Audi A6 Typ 4G: General, Technical data
Repair Information
Guidelines for Clean Working Conditions
- Always clean the connection locations and the area around them before loosening.
- Clean the transmission and transmission components using Cleaning Solution -D 009 401 04-.
- Use lint-free cloths when cleaning, for example, the "WYPALL X70/WORKHORSE" cloth made by Kimberly-Clark Professional.
- Seal all open lines and connections immediately with clean plugs or caps from the Engine Bung Set -VAS6122-.
- Place removed parts on a clean surface and cover them. Use foil or lint-free cloths.
- Cover or plug unpacked components if repairs cannot be performed immediately.
- Only install clean components: Remove the replacement parts from their packaging just prior to installing them.
- Protect the disconnected connectors from dirt and moisture and only connect when they are dry.
General Repair Information
Using the Repair Manual
Refer to the "7-speed DSG transmission (S tronic)" repair manual for all special procedures with the transmission installed, depending on the model. The servicing repair manual either does not describe them or describes them only partially. Both repair manual are needed for a successful repair.
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.
Some general repair information that applies to several procedures throughout this manual is summarized here. They apply to this repair manual.
Oil, Environmental and Disposal Regulations
- Handle ATF, transmission fluid and other oils carefully.
- Dispose of the drained fluids properly.
- Follow the legal environmental and disposal regulations.
- Follow the information provided on oil packaging.
Special Tools and Equipment
For a complete list of special tools used in the repair manual. Refer to Workshop Equipment and Special Tools.
Transmission
- Follow all the guidelines for clean working conditions. Refer to → Chapter "Guidelines for Clean Working Conditions".
- If installing parts that can be used again, clean and check them and replace if necessary.
- During installation, make sure that the alignment bushings are fitted correctly.
O-Rings, Shaft Seals, Seals
- 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.
- Clean the housing separating surface thoroughly before assembling.
- Before installing, lightly lubricate shaft seal outer circumference and sealing lips with ATF or gear oil, depending on installation location.
- Coat O-rings lightly with ATF or transmission fluid before installing them. This prevents them crimping when being installed.
- Always only use approved ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.
- The open side on the shaft seals faces the fluid to be sealed off.
- After installing, check and correct the ATF level or the transmission fluid level (MTF) with the transmission installed. Refer to → S tronic Transmission; Rep. Gr.34; Automatic Transmission Fluid; ATF Level, Checking or → S tronic Transmission; Rep. Gr.39; Transmission Fluid; Transmission Fluid Level, Checking. Specification. Refer to the Parts Catalog.
Bolts and Nuts
- Loosen the bolts opposite the tightening sequence.
- Nuts and bolts which secure covers and housings should be tightened in steps according to the specified tightening sequence and method.
- Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
- Always replace self-locking nuts and bolts.
- If nothing else is specified: Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Use locking fluid when installing the bolts. Refer to the Parts Catalog.
- Threaded holes with self-locking bolts or bolts coated with locking fluid must be cleaned, for example using a thread tap. Otherwise there is a risk that the bolts will shear the next time they are removed.
- The tightening specifications stated apply to non-oiled nuts and bolts.
Circlips, Snap Rings
- Do not overstretch the circlips.
- Replace damaged or stretched circlips.
- The circlips must fit completely inside the groove.
Bearings
- Install needle bearings with lettered side (thicker metal) racing the fitting tool.
- Coat and install the bearings with gear oil or with ATF, depending on the installation location.
- Do not interchange the outer or inner races of bearings of the same size.
- Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.
Adjusting Shims
- Measure the adjusting shims at several locations with a micrometer. Different shim thicknesses make it possible to select the required thickness precisely; install two shims if necessary.
- Check for burrs and damage. Only install perfect shims.
Mechatronic
Caution
There is a risk of destroying the transmission control module (Mechatronic) with electrostatic discharge.
- Always discharge "static electricity" before working with connectors or the Mechatronic. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.
- Do not touch contacts in transmission connector with hands.
Contact Corrosion
Contact corrosion can occur if unsuitable fasteners (bolts, nuts, washers, etc.) are used.
For this reason, only fasteners with a special surface coating may be installed.
In addition, rubber or plastic parts and adhesive are made of materials that do not conduct electricity.
If there are doubts about whether parts can be used or not, then use new parts. Refer to the Parts Catalog.
Note
- Original replacement parts are recommended because they have been tested.
- The use of Audi accessories is recommended.
- Damage resulting from contact corrosion is not covered by the warranty.
