Repair Instructions
Repair instructions - 01J, Continuously Variable Transmission (CVT)
CAUTION!
Shift selector lever into position "P" and engage parking brake before working with the engine running.
When engine is running, an exhaust extraction system must always be connected to exhaust system.
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points, are summarized here.
Contact corrosion!
^ Transmission housing of continuously variable automatic transmission Multitronic 01J consists of a magnesium alloy.
^ Bolts and other components which have direct contact with transmission have a surface coating which is matched to magnesium transmission housing.
^ On magnesium transmissions, bolts must always be replaced on following bolted connections: transmission cover to transmission housing and final drive cover to transmission housing.
^ Contact corrosion occurs when incorrect components (bolts, nuts, washers, etc.) are used. The transmission housing will be damaged.
^ Transmission housing, transmission cover and differential cover must all be of same material.
^ If you are not sure whether used parts can be re-installed, always install new parts.
CAUTION!
^ Use only Genuine Audi Parts!
^ Damage resulting from contact corrosion is not covered by the warranty!
General Repair Notes
Transmission
^ Observe rules of cleanliness for working on the transmission.
^ Do not run engine with end cover removed or without ATF filling and do not tow vehicle.
^ Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.
^ After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear and axle oil in front final drive.
O-rings, seals, gaskets
^ Always replace O-rings, gaskets and seals.
^ 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.
^ To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.
^ Lightly lubricate O-rings with ATF when installing to prevent the rings from being pinched when components are assembled.
^ Only use ATF for automatic transmission components. Other types of lubrication cause faults to occur in the transmission hydraulics.
^ Open sides of oil seals face fluid side.
^ When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
^ After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear and axle oil in front final drive.
Bolts and nuts
^ Loosen bolts in reverse of tightening sequence.
^ Nuts and bolts which secure covers and housings should be tightened in stages according to specified sequence and tightening method.
^ Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
^ The tightening torques stated apply to unoiled bolts and nuts.
^ Replace self-locking bolts and nuts.
^ Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with locking fluid AMV 185 101 A1.
^ Threaded holes into which self-locking bolts or bolts coated with locking fluid are installed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
Locking elements
^ Do not over-stretch circlips.
^ Always replace circlips which have been damaged or over-tensioned.
^ Circlips must be properly seated in the base of the groove.
Bearings
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
^ Insert bearing with axle oil or ATF, depending on installation location.
^ Do not interchange outer or inner races of bearings of the same size.
^ Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.
Adjustment shims
^ Use a micrometer to measure shims at several points. Varying tolerances make it possible to measure the required shim thickness exactly.
^ Inspect for burrs and signs of damage. Install only shims that are in perfect condition.
Guided Fault Finding
Always perform Guided Fault Finding using Diagnostic Operation System VAS 5051 A before starting disassembly and assembly work.
Rules for cleanliness when working on transmission
^ Carefully clean all joints and adjacent areas before disconnecting.
^ Place removed parts on a clean surface and cover them. Use sheeting or paper. Do not use fluffy cloths!
^ Carefully cover or plug unpacked components if repairs cannot be performed immediately.
^ Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.
Transmission bell housing, ATF leaking
Note:
^ If ATF leak is determined from check hole behind ATF breather pipe - A - at level of bolt - B -, transmission is malfunctioning and must be replaced.