PRECAUTIONS FOR DISABLING THE HIGH VOLTAGE SYSTEM
- The high voltage system may only be disabled by suitably qualified personnel (Audi high voltage technicians). Definition and explanation of qualifications. .
- Before beginning any work on the high voltage systems, the high voltage system must be turned off .
- Follow each step when working on the already disabled high voltage system. Additional information regarding the disabling of the high voltage system. .
- All additional safety precautions and instructions must be observed when working with high voltage systems .
Note. Any questions or concerns about the concepts "electrically trained person", "Audi high voltage technician", "Audi high voltage system specialist " or concerning the high voltage system, should be addressed with the registered importer before beginning any work.
For work during which the voltage must be disabled.
Disabling the high voltage system can only be done using the Guided Fault Finding on the vehicle diagnostic tester.
| CAUTION | Deadly voltage Risk of electrocution or severe injury. People with electronic/medical life- and health sustaining devices in or on their person must, for safety reasons, not perform any work on the high voltage system. This includes life- and health sustaining devices such as internal pain killer pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids. The high voltage system may only be disabled by suitably qualified personnel (Audi high voltage technicians). Make certain that the voltage in the high voltage system is, without a doubt, disabled. Only the vehicle diagnosis tester via the "Guided Fault Finding" can determine if the voltage is safe. Qualified personnel (Audi high voltage technicians) secure the system from restarting with the locking cap T40262. Securing the system from restarting requires that the storage of the ignition key and of the high voltage system maintenance connector - TW - be carried out by qualified personnel. Qualified personnel (Audi high volt technicians) mark the vehicle by attaching warning and information signs. |
RESTARTING THE HIGH VOLTAGE SYSTEM
- Only suitably qualified personnel (Audi high volt technicians) may restart the high voltage system. Definition and explanation of qualifications. .
- Restarting the high voltage system .
- All additional safety precautions and instructions must be observed when working with high voltage systems .
Note. Any questions or concerns about the concepts "electrically trained person", "Audi high voltage technician", "Audi high voltage system specialist " or concerning the high voltage system, should be addressed with the registered importer before beginning any work.
Only by using the Guided Fault Finding in the vehicle diagnosis tester can the high voltage system be restarted.
| CAUTION | Deadly voltage Risk of electrocution or severe injury People with electronic/medical life- and health sustaining devices in or on their person must, for safety reasons, not perform any work on the high voltage system. This includes life- and health sustaining devices such as internal pain killer pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids. Only suitably qualified personnel (Audi high volt technicians) may restart the high voltage system. Only the vehicle diagnosis tester via the "Guided Fault Finding" can guarantee if the voltage has been restarted. Qualified personnel (Audi high volt technicians) restart the vehicle. Qualified personnel (Audi high volt technicians) mark the vehicle by attaching warning and information signs. |
GENERAL INFORMATION FOR SAFETY PRECAUTIONS AND PROCEDURES
- All additional safety precautions and instructions must be observed when working with high voltage systems .
Note. Any questions or concerns about the concepts "electrically trained person", "Audi high voltage technician", "Audi high voltage system specialist " or concerning the high voltage system, should be addressed with the registered importer before beginning any work.
Perform a visual inspection of the high voltage components when working near them.
| CAUTION | Deadly voltage from damaged high voltage components. Observe the following when working near high voltage components and high voltage wires: Cutting, forming, sharp-edged tools or heat sources such as welding, soldering, hot air or thermal glue are not allowed. Perform a visual inspection in the work area before beginning any work on the high voltage components. Perform a visual inspection of the electric drive power and control electronics -JX1-, the electro-drive drive motor -V141-, the electrical Air Conditioning (A/C) compressor -V470- and the high voltage lines. When working on the underbody, perform a visual inspection of the high voltage cables and the covers. When working in the rear lid area, perform a visual inspection of the high voltage cables and the electro box with the high voltage system maintenance connector -TW -. Visually inspect all of the potential equalization cables. Note the following when performing a visual inspection: None of the components should display any signs of exterior damage. The high voltage cable insulation and the potential equalization cable insulation must not be damaged. The high voltage cables must not be deformed in any way. Every high voltage component must be labeled with a red warning label. |
For work, where the ignition must be turned on.
| CAUTION | There is a risk of unexpected engine start and of being poisoned by gas in enclosed spaces when working with the ignition already turned on or with the engine running. Risk of personal injury or to clothes when connecting. Perform the following items before turning on the ignition: Place the selector lever in position P Activate the parking brake Turn the ignition off. Open the hood Connect the charging device for example battery charger VAS 5095A on the battery jump start terminal for the 12V vehicle electrical system. Turn the ignition on. |
General safety precautions and safety precautions for work performed whereby the ignition must not be turned on.
| WARNING | Risk of unintended engine start. For all work on high voltage vehicles, the ignition must be turned off and the ignition key must remain outside of the vehicle. |
| WARNING | Handling high voltage cables: Do not stand on or place tools on the high voltage cables or high voltage components. there is a risk of damaging the insulation. High voltage cables must not be severely bent or kinked. Risk of damaging the insulation. The round high voltage connector is coded with a colored exterior ring and mechanically coded with the guide tabs or the code tabs. Always follow the coding when connecting the round high voltage connectors to avoid mechanically damaging the high voltage connector. |
Observe the following to avoid personal injury and vehicle damage
| WARNING | There is a risk of injury and accident from accidentally engaging a gear when the engine is running. Before performing any work with the engine running, move the selector lever into "P" and press the parking brake button to set the electro-mechanical parking brake. Danger of poisonous exhaust gas when the engine is running. When the engine is running, an exhaust extraction system must always be connected to exhaust system. |
Safety Precautions, Vehicles with Start/Stop System
| WARNING | Danger of injury through automatic motor starting with vehicles with the Start/Stop System. For vehicles with an activated Start/Stop System (recognizable from a notification in the instrument cluster), the motor can be started automatically if needed. Thus, make sure that the Start/Stop System is disabled when working on the vehicle (turn off ignition, if needed, turn the ignition back on). |
To prevent personal injury and damage to electrical and electronic components, observe the following
- Connect and disconnect test equipment only when the ignition is off.
| CAUTION | Risk of damaging electronic components when disconnecting the battery. Complete the steps for disconnecting the battery. Always turn off the ignition before disconnecting the battery. |
Disconnect the battery. Refer to [For engine(s) CAEB, CALB] Removal and Installation .
If testing equipment must be used during a road test, observe the following
| WARNING | Distraction and testing equipment that is not secured properly can cause accidents. The passenger airbag could pose a risk if it deploys in a collision. Operating testing equipment while driving causes it to shift position. There is an increased risk of injury due to unsecured testing equipment. Always secure testing equipment on the rear seat using a strap and have a second person in the rear seat operate it. |
REAR FINAL DRIVE IDENTIFICATION
The 0BC rear final drive unit is used with the following transmissions
- 6-Speed Manual Transmission 0B2 AWD
- 6-Speed Manual Transmission 0B4 AWD
- 7-Speed DSG Transmission 0B5 AWD
- 6-Speed Automatic Transmission 0B6 AWD
- 8-Speed Automatic Transmission 0BK AWD
- 8 speed automatic transmission 0BW AWD (only Q5 hybrid)
Allocation Rear Final Drive
- Audi A4 from MY 2008
- Audi A5 Coupe from MY 2008
- Audi A5 Cabriolet from MY 2009
- Audi Q5 from MY 2008 «TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES»(/audi/q5/i-2008-2012/remont/automatic-trans/#general-technical-data-rear-final-drive-0bc__transmission-allocations-ratios-and-capacities)
- Audi Q5 Hybrid from MY 2008 «TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES»(/audi/q5/i-2008-2012/remont/automatic-trans/#general-technical-data-rear-final-drive-0bc__transmission-allocations-ratios-and-capacities)
- Audi A6 from MY 2011
- Audi A7 from MY 2011
- Audi A8 from MY 2010
Location on Rear Final Drive
Scheme 1
Final Drive 0BC -arrow 1- and 0AR
Engine code and build date -arrow 2
Final Drive 0BC -arrow- and 0AR
Scheme 2
Note. "0AR" can always be found on the rear final drive housing. Changes to the housings is what differentiate the "0BC" and "0AR" final drives. They can also be distinguished by the location of the threaded holes -arrows- for securing the crossmember on the rear final drive. The final drive "0BC" has 4 threaded holes -arrows- in the housing for securing the crossmember There is also an additional threaded hole for securing the final drive to the subframe under the flange/driveshaft.
Rear Final Drive Code Letters and Build Date
Scheme 3
| Example | JKS | 15 | 03 | 07 |
|---|---|---|---|---|
| I | I | I | I | |
| Code letters | Day | Month | Production year -2007 |
Additional data can be ignored.
Note. When installing a new rear final drive unit, the final drive code, the PR number and the vehicle engine code must be verified. This is the only way to assure the correct allocation.
REPAIR INFORMATION
Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the Repair information, are summarized here under the topic "Components". Refer to COMPONENTS .
COMPONENTS
Rear Final Drive
- Allocate bolts and other components according to final drive code.
- When installing, check the oil level in the rear final drive and fill if necessary. Refer to «REAR FINAL DRIVE GEAR OIL, CHECKING»(/audi/q5/i-2008-2012/remont/axle-shafts/#rear-final-drive-0bc__rear-final-drive-gear-oil-checking) .
- Capacities and specifications, refer to «SPECIFICATIONS»(/audi/q5/i-2008-2012/remont/automatic-trans/#general-technical-data-rear-final-drive-0bc) .
- Clean the contact surfaces when installing the brackets as well as any waxed components. Contact surfaces must be free of grease and wax.
- Always clean the connection locations and the area around them before loosening.
Oil, Environmental and Disposal Regulations
- Handle ATF, transmission fluid and other oils with care.
- Dispose of drained ATF properly.
- Follow the legal environmental and disposal regulations.
- Follow the information provided on oil packaging.
O-rings, Shaft Seals, Seals
Scheme 4
- O-rings, shaft seals and seals must be replaced.
- After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
- Thoroughly clean housing joint surfaces before assembling.
- Before installing the shaft seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with grease G 052 128 A1.
- The open side of the shaft seals point toward the fluid to be sealed in.
- Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.
- After replacing the seals and sealing rings, check the transmission fluid level and fill if necessary. Refer to «REAR FINAL DRIVE GEAR OIL, CHECKING»(/audi/q5/i-2008-2012/remont/axle-shafts/#rear-final-drive-0bc__rear-final-drive-gear-oil-checking) .
Fasteners
Scheme 5
- Do not overstretch the circlips.
- Always replace damaged or stretched circlips.
- The circlips must fit completely inside the groove.
- Replace the adapter sleeves. Installed position: Slit -A- should be in line with the line of force -arrow-.
Bolts and Nuts
Scheme 6
- Always loosen or tighten bolts and nuts on covers and housings diagonally.
- Parts which are particularly sensitive to distortion must be kept straight when removing and installing; loosen or tighten diagonally in stages.
- The tightening specifications stated apply to non-oiled nuts and bolts.
- Always replace self-locking nuts and bolts.
- Clean threads of bolts that were applied with locking fluid using a wire brush (does not apply to driveshaft bolts: these must be replaced). Next, use locking compound AMV 185 101 A1 to install the bolts.
- Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (for example tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
SPECIAL TOOLS AND EQUIPMENT
Complete list of special tools used in this Workshop information. See Special Tools and Equipment.
DRIVETRAIN OVERVIEW
- Shown with the 6-speed manual transmission 0B4 AWD.
Note. The -arrows- point in direction of travel.
Scheme 7
- 1 - Engine
- 2 - Drive Plate With a needle bearing for the input shaft bearing
- 3 - Clutch Module Consists of the pressure plate, clutch disc and dual mass flywheel with transfer plate
- 4 - Front Differential
- 5 - Driveshaft (main shaft)
- 6 - Front Drive Pinion with Side Shaft
- 7 - Output Shaft
- 8 - Manual Transmission
- 9 - Center Differential
- 10 - Driveshaft
- 11 - Rear Pinion
- 12 - Rear Differential
- I - 1st Gear
- II - 2nd Gear
- III - 3rd Gear
- IV - 4th Gear
- V - 5th Gear
- VI - 6th Gear
- R - Reverse Gear
- S - Intermediate Drive Gears
- A1 - Front Final Drive
- A2 - Rear Final Drive
TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES - NON HYBRID
| Rear Final Drive | 0BC | ||||
|---|---|---|---|---|---|
| Code Letters | KCC | KLL | KLM | ||
| Ratio | Final drive Z 2 : Z 1 | 43 : 13 = 3.308 | 35 : 8 = 4.375 | 35 : 8 = 4.375 | |
| Driveshaft flange diameter | 75.5 mm | 70.7 mm | 75.5 mm | ||
| Gear oil - capacity | Maintenance, Diagnosis | ||||
| Production date Gear oil specification The engine, manual transmission and automatic transmission allocation using the code letters and the PR numbers | |||||
| Rear Final Drive | 0BC | ||||
|---|---|---|---|---|---|
| Code Letters | LAW | ||||
| Ratio | Final drive Z 2 : Z 1 | 42 : 9 = 4.666 | |||
| Driveshaft flange diameter | 75.5 mm | ||||
| Gear oil - capacity | Maintenance, Diagnosis | ||||
| Production date Gear oil specification The engine, manual transmission and automatic transmission allocation using the code letters and the PR numbers | |||||
TRANSMISSION ALLOCATIONS, RATIOS AND CAPACITIES - HYBRID
| Rear Final Drive | 0BC | ||||
|---|---|---|---|---|---|
| Code Letters | NPR | ||||
| Ratio | Final drive Z 2 : Z 1 | 43 : 13 = 3.308 | |||
| Driveshaft flange diameter | 75.5 mm | ||||
| Gear oil - capacity | Maintenance, Diagnosis | ||||
| Production date Gear oil specification The engine, manual transmission and automatic transmission allocation using the code letters and the PR numbers | |||||