Transmission Fluid, Checking and Filling

Transmission Fluid, Checking and Filling

Special tools, testers and auxiliary items required

• Oil Collecting and Extracting Device (V.A.G 1782)

• Vehicle Diagnosis Tester, for example, Vehicle Diagnosis, Testing and Information System (VAS 5051B)

• Adapter for Oil Filling (VAS 6262 A)

• Protective eyewear

• Acid-resistant protective gloves

Procedure

• Tightening specifications, refer to => [ Drain Plug, Inspection Plug and Overflow Tube for Transmission Oil Overview ] Drain Plug, Inspection Plug and Overflow Tube For Transmission Oil Overview.

• Refer to => [ Repair Information ] Repair Information.

• Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• Observe notes for direct-shift gearbox 02E, Disposal regulations for oils, refer to => [ Transmission ] Transmission.


• Always keep a safe distance away from the radiator fan whenever working on the cooling system - danger of injury!

• Fan can switch on by itself.

• Wear protective eyewear.

• Wear protective gloves.


• Do not start the engine if there is little or no oil in the transmission due to repair work or severe loss of transmission fluid.

• In this case, fill first with transmission fluid for direct manual transmissions.

• Only transmission fluid for direct shift transmission available as replacement part must be used in the Direct Shift Transmission 02E. Using other oils can lead to function problems or can even cause the transmission to fail. For the specification, refer to the electronic parts catalog ETKA.

Test Conditions

• The transmission must not be in the emergency running.

• Move the vehicle onto a 4-column shop hoist or over a work pit so it is completely level.

• Place selector lever in position "P", engage parking brake.

• Exhaust hose/hoses of an exhaust extraction system connected.

• Engine running at idle.

• The A/C and the heater are off.

• Vehicle diagnosis tester connected, select Vehicle Self-Diagnosis and 02 -Transmission Electronics => Vehicle Diagnosis Tester.

• At the start of the testing, the transmission oil temperature must not be higher than 30 °C (86 °F); let the transmission oil cool down.

• The vehicle diagnosis tester reads the transmission oil temperature.

• The transmission oil level changes with the gear oil temperature.

• A transmission oil inspection with a transmission oil temperature that is too low will lead to over-filling.

• A transmission oil inspection with a transmission oil temperature that is too hot will lead to insufficient filling.

• Overfilling or underfilling will influence the function of the transmission.

Read the Transmission Oil Temperature:

Display on the vehicle diagnosis tester:





- In selection - 1 - press the function Measured Values and go further by pressing the ->-button.

Display on the vehicle diagnosis tester:





- Press 1 9 in field - 1 - for "display group 019" and then press Q to confirm the entry.

Display on the vehicle diagnosis tester:





- Read transmission oil temperature in display field - 1 -.

Transmission Oil Level, Checking

• All precautionary measures and test conditions must be followed.

- Remove the noise insulation - 1 -.





• Depending on the version, different noise insulation may be installed.

- Press the brake pedal and hold it down.

- With brake pressed, shift through all selector lever positions "P, R, N, D, S" at idle, retaining each position for at least 3 seconds.

- Place the (V.A.G 1782) under the transmission.

Display on the vehicle diagnosis tester:





- Read transmission oil temperature in display field - 1 -.

- Remove the check plug - B - when the transmission oil temperature reaches 35 °C (95 °F).





• The inspection plug - B - is located next to the pendulum support.

First, the transmission oil will drip into the overflow tubes - arrow 2 -.





• Even if the level of oil is too low, first a small amount of transmission oil will flow out of the overflow tubes, because it fills during operation.

- Check to see if the overflow tubes are correctly screwed into the transmission, tighten if necessary.

• If the overflow tube is not correctly connected, the correct oil status cannot be determined.

- Allow the excess transmission oil to drain.

The transmission oil level is correct if a small amount of fluid drips out with a transmission oil temperature between 35 °C and 45 °C (95 °F and 113 °F) (this is normal as the fluid expands as it heats up).

In this case, no more transmission fluid must be added; the fluid level is OK.

• Every 30 seconds, a small wave of fluid exits the oil level tube, regardless of the height of the oil level (Reason: cooling oil impulse to clutch.) This wave does not mean there is excess fluid and does not indicate the fluid level.

• The transmission oil drained may not be used again. Dispose of drained oil properly.

If no oil leaks with a transmission oil temperature between 35 °C and 45 °C (95 °F and 113 °F), add more transmission oil.

Continuation for Correct Transmission Fluid Level:

- Replace seal - arrow - for inspection plug.





- Install the inspection plug - B - with a new seal. The transmission oil level test is now completed.





- End function Measured Values. Measured values by pressing ← button.

- Press End Output.

- Switch ignition off and disconnect Data Link Connector (DLC).

Transmission Fluid, Filling

• All precautionary measures and test conditions must be followed.

• Place selector lever in position "P", engage parking brake.

• Exhaust hose/-hoses of an exhaust extraction system connected.

• Engine running at idle.

Display on the vehicle diagnosis tester:





- Read transmission oil temperature in display field - 1 -.

Add transmission fluid if no oil escapes the overflow tube - arrow 2 - with a temperature between 35 °C and 45 °C (95 °F and 113 °F) with a running engine:






The (VAS 6262 A) must be clean and transmission fluid must not be mixed with another fluid!

- Install transmission fluid container on the (VAS 6262 A); parts number, refer to the electronic parts catalog ETKA.





- Screw in (VAS 6262 A) into the opening of the inspection plug - B -.





- Hold transmission fluid container as high as possible over transmission and allow fluid to run into transmission.

Check Transmission Fluid Level (several times, if necessary):

- Disconnect quick-release coupling at (VAS 6262 A) and seal off hose with a clean stopper or with a finger.

First, the transmission oil will drip into the overflow tubes - arrow 2 -.





- Allow the excess transmission oil to drain.

The transmission oil level is correct if a small amount of fluid drips out with a transmission oil temperature between 35 °C and 45 °C (95 °F and 113 °F) (this is normal as the fluid expands as it heats up).

In this case, no more transmission fluid must be added; the fluid level is OK.

• Every 30 seconds, a small wave of fluid exits the oil level tube, regardless of the height of the oil level (Reason: cooling oil impulse to clutch.) This wave does not mean there is excess fluid and does not indicate the fluid level.

• The transmission oil drained may not be used again. Dispose of drained oil properly.

If no transmission fluid drops out of inspection hole, you must continue adding fluid and checking until fluid level is OK (observe transmission fluid temperature).

Continuation for Correct Transmission Fluid Level:

- Remove the (VAS 6262 A) from the transmission.

- Replace seal - arrow - for inspection plug.





- Install the inspection plug - B - with a new seal. The transmission oil level test is now completed.





- End function Measured Values. Measured values by pressing ← button.

- Press End Output.

- Switch ignition off and disconnect data link connector (DLC).