temperature is not above about 86°F (30°C). Park vehicle on level surface. Set selector lever to Park. Apply parking brake. Remove noise insulation tray (if equipped). (Scheme 37) Connect ATF reservoir from VAG 1924 filling system to vehicle.
2. Connect Scan Tool VAS (1551) to Data Link Connector (DLC), located under left side of instrument panel. Start engine. Press 0 and 8 to select "Read Measuring Value Block" function 08. Press Q to confirm input. Press 0, 0 and 4 to input display group number 004. Press Q to confirm input. ATF temperature is indicated on scan tool display.
3. Raise and support vehicle. Place drain pan under transaxle. Allow temperature to reach 95-113°F (35-45°C), or in hot climates, 122°F (50°C). Remove ATF inspection plug (2) from oil pan. (Scheme 38) A small amount of ATF should drip from inspection hole with engine running. If fluid level (3) is okay, install NEW seal on inspection plug and tighten to 59 ft. lbs. (80 N.m). Turn engine off.
4. If additional fluid is required, using ATF Filling System (VAG 1924), carefully insert fill hose through an opening in the deflector cap (4). (Scheme 38) Ensure deflector cap is not pushed upward out of position. Fill until ATF runs out of inspection hole. Use VW ATF fluid only. DO NOT use any lubricant additives.
5. Install NEW seal on inspection plug and tighten to 59 ft. lbs. (80 N.m). Turn engine off. Press right arrow key on scan tool. Press 0 and 6 to select "End Output" function 06. Press Q to confirm input.
6. On models with auxiliary ATF cooler, let engine run until ATF temperature reaches at least 185°F (85°C). It may be necessary to test drive vehicle to increase ATF temperature. The thermostat at inlet to auxiliary ATF cooler does not open until temperature reaches 176°F (80°C). ATF will then flow into cooler. Ensure ATF is at test temperature. Turn engine off and let ATF cool down until temperature is less than 95°F (35°C). Check ATF level and add fluid as needed as described in steps 3 and 4.

Front Final Drive

1. Drive vehicle a short distance to warm up gear oil to 140° F (60° C). Position vehicle on level surface (4-post hoist or over pit). Turn engine off and let gear oil settle for 5 minutes.
2. Place drain pan under final drive. Remove fill plug (arrow) on side of final drive. (Scheme 39) 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-01v__recommended-fluids). Install fill plug and tighten to 22 ft. lbs. (30 N.m).
3. If gear oil needs to be replenished following final drive repair, fill front final drive slowly and evenly over a period of at least 5 minutes until gear oil drips out over lower edge of fill hole. A filling time of at least 5 minutes is necessary to allow gear oil time to settle evenly in differential and cavities.

Scheme 38

Center Differential

Note. Some models are equipped with All Wheel Drive (AWD), which is equipped with center differential.

1. Position vehicle on level surface (4-post hoist or over pit). If necessary, loosen or remove relevant exhaust system components to gain access to oil fill plug. Place drain pan under center differential. Remove fill plug (B) and check gear oil level. (Scheme 40)
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-01v__recommended-fluids). Install NEW fill plug and tighten to 26 ft. lbs. (35 N.m). Road test vehicle for 15 minutes. Recheck gear oil level and add fluid as needed.

Scheme 39

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 41) Oil level is correct when the rear final drive is filled to the lower edge of the fill hole. Install plug and tighten to 26 ft. lbs. (35 N.m).

Scheme 40

RECOMMENDED FLUIDS

RECOMMENDED FLUIDS

FLUID CAPACITIES

TRANSAXLE FLUID CAPACITIES

FINAL DRIVE & CENTER DIFFERENTIAL FLUID CAPACITIES

Note. In the following procedures, numbers in parenthesis are shown in illustrations.

1. Ensure all electrical components are switched off. Ensure transaxle ATF temperature is not above about 86°F (30°C). Park vehicle on level surface. Set selector lever to Park. Apply parking brake.
2. Remove noise insulation tray (if equipped). (Scheme 37) Connect ATF reservoir from VAG 1924 filling system to vehicle. Raise and support vehicle. Place drain pan under transaxle. Remove drain plug (1). (Scheme 38) Drain ATF. Install NEW seal and drain plug. Tighten drain plug to 30 ft. lbs. (40 N.m).
3. Remove ATF inspection plug (2). Using ATF Filling System (VAG 1924), carefully insert fill hose through an opening in deflector cap (4). (Scheme 38) Ensure deflector cap is not pushed upward out of position. 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 and add ATF as necessary. Replace seal on ATF inspection plug. Tighten inspection plug to 59 ft. lbs. (80 N.m).

Note. In the following procedures, letters and numbers in parenthesis are shown in illustrations.

1. If there is debris in the ATF, blow through the ATF cooler and ATF lines with compressed air before installing transaxle. Release bracket for rigid ATF lines on transaxle.
2. Remove bolt (2). (Scheme 42) Pull ATF lines off transaxle. Connect a hose to ATF pipe (A) and secure with a hose clamp. Hang other end of hose in a suitable container. Clear ATF line (B) with compressed air. Change hose from ATF pipe (A) over to ATF pipe (B) and repeat sequence.
3. Prior to installing ATF lines to transaxle, replace "O" rings (1). Moisten "O" rings with ATF. Insert ATF lines completely by hand onto stop in transaxle. Do not tighten bolt until ATF lines are completely inserted. Tighten bolt to 15 ft. lbs. (20 N.m). Check and top off ATF level. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels). When checking ATF level, check ATF line connections (A) and (B) for leaks. (Scheme 42)

Scheme 41

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 .

ADJUSTMENTS

Scheme 42

1. Remove selector lever handle. See «SELECTOR LEVER HANDLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Remove center console. See «CENTER CONSOLE, FRONT SECTION»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Shift selector lever into "P" position. Loosen locking cable support bracket bolt. It must be possible to slide bracket in direction of arrow. Adjust steering column downward. Locate Position Setting Bar (3352) between lever (for locking cable) and locking cable eye. (Scheme 43)
2. Pull locking cable in direction of arrow and tighten bolt to 89 INCH lbs. (10 N.m). (Scheme 43) Remove setting bar. Ensure ignition key can be easily removed after each adjustment of the locking cable. Install center console. Install selector lever handle.

Scheme 43

Scheme 44

1. To check cable, shift selector lever to "P" position. Raise and support vehicle. Remove noise insulation tray (if equipped). (Scheme 37) Remove selector lever cable protective plate.
2. Using a pry bar, remove selector lever cable from selector shaft lever (arrow). (Scheme 44) Shift selector lever from "P" to "2" position. Selector lever mechanism and selector lever cable must move freely. Replace selector lever cable or service selector lever mechanism as necessary. Shift selector lever to "P" position.
3. Bring selector shaft lever on transaxle to "P" position. Locking lever must engage in park lock wheel, and both front wheels should be blocked (cannot be turned together in a direction). It should be possible to push the selector lever cable onto the selector shaft lever. Adjust selector lever cable (if necessary).
4. To adjust cable, ensure selector lever cable is disconnected from selector shaft lever. Shift selector lever into "P" position. Bring selector shaft lever on transaxle to "P" position. Locking lever must engage in park lock wheel, and both front wheels should be blocked (cannot be turned together in a direction).
5. Loosen bolts (arrows) securing support bracket to transaxle. (Scheme 45) Using a pair of pliers, carefully push the selector lever cable onto the selector shaft lever. When doing this, take care not to bend the selector shaft lever, otherwise the selector mechanism will not be able to be adjusted correctly. Align selector lever cable, free of stress, on the support bracket using the oblong holes.
6. Tighten securing bolts for support bracket to 17 ft. lbs. (23 N.m). Check selector lever mechanism operation. Install selector lever cable protective plate. Tighten bolts to 17 ft. lbs. (23 N.m). Install noise insulation tray (if equipped).

REMOVAL & INSTALLATION

Scheme 45

Scheme 46

1. Remove radio. See «RADIO (CHORUS/SYMPHONY)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__radio-chorussymphony) or «RADIO (CONCERT)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__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-01v).
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 46) Remove A/C control head (B).
4. Press back harness connector release catches (F) and disconnect harness connectors (A) through (D). (Scheme 47) 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 47

1. Remove radio. See «RADIO (CHORUS/SYMPHONY)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__radio-chorussymphony) or «RADIO (CONCERT)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__radio-concert).
2. Remove bolts (A). (Scheme 48) 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 47) Press back harness connector releases catches (G) and disconnect harness connector (E) for rear window heating.
4. To install, reverse removal procedure.

(Scheme 49)for procedures.

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. Remove rear section of center console. See «CENTER CONSOLE, REAR SECTION»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v).
2. Only for "Chorus and Concert" radios, open front ashtray. Unclip trim section (2) at fasteners (3). There are 6 clips. (Scheme 54)
3. Remove radio. See «RADIO (CHORUS/SYMPHONY)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__radio-chorussymphony) or «RADIO (CONCERT)»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__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 HEAD»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v).
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-01v). Remove front ashtray for vehicles with "Symphony" radio systems and "radio-navigation plus".
7. Unclip switch-panel trim (5) at fasteners (4). (Scheme 54) 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 54)

Scheme 54

Scheme 55

Scheme 56

1. Remove rear air vent and rear air-duct connecting piece from center console, rear section.
2. If necessary, remove center armrest. (Scheme 55)
3. Remove nut (3). Remove mat lining (2) upward. Remove bolt (8). (Scheme 56)
4. Twist off shifter knob (4). Unclip center console insert (6) upward. Remove bolts (7). (Scheme 56)
5. Remove parking brake pry trim. (Scheme 57)
6. Raise rear section of center console (1) at front and detach connector for mirror adjustment switch (9). (Scheme 57)
7. Pull parking brake pry up as far as it will go. Unfasten trim (10) from retainer (11) on parking brake pry. (Scheme 57) 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 57) Make sure air ducts are properly installed when installing rear section of center console (1).

Scheme 57

Scheme 58

Scheme 59

1. Remove right front wheel. Remove heat shield for right drive axle. Remove right drive axle. Remove left front and right front exhaust pipes. Remove right transaxle support.
2. Prevent drive flange from turning using mandrel and remove center bolt from right drive flange (arrow). (Scheme 58) Place drain pan underneath transaxle to catch spilled fluid. Pull out right drive flange.
3. 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 59) Replace "O" ring (arrow). (Scheme 60)
4. To install, reverse removal procedure. Tighten bolts in sequence in 2 stages. For first stage, tighten bolts (1, 2 and 3) by hand. 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-01v__checking-fluid-levels) under LUBRICATION.

Note. In the following procedures, numbers in parenthesis are shown in illustration.

Scheme 60

Scheme 61

Scheme 62

1. Remove both front wheels. Remove heat shield for right and left drive axles. Remove both drive axles. Prevent drive flange from turning using mandrel and remove center bolt from right drive flange (arrow). (Scheme 58) Place drain pan underneath transaxle to catch spilled oil. Pull out right drive flange. Remove right transaxle support.
2. 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 59) Remove differential gear.
3. Remove bearing outer race (1) and adjustment shim (2) from transaxle housing by hand. (Scheme 61) Remove left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Remove double sealing ring using Release Lever (VW 681). (Scheme 62)
4. Check sealing ring seat in transaxle housing for damage and repair if necessary. Slide double sealing ring onto Pressure Piece (3383). Projecting sealing lip of sealing ring faces tool. Drive double sealing ring for torque converter in to stop using Pressure Piece (3383). (Scheme 63) Install adjustment shim (2) and outer bearing race (for differential) in transaxle housing by hand, until stopped. (Scheme 61) Do not tilt race.
5. Replace differential cover "O" ring (arrow). (Scheme 60) Install differential gear in transaxle housing. Install differential cover. Tighten bolts in 2 stages in sequence. For the first stage, tighten bolts (1, 2 and 3) by hand. For the second stage, tighten bolts (1 through 12) to 17 ft. lbs. (23 N.m) in sequence. (Scheme 59)
6. Install left drive flange. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__torque-specifications). Check final drive fluid level and correct as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels) under LUBRICATION.

Output flang/driveshaft oil seal, replacing

(Transmission in vehicle)

Special tools, testers and auxiliary items required

Scheme 63

1. Pressure piece 3402

Removing

1. Disconnect left and right catalytic converter from rear exhaust system and press both converters back and apart. NOTE: Remove rear part of exhaust system if necessary.

Scheme 64

1. Remove heat shield - A - from vehicle floor.
2. Remove cover plate - B - - arrows -.
3. Disconnect drive shaft from transmission. Secure drivshaft with wire on fuel line bracket.
4. Place drip tray underneath.

1. Drain axle oil in transfer case.

Scheme 65

1. Unbolt rear flanged shaft, secure flanged shaft against turning using a drift while doing so.
2. Pull out flanged shaft.

Scheme 66

1. Remove O-ring using appropriate screwdriver.

Installing

Installation is performed in the reverse order of removal. Pay attention to the following

1. Coat outer circumference and sealing lips of sealing ring with axle oil.
2. Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .

Scheme 67

1. Drive in sealing ring to stop using pressure piece 3402.
2. Secure rear flanged shaft using a socket head bolt.
3. Connect drive shaft to flange.
4. Install front exhaust system with catalytic converter.

1. Fill transfer case with axle oil and check oil level, «Front Final Drive»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__front-final-drive) .

Scheme 68

Scheme 69

1. Unclip trim section. (Scheme 49)
2. Unclip center console insert (2). (Scheme 69) Open front ashtray. Remove bolts (1).
3. Using a screwdriver (2), pull out retainers (1) on left and right in direction of arrow. (Scheme 70) 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 70

1. Remove left front and right front exhaust pipes. Remove heat shield for selector lever cable. Unbolt heat shield for drive shaft from differential cover. Unbolt drive shaft from transaxle and let it rest on heat shield. Secure drive shaft using wire at bracket. Drain center differential gear oil. Loosen mounting bolts for center differential housing in diagonal sequence and remove center differential (if equipped).
2. Remove front final drive housing cover bolts in reverse order of tightening sequence shown in illustration (start at 14, finish at 1). (Scheme 71) Remove front final drive housing cover.
3. Ensure dowel sleeve (arrow A) is located properly. (Scheme 71) Install gasket. Install front final drive housing cover. Tighten bolts in sequence in 2 stages. For first stage, tighten bolts (1, 2 and 3) by hand. When tightening the bolts by hand (first stage), ensure that the gap between the cover and the transaxle housing decreases uniformly all the way around the cover.
4. For second stage, tighten bolts (1 through 14) to 17 ft. lbs. (23 N.m) in sequence. Tighten all other bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__torque-specifications). Change or top off ATF after repair. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels) under LUBRICATION.

1. Faulty "O" rings on the internal oil line allow ATF to enter the differential. Differential then becomes overfilled and oil will seep out of the breather holes of the differential. If an oil line is removed, it should generally be replaced. The oil line should only be inserted using Fitting Tool (3381). Otherwise there is a danger of the oil line becoming bent, which will cause leaks to occur.
2. Remove valve body. See «VALVE BODY ASSEMBLY»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Pry internal oil line off transaxle housing using a screwdriver. (Scheme 72) Replace "O" rings. Insert internal oil line into fitting tool. Open side of fitting tool faces toward outside of transaxle. (Scheme 73)
3. Using a plastic hammer, drive the oil line into the transaxle housing until the fitting tool makes contact. Ensure oil line is kept straight. Drive both oil line ends in evenly. Install valve body. Fill with ATF, check ATF level and top off as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels) under LUBRICATION.

Scheme 71

Scheme 72

Note. In the following procedures, letters in parenthesis are shown in illustration.

1. Remove fill plug (arrow) on side of final drive. (Scheme 39) Remove about 1/2 quart of gear oil from final drive using Suction Device (VAG 1358 A). Remove left front wheel. Remove heat shield for left drive axle. Remove left drive axle. Remove vehicle speed sensor. Remove bracket for connector from drive flange bracket. Remove bracket for left drive flange (arrows). (Scheme 74) Pull out left drive flange.
2. To install flange, reverse removal procedure. Replace "O" ring (arrow B) for left drive flange bracket. (Scheme 75) Check end of left drive flange (arrow) for burrs and sharp edges and deburr if necessary. (Scheme 76) 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-01v__torque-specifications). Check final drive fluid level and correct as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels) under LUBRICATION.

Note. In the following procedures, letters in parenthesis are shown in illustration.

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

1. Remove left drive flange. See «LEFT DRIVE FLANGE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Remove circlip (arrow A) for ball bearing. (Scheme 75) Place left drive flange bracket on Pressure Plates (VW 401 and VW 402). Using Thrust Piece (VW 412), press drive flange out of bracket. (Scheme 77)
2. Remove impulse wheel (if equipped) for speedometer vehicle speed sensor from drive flange or bracket. Place bracket on pressure plates and press ball bearing out of bracket using Thrust Piece (VW 407). (Scheme 78)
3. Install impulse wheel for vehicle speed sensor (arrow) on drive flange and check installation position. (Scheme 79) Press NEW ball bearing into bracket as follows: Place bracket on Pressure Plates (VW 401 and VW 402). Press bearing in using Thrust Piece (VW 412) and Pressure Pipe (32-109). (Scheme 80)
4. Press bracket (together with ball bearing) onto left drive flange as follows: Place drive flange on Pressure Plate (VW 401). Press bracket on using Thrust Piece (VW 412), Pipe Piece (2040) and Pressure Pipe (32-109). (Scheme 81) Install circlip (arrow A). (Scheme 75) Install left drive flange. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__torque-specifications). Check final drive fluid level and correct as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels) under LUBRICATION.

LOCKING CABLE

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.

Note. Ensure locking cable is not kinked during installation.

Note. Vehicles may be equipped with a Tiptronic shift mechanism. Selector lever may be shifted from "D" position to Tiptronic gate. This gate allows selector lever to be shifted forward (upshift) or backward (downshift) during vehicle operation.

Scheme 78

1. To remove cable, shift selector lever into "2" position. Turn ignition switch off. Disconnect negative battery cable. Remove selector lever handle. See «SELECTOR LEVER HANDLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Remove center console. See «CENTER CONSOLE, FRONT SECTION»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v).
2. Remove steering wheel with air bag. See appropriate AIRBAG article in RESTRAINTS. Turn ignition key to "ignition on" position. Move selector lever to "P" position. Release locking clip and pull locking cable out from ignition switch.
3. Shift selector lever into "P" position by pulling pull rod. Ensure ignition switch is off. Remove cover of center console above shift mechanism. Carefully disengage 4 clips (arrows) and remove cover upward. (Scheme 82)
4. Unclip locking cable from securing spring on support bracket. To do this, lift securing spring slightly. Release locking cable from cable tie at instrument panel support and remove. (Scheme 43)
5. To install cable, route locking cable free of kinks. Turn ignition key to "ignition on" position. Install locking cable to ignition switch. Ensure locking device engages. Secure locking cable to air bag sensor with cable tie. Turn ignition switch to LOCK position (ignition off).
6. Move selector lever to "P" position. Hook locking cable into locking lever and clip locking cable support bracket into securing spring of bracket. (Scheme 43) Install selector lever handle. Adjust locking cable. See «LOCKING CABLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__locking-cable) under ADJUSTMENTS.

RADIO (CHORUS/SYMPHONY)

Scheme 79

Scheme 80

Scheme 81

1. Insert radio removal tools (T10057) into release slots (arrows) as shown until they engage. (Scheme 83)and (Scheme 84). 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 85)
3. Connect electrical connections to radio. Slide radio evenly into instrument panel, until it engages in assembly frame.

RADIO (CONCERT)

Scheme 82

Scheme 83

1. Insert removal tools (3344) into front of radio. (Scheme 86)and (Scheme 87). 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.

1. Remove right front wheel. Remove heat shield for right drive axle. Remove right drive axle. Prevent drive flange from turning using mandrel and remove center bolt from right drive flange (arrow). (Scheme 58) Place drain pan underneath transaxle to catch spilled fluid. Pull out right drive flange. Remove sealing ring for right drive flange with Release Lever (VW 681). (Scheme 88)
2. Drive sealing ring for right drive flange in to stop using Pressure Piece (3382). (Scheme 89) Sealing ring must be seated at uniform depth (around circumference) in housing. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__torque-specifications). Check final drive fluid level and correct as necessary. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels) under LUBRICATION.

To remove securing spring, slightly lift spring at top (arrow "B"). Remove locking cable from shift mechanism. (Scheme 90) 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 90)

Scheme 84

For selector lever handle removal and installation procedures (Scheme 91)

Scheme 85

Note. Vehicles may be equipped with a Tiptronic shift mechanism. Selector lever may be shifted from "D" position to Tiptronic gate. This gate allows selector lever to be shifted forward (upshift) or backward (downshift) during vehicle operation.

Note. In the following procedures, letters and numbers in parenthesis are shown in illustrations.

Scheme 86

Scheme 87

1. To remove cable, shift selector lever into "P" position. Raise and support vehicle. Remove crossmember below exhaust system (if installed). Disconnect front exhaust pipes with catalytic converter from rear exhaust system and tie them aside. Remove heat shields from above drive shaft and differential. Unbolt drive shaft from transaxle and wire aside. Remove selector lever cable rubber sleeve and push back. Remove cover from shift mechanism housing (arrows). (Scheme 92)
2. Disconnect selector lever cable from shift mechanism housing as follows: Press together ends of securing clip (B) and remove. Pull down locking plate (A) and remove. (Scheme 93) Locking plate is used to secure selector lever cable to mounting bracket. Pull selector lever cable off selector lever.
3. Using lever (80-200), remove selector lever cable from selector shaft lever (arrow). (Scheme 44) Remove support bracket from transaxle. Release selector lever cable from support bracket. Pull selector lever cable out from shift mechanism housing. Do not kink cable when removing from housing.
4. To install cable, push selector lever cable and shift selector shaft lever into "P" position. Take care not to bend or kink selector lever cable. Slightly lubricate eye and socket before installing. Carefully guide selector lever cable into mounting bracket. Attach selector lever cable on selector lever.
5. Press ends of spring clamp (B) together and secure selector lever cable. (Scheme 93) Install selector lever cable lock plate (A) at mounting bracket. Ensure angled ends of lock plate are pointed toward end of selector lever cable.
6. Attach selector lever cable to bracket and hand-tighten. Attach bracket to transmission and hand-tighten. Do not bed or counter-hold lever when pressing on, since shift mechanism will not be able to be adjusted. Attach selector lever cable to lever selector shaft. Straighten selector lever cable in bracket.
7. Tighten bolts securing support bracket to transaxle (1) to 17 ft. lbs. (23 N.m). Secure selector lever cable to support bracket (2). Tighten bolts to 106 INCH lbs. (12 N.m). When doing this, counterhold on the hex (3). (Scheme 94)
8. Tighten shift mechanism cover nuts to 89 INCH lbs. (10 N.m). Check selector lever cable adjustment, and adjust if necessary. See «SELECTOR LEVER CABLE»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v) under ADJUSTMENTS. Install crossmember below exhaust system (if removed). Connect front exhaust pipes with catalytic converter to rear exhaust system. Install drive shaft to transaxle. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__torque-specifications).

Scheme 88

Note. In the following procedures, numbers in parenthesis are shown in illustrations.

1. Remove multifunction TR switch. See «TRANSAXLE RANGE SWITCH»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Using appropriate pry bar, remove selector lever cable from selector shaft lever. (Scheme 44) Drive spring pin (1) out of transaxle selector lever (2) until transaxle selector lever can be removed from selector shaft. (Scheme 95) Using a screwdriver, pry out oil seal.
2. To install, apply ATF to circumference and sealing lips of oil seal. Open side of seal faces transaxle. Using appropriate driver, drive in NEW oil seal until driver contacts stop. (Scheme 96) Ensure oil seal remains straight during installation. Push transaxle selector lever onto selector shaft and install spring pin. Carefully press selector lever cable onto selector shaft using a pair of pliers. Take care not to bend selector shaft lever, otherwise selector mechanism will not be able to be adjusted correctly. Install multifunction TR switch.

Scheme 89

Scheme 90

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

Note. In the following procedures, numbers in parenthesis are shown in illustrations.

Scheme 91

1. Remove noise insulation tray (if equipped). (Scheme 37) Place drain pan under transaxle. Remove drain plug (1). (Scheme 38) 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 97) Pull ATF screen off of valve body. To install ATF screen, lubricate seal on intake neck of ATF screen with ATF. Carefully push intake neck of ATF screen into opening of valve body. Install bolts and tighten to 53 INCH lbs. (6 N.m).
3. Install NEW oil pan gasket and oil pan. Install oil pan bolts and tighten in diagonal sequence to 89 INCH lbs. (10 N.m). Install NEW drain plug with sealing washer. Tighten plug to 30 ft. lbs. (40 N.m). Fill transaxle with ATF. See «DRAINING & REFILLING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v) under LUBRICATION.

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

Note. In the following procedures, numbers in parenthesis are shown in illustration.

1. Raise and support vehicle. Remove left wheel. Remove left transaxle support. Unscrew bolts and detach multifunction TR switch from transaxle. Pull switch off selector shaft. (Scheme 98)
2. 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). Do not tilt or use force when installing switch. Switch contacts may be damaged. Turn switch so that drilling (4) on switch housing can be installed on locating pin (2) on transaxle housing. (Scheme 98) Install bolts and tighten to 71 INCH lbs. (8 N.m). Install left transaxle support and left wheel.

Scheme 92

TRANSAXLE RPM SENSOR

Note. On transaxles with hydraulic control system type E17, transaxle RPM sensor for the transaxle input signal (inductive sensor) is attached to the underside of the valve body. On transaxles with hydraulic control system type E18, transaxle RPM sensor for the transaxle input speed (Hall sensor) is attached to the transaxle housing behind the valve body.

Removal & Installation (With E17 Valve Body)

Note. In the following procedures, numbers in parenthesis are shown in illustration.

Remove valve body. See VALVE BODY ASSEMBLY. Turn valve body over and unplug connector from transaxle RPM sensor (1). (Scheme 99) Remove bolts and remove sensor from valve body. Install sensor with spacer (2) and tighten bolts to 62 INCH lbs. (7 N.m). Ensure sensor is installed correctly. Side of sensor with plug contacts faces toward center of valve body. Install connector to sensor. Install valve body. Fill with ATF and check ATF level. See CHECKING FLUID LEVELS under LUBRICATION.

Removal & Installation (With E18 Valve Body)

Note. In the following procedures, letters in parenthesis are shown in illustration.

Remove valve body. See VALVE BODY ASSEMBLY. Remove bolt (B) and remove transaxle RPM sensor (A). (Scheme 100) To install reverse removal procedure. Tighten bolt to 80 INCH lbs. (9 N.m). To ensure wiring harness does not become trapped when installing the valve body, route the wire with connector (C) according to the illustration. (Scheme 100) Fill with ATF and check ATF level. See CHECKING FLUID LEVELS under LUBRICATION.

Scheme 93

Scheme 94

Note. In the following procedure, numbers in parenthesis are shown in illustration.

Remove oil pan. Pull connector off transaxle vehicle speed sensor. see scheme 74 Remove bolt and transaxle vehicle speed sensor (2). (Scheme 101) To install, position speed sensor with spacer (1) and tighten bolt to 71 INCH lbs. (8 N.m). Connect speed sensor connector. Install oil pan. Fill with ATF and check ATF level. See CHECKING FLUID LEVELS under LUBRICATION.

Scheme 95

Note. In the following procedure, letters in parenthesis are shown in illustration.

Scheme 96

1. Remove valve body. See «VALVE BODY ASSEMBLY»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Using a small screwdriver, pry out retaining tabs on solenoid valve connectors, and pull off connectors (A) one at a time. (Scheme 102) Disengage wiring harness from retainers (B) on side of valve body. Turn valve body over, and unplug connector from transaxle RPM sensor (1). Remove first retaining clip (A) and unclip harness from second retaining clip (B). Pull connector (3) off transaxle RPM speed sensor. (Scheme 99)
2. To install, reverse removal procedure. When installing wiring harness, plug the connectors onto the respective solenoid valves. Clip the wiring harness into the retaining clips. If not installed correctly, wiring harness can be trapped when the valve body is installed. Install valve body. Fill with ATF and check ATF level. See «CHECKING FLUID LEVELS»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v__checking-fluid-levels) under LUBRICATION.

Note. In the following procedures, letters in parenthesis are shown in illustration.

Remove left wheel. Remove left axle shaft protective plate. Pull connector (A) off sensor. Press down sensor retaining catch and turn (arrow). see scheme 69 Pull out sensor. To install, reverse removal procedure. Replace "O" rings (arrows) and lubricate with gear oil before inserting. see scheme 70 Install sensor and engage retaining catch on bearing bracket for flange shaft. Install left axle shaft protective plate and left wheel.

Scheme 97

Scheme 98

Note. A differentiation is made between two types of transmissions. Transmission with hydraulic control E17, on which the sensor for transmission RPM (inductive sensor) is secured to the underside of the valve body. see scheme 71 Transmission with hydraulic control E18/2, on which the sensor for transmission RPM (hall sensor is secured behind the valve body on transmission housing. see scheme 72

Note. Always replace soiled or faulty valve body.

Note. In the following procedures, letters and numbers in parenthesis are shown in illustrations.

Scheme 99

Scheme 100

Scheme 101

Scheme 102

1. Raise and support vehicle. Remove noise insulation panel (arrows). (Scheme 37) Place drip tray underneath transmission. Remove ATF drain plug (1) and drain ATF. (Scheme 38) Remove oil pan bolts diagonally in stages Remove oil strainer bolts (arrows). (Scheme 97) Pull oil strainer off valve body. Remove wiring harness connector securing clip (arrow). see scheme 73
2. On vehicles equipped with hydraulic control E17, disconnect transmission vehicle speed sensor (G38) harness connector (arrow). see scheme 74 On vehicles equipped with hydraulic control E18/2), disconnect transmission vehicle speed sensor harness connector (A) and transmission RPM (G182) (B). see scheme 75
3. On all vehicles, remove valve body securing bolts (arrows). see scheme 76 While guiding wiring harness connector, remove valve body.
4. To install, lightly coat wiring harness connector "O" ring with ATF. Insert wiring harness connector into transmission housing ensuring flat part of rear shoulder points downward, and tabs at shoulder are horizontal.
5. On vehicles equipped with hydraulic control (E18/2), route wire with connector (C) so that wiring is not pinched during installation of valve body. (Scheme 100) On all vehicles, place valve body in position, without force, until detent plate (1) engages in selector lever slide groove (2). see scheme 77 Tighten valve body bolts starting from inner working outward.
6. On vehicles equipped with hydraulic control (E18/2), pull wire with transmission RPM (G182) sensor connector between valve body and wiring harness upward. Connect connector (B) at wiring harness. see scheme 75 Connect connector (A) to transmission vehicle speed sensor (G38). On vehicle equipped with hydraulic control E17, connect harness connector (arrow) to transmission vehicle speed sensor (G38). see scheme 74
7. On all vehicles, install securing clip onto wiring harness connector (arrow). see scheme 73 Lightly coat oil strainer suction shoulder with ATF. Apply thin coat of petroleum jelly to gasket on suction shoulder of oil strainer. Bolt on oil strainer.
8. Clean all oil pan magnets in beads. Check for full contact of magnets on oil pan. Install NEW gaskets. Install oil pan bolts diagonally in stages. Install ATF according to specifications. See «DRAINING & REFILLING»(/audi/a6/c5-1997-2001/remont/automatic-trans/#servicing-at-01v). Install noise insulation panel. (Scheme 37)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• RECOMMENDED FLUIDS
• CHECKING FLUID LEVELS
• ADJUSTMENTS
• REMOVAL & INSTALLATION
• SELECTOR LEVER HANDLE
• RADIO (CHORUS/SYMPHONY)
• RADIO (CONCERT)
• TORQUE SPECIFICATIONS
• Front Final Drive
• LOCKING CABLE