0cj Audi Dupla Embreagem Audi q5

Service
Repair Manual
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ ,
Audi A4 China 2016 ➤ ,
Audi A4 allroad quattro 2016 ➤ ,
Audi A5 2016 ➤ , Audi A6 2011 ➤ ,
Audi A6 2019 ➤ , Audi A6 Avant 2011 ➤ ,
Audi A6 China 2012 ➤ ,
cardiagn.com
Audi A7 Sportback 2011 ➤ ,
Audi A7 Sportback 2018 ➤ ,
Audi A7 Sportback USA 2011 ➤ ,
Audi Q5 2008 ➤ , Audi Q5 2017 ➤ ,
Audi Q5 China 2019 ➤
Servicing - 7-Speed Dual Clutch Transmission 0CJ,
0CL, 0CK, 0DN, 0DP, 0HL
Edition 05.2018
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
cardiagn.com
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Audi AG, Ingolstadt D4B804AF0CA

Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A4 China 2016 ➤ , Audi A4 a ...
Servicing - 7-Speed Dual Clutch Transmission 0CJ, 0CL, 0CK, 0DN, 0DP, 0HL - Edition 05.2018
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 ATF Pump, Deactivating and Draining the Hydraulic Pump Reservoir . . . . . . . . . . . . . . . . 4
2 Rules for Cleanliness when Working on DSG® Transmission . . . . . . . . . . . . . . . . . . . . . . 5
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Overview - Flywheel and Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Flywheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Dual Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
cardiagn.com
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Overview - Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 Transmission Fluid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Overview - Transmission Fluid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Transmission Fluid Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
6 ATF Circuit . . . . . . . . . .with. . respect
. . . . .to.the
. .correctness
. . . . . . of. .information
. . . . . .in.this
. . document.
. . . . . .Copyright
. . . . . by
. .AUDI
. . .AG.
......... 48
7 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9 Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.1 Overview - Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.2 Overview - Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.3 Overview - Solenoid Valves and Pressure Regulating Valves in Valve Body . . . . . . . . . . 55
9.4 Overview - Transmission Control Module J217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.5 Transmission Fluid Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.6 Mechatronic, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.7 Transmission Control Module J217 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 65
9.8 Valve Body, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.9 Hydraulic Pressure Sensor 1 G545 and Hydraulic Pressure Sensor 2 G546 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.10 Transmission Fluid Auxiliary Hydraulic Pump V552 , Removing and Installing . . . . . . . . . . 73
9.11 Solenoid Valves and Pressure Regulating Valves in Valve Body, Removing and Installing
........................................................................ 76
9.12 Valve Body Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1 Gears and Shafts, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Gear Set, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Contents i
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1 Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1 Component Location Overview - Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.1 Component Location Overview - Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.1 Overview - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.2 Left Flange Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.3 Right Flange Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4 Center Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 Overview - Center Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2 Center Differential, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3 Transmission Output Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4 Transmission Output Shaft Ball Bearing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.5 Center Differential Ball Bearing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
cardiagn.com
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ii Contents
00 – General, Technical Data

1 Repair Information
(Edition 05.2018)
⇒ “1.1 General Repair Information”, page 1
⇒ “1.2 Contact Corrosion”, page 3
⇒ “1.3 ATF Pump, Deactivating and Draining the Hydraulic Pump
Reservoir”, page 4
1.1 General Repair Information

Using the Repair Manual
Refer to the “7-Speed DSG® Transmission 0CK” repair manual
for all special procedures with the transmission installed, depend‐
ing on the model. The servicing repair manual either does not
describe them or describes them only partially. Both repair man‐
uals are needed for a successful repair.
cardiagn.com
The highest level of care and cleanliness along with tools that
function properly are required to ensure a proper and successful
transmission
with respectrepair. Of course the general safetyCopyright
precautions
by AUDI also
to the correctness of information in this document. AG.
apply when carrying out repair work.
Some general repair information that applies to several proce‐
dures 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 drained fluid properly.
♦ Follow the legal, environmental, and disposal regulations.
♦ Follow the instructions listed on the fluid packaging.
Special Tools
Refer to Workshop Equipment and Special Tools for a complete
list of special tools used in the repair manual.
Transmission
♦ Follow all the guidelines for clean working conditions. Refer to
⇒ “2 Rules for Cleanliness when Working on DSG® Trans‐
mission”, page 5 .
♦ Do not run the engine or tow the vehicle when the transmission
is open or when there is no transmission fluid.
♦ If installing parts that can be used again, clean and check them
and replace if necessary.
♦ During installation, make sure the alignment sleeves are fitted
correctly.
O-rings, Shaft Seals, Seals
♦ Always replace the O-rings, shaft seals and seals.
♦ After removing the seals, examine the contact surface on the
housing or shaft for burrs resulting from removal or for other
signs of damage.
♦ Clean the housing separating surface thoroughly before as‐
sembling.
1. Repair Information 1
♦ Before installing, lightly lubricate shaft seal outer circumfer‐

ence and sealing lips with ATF or gear oil, depending on the
installation location.
♦ Depending on the component location, coat the O-rings lightly
with ATF or transmission fluid to insert them. This prevents
them from being crushed when being installed.
♦ Use only ATF in the ATF area. Other lubricants cause mal‐
functions in the hydraulic transmission control.
♦ The open side on the shaft seals faces the fluid to be sealed
off.
♦ After installing check the ATF level or the transmission fluid
level with the transmission installed and correct. Refer to “7-
Speed Dual Clutch Transmission 0CJ, 0CK, 0CL” ⇒ Rep. Gr.
34 ; ATF; ATF Level, Checking or for transmission fluid level
checking and correcting, refer to ⇒ Rep. Gr. 34 ; Transmission
Fluid . 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
cardiagn.com
tightened in steps according to the specified tightening se‐
quence or method.
♦ Bolts or nuts for securing covers and housings should be loos‐
ened and tightened diagonally in stages if no tightening se‐
quence is specified.
♦ Always replace self-locking bolts and nuts.
♦ 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.
♦ If self-locking bolts were installed or if regular bolts were in‐
stalled with locking fluid, thenProtected
the threaded
by copyright.holes
Copyingmust beor commercial purposes, in part or in whole, is not
for private
cleaned, for example with a thread tap. Otherwise there is the
risk that the bolts could break off the next time they are re‐
moved.
♦ The tightening specifications given apply to unoiled bolts and
nuts.
Circlips, Snap Rings
♦ Do not stretch the circlips.
♦ Replace damaged or stretched circlips.
♦ The circlips must rest at the bottom of the groove.
Bearings
♦ Install needle bearings with the lettered side (thicker metal)
facing the fitting tool.
♦ Coat and install the bearings with gear oil or with ATF, de‐
pending 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 to‐
gether and use new bearings from a single manufacturer.
Shims
♦ Measure the shims at several locations with a micrometer.
Different shim thicknesses make it possible to select the re‐
quired thickness precisely; install two shims if necessary.
2 Rep. Gr.00 - General, Technical Data

♦ Check for burrs or damage. Only install flawless 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
Protected byacopyright. Copying for private or commercial purposes, in part or in whole, is not
grounded object, for example vehicle ground, the heater
or the hoist. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Do not touch connector terminals in the transmission con‐

nector with hands.
1.2 Contact Corrosion

Contact corrosion can occur if inadequate fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating may
cardiagn.com
be installed.
In addition, rubber or plastic parts and adhesives are made of
non-conductive materials.
If there are doubts about whether parts can be used or not, 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.
♦ Contact corrosion damage is not covered under warranty.
1. Repair Information 3
1.3 ATF Pump, Deactivating and Draining

the Hydraulic Pump Reservoir
WARNING
The system is under pressure.

The ATF transmission “7-Speed Dual Clutch Transmission
0CJ, 0CK, 0CL” is equipped with an electronic ATF pump and
a hydraulic pressure reservoir.
The electronic ATF pump can start up at any time.
The ATF system also remains under pressure with the ignition
switched off due to the hydraulic pressure reservoir.
♦ The electronic ATF pump must be deactivated every time
before opening the transmission, and the hydraulic pres‐
sure reservoir is drained.
♦ When the system status is not clear, for example the
cause of a faulty transmission control module or transmis‐
sion is unknown, only loosen the mechatronic bolts to a
minimal degree, so that the oil pressure in the pressure
cardiagn.com
reservoir can decrease slowly.
♦ Disconnect the Transmission Control Module - J217- con‐
nector before removing the oil pan.
♦ Wear protective eyewear.
ATF Pump, Deactivating and Draining the Hydraulic Pump Res‐

ervoir
– Connect Vehicle Diagnostic Tester with the vehicle and start
the Diagnostic mode.
♦ Select vehicle test
♦ 02-Transmission electronics, functions
♦ 02 ATF pressure reduction/Disabling the ATF pump or
02-ATF level ⇒ Draining ATF
4 Rep. Gr.00 - General, Technical Data

2 Rules for Cleanliness when Working

on DSG® Transmission
♦ Thoroughly clean the connection points and the surrounding
area before loosening.
♦ Clean the transmission and transmission components using
Cleaning Solution - D 009 401 04- .
♦ Use lint-free cloths for cleaning, for example, the “WYPALL
X70/WORKHORSE” cloth made by Kimberly-Clark Professio‐
nal.
♦ Seal all open lines and connections immediately with clean
plugs or caps from the Engine Bung Set - VAS6122- .
♦ Place the removed parts on a clean surface and cover them.
Use foil or lint-free cloths.
♦ Carefully cover or seal opened components if the repair will
not be done immediately.
♦ Only install clean parts: remove the replacement parts from
their packaging just before installing them.
cardiagn.com
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
2. Rules for Cleanliness when Working on DSG® Transmission 5

30 – Clutch
1 Clutch
⇒ “1.1 Overview - Flywheel and Dual Clutch”, page 6
⇒ “1.2 Flywheel, Removing and Installing”, page 7
⇒ “1.3 Dual Clutch, Removing and Installing”, page 9
⇒ “1.4 Input Shaft Seal, Replacing”, page 14
⇒ “1.5 Input Shaft Seal, Replacing”, page 15
1.1 Overview - Flywheel and Dual Clutch
1 - Flywheel
❑ Refer to the Parts Cata‐
log because there are Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
different versions de‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
pending on the date of with respect to the correctness of information in this document. Copyright by AUDI AG.
cardiagn.com
manufacture.
❑ Removing an installing.
Refer to
⇒ “1.2 Flywheel, Re‐
moving and Installing”,
page 7 .
2 - Shaft Seal
❑ Replacing. Refer to
⇒ “1.5 Input Shaft Seal,
Replacing”, page 15 .
❑ For the input shaft
3 - Dual Clutch
❑ Refer to the Parts Cata‐
log because there are
different versions de‐
pending on the date of
manufacture.
Refer to
⇒ “1.3 Dual Clutch, Re‐
page 9 .
4 - Engaging Bearing
❑ Pay attention to the in‐
stalled position.
❑ Can only be replaced to‐
gether with the clutch
Refer to
page 9 .
5 - Clutch Slave Cylinder
❑ Can only be replaced together with the clutch
❑ Removing an installing. Refer to ⇒ “1.3 Dual Clutch, Removing and Installing”, page 9 .
6 - Bolt
❑ 10 Nm + 90°
6 Rep. Gr.30 - Clutch

❑ Always replace
❑ Tighten diagonally to the tightening specification
❑ M8
7 - Seal
❑ Always replace
8 - Double Shaft Seal
❑ Always replace
❑ Removing and installing. Refer to ⇒ “1.4 Input Shaft Seal, Replacing”, page 14 .
9 - Guide Sleeve
❑ Pay attention to the installed position.
❑ Removing and installing. Refer to ⇒ “1.4 Input Shaft Seal, Replacing”, page 14 .
10 - Seal
❑ Always replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Seal with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Always replace
12 - Seal
cardiagn.com
❑ Always replace
13 - Alignment Sleeve
14 - Bolt
❑ 5 Nm + 30°
❑ Tighten evenly
❑ Not present depending on the version.
❑ M6
15 - Bolt
❑ 60 Nm
❑ M10 x 15.5
1.2 Flywheel, Removing and Installing

Special tools and workshop equipment required
♦ Puller - Clutch Module - T40176-
♦ Engine And Transmission Holder - VAS6095-
♦ Clutch Disc Shaft Spline Lubricant - G 000 100-
♦ Sealing Grease. Refer to the Parts Catalog.
Removing
1. Clutch 7
Note
♦ There is a normal »clicking« in the dual mass flywheel with

“LuK” centrifugal pendulum absorber -A-.
♦ A »clicking« is heard when turning the clutch module -A- ap‐
proximately every 90°. This noise comes from shifting pendu‐
lum masses (centrifugal pendulum absorber) in the dual mass
flywheel and is not a fault.
• Secure the transmission on the -VAS6095- . Refer to

⇒ “3 Securing on Engine and Transmission Holder”,
page 23 .
– Remove the left flange shaft. Refer to
⇒ “3.2 Left Flange Shaft, Removing and Installing”,
page 106 .
– Attach the -T40176- to the flywheel -A- with the nut -B-
-arrow-.
– Turn the -T40176- upward.
cardiagn.com
Note
To prevent the flywheel from tilting, counterhold it underneath as

shown.
– Remove the flywheel from the input shaft -arrow-. Do not tilt
the flywheel when doing this.
Installing
Install in reverse order of removal. At the same time note the fol‐
lowing:
– Always clean the transmission housing in the area where the
differential is accessed -arrow A- and the shaft seal

-arrow B-.
Note
Replace the shaft seal between the differential and transmission

housing -arrow B- if it is damaged.
– Fill the space between the sealing/dust lip halfway with sealing
grease. Refer to the Parts Catalog for the correct sealing
grease.

– Clean the input shaft -arrow-.

– Lubricate the input shaft splines using Grease for Clutch Disc
Shaft Splines - G 000 100- .
– Slide the clutch module onto the input shaft -arrow- carefully
without tilting it.
cardiagn.com
– Remove the -T40176- from the flywheel -A-.
– Install the left flange shaft. Refer to
page 106 .
1.3 Dual Clutch, Removing and Installing

♦ Shop Crane - VAS6100-
♦ Dual Clutch Lifting Device - T40123A- and Dual Clutch Lifting
Device - Sleeve - T40123A/2-
♦ Pressure Stand - T40099-
♦ Guide Pins - Gearbox - T40288-
♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/
2-
Removing
• Secure the transmission on the -VAS6095- . Refer to
⇒ “3 Securing on Engine and Transmission Holder”,
page 23 .
– Remove the flywheel. Refer to
⇒ “1.2 Flywheel, Removing and Installing”, page 7 .
– Turn the transmission in the -VAS6095A- so that it is vertical.
1. Clutch 9
– Remove the bolts -1 to 12-.
– Secure the Dual Clutch Lifting Device - T40123A- and Dual

Clutch Lifting Device - Sleeve - T40123-2- on the clutch input
shaft --.
– Make sure the puller is secure on the input shaft.
cardiagn.com
– Connect the Dual Clutch Lifting Device - T40123A- with the
Engine Support Bridge - Additional Hooks (2 pc.) - 10 - 222 A /
2- and engage in the Shop Crane - VAS 6100- .
– Carefully remove the dual clutch out of the transmission hous‐
ing.
Caution
When removing, the engaging bearing and both alignment

sleeves can fall out of the transmission housing.
♦ A damaged or dropped engaging bearing must be re‐
placed.
Note
♦ The dual clutch is extensively calibrated on the engaging bear‐

ing and slave cylinder.
♦ Calibrating with service equipment is not possible.
♦ A damaged engaging bearing or slave cylinder must for this
reason always be replaced with a new clutch.
♦ A new clutch is always supplied with a calibrated engaging
bearing and slave cylinder. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Caution
There is a risk of damaging the dual clutch from mishandling.

• The hub for "clutch 2" -arrow- is clipped in the inner disk
support and can be loosed through mishandling of the
clutch.
• Transport and position the clutch only as shown:
cardiagn.com
1. Clutch 11
It Can Be Checked by Measuring the Height Dimension If the

Clutch Is Damaged. Refer to ⇒ page 13
– Remove the three bolts -arrows- and remove the engaging
bearing with the slave cylinder.
Note
Depending on the version the three bolts -arrows- may not be

present.
Installing
Note
The double shaft seal for the input shaft must always be replaced!
Refer to ⇒ “1.4 Input Shaft Seal, Replacing”, page 14 .
– Check if the sleeves -1 and 2- are installed.
cardiagn.com
– Coat the new seals -3, 4 and 5- with ATF and install.
– Insert the seal -6-.
Note
Make sure no dirt can fall into the transmission while cleaning.
– Install the engaging bearing with the
with respect to theslave cylinder
correctness and tighten
of information in this document. Copyright by AUDI AG.
the three bolts -arrows- evenly.
Note
Depending on the version the three bolts -arrows- may not be

present.

Note
♦ Pay attention that the engaging bearing is installed correctly

to the slave cylinder.
♦ The ball bearings are visible! -Arrow-
– Install the -T40288- in the threaded hole approximately 120° Copying for private or commercial purposes, in part or in whole, is not
cardiagn.com
Protected by copyright.
offset. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Check the Clutch Installation Height
• Before installing the clutch the dimension -x- must be deter‐

mined.
• To do so use the -T40100- and -VAS6087- to determine the
height of the clutch cover to the hub offset as shown.
The dimension -x- must be located within the tolerance of 98.91
to 99.61 mm.
Note
If the dimension -x- is outside of the tolerance, the clutch must be

replaced because it is damaged.
1. Clutch 13
– Place the dual clutch as shown in the transmission housing.
– Tighten the bolts -1 to 12- for the clutch cover diagonally in
cardiagn.com
steps. Tightening specification. Refer to
⇒ “1.1 Overview - Flywheel and Dual Clutch”, page 6 .
– Install the flywheel. Refer to permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “1.2 Flywheel, Removing and Installing”, page 7 .
• After installing the transmission fill the ATF and transmission
fluid. Refer to⇒ 7-Speed Dual Clutch Transmission 0CJ, 0CK,
0CL; Rep. Gr. 34 ; ATF; ATF, Draining and Filling and ⇒ 7-
Speed Dual Clutch Transmission 0CJ, 0CK, 0CL; Rep. Gr.
34 ; Transmission Fluid; Transmission Fluid, Draining and Fill‐
ing
• After changing the dual clutch the clutch must be adapted.
Refer to Vehicle Diagnostic Tester .
Procedure
– Connect the Vehicle Diagnostic Tester .
– Select Diagnostic mode and start the diagnostics.
– Select the Test plan tab.
– Select individual test button and select the following
tree structure one after the other:
♦ Drivetrain
♦ 7-Speed Dual Clutch Transmission 0CK/0CL
♦ 01 - OBD-capable systems
♦ 02 - Transmission electronics 0CK
♦ 02 - Transmission electronics, functions
♦ 02 - Basic Setting
♦ ⇒ Clutch valve calibration
1.4 Input Shaft Seal, Replacing

♦ Puller - Crankshaft/Power Steering Seal - T20143-
♦ Thrust Piece - T40300-

• Clutch, engaging bearing and slave cylinder removed. Refer

to ⇒ “1.3 Dual Clutch, Removing and Installing”, page 9 .
– With the -T20143- carefully remove the seal -arrow- from the
housing.
– A waved washer -arrow- is located behind the seal, it does not

need to be replaced.
Note
cardiagn.com
Pay attention to the installed position.
– Drive in the new seal to the stop using the -T40300- .

– Install the clutch. Refer to
⇒ “1.3 Dual Clutch, Removing and Installing”, page 9 .
1.5 Input Shaft Seal, Replacing

♦ Assembly Sleeve - T40308-
Removing
• The clutch is installed.
Caution
There is a risk of damaging the clutch from mishandling.

♦ The shaft seal can only be replaced when the clutch is
installed. Refer to ⇒ page 11
1. Clutch 15
– Pry out the shaft seal -arrow- carefully with the -T20143- .
Note
Do not damage the contact surface on the shaft.
Installing
– Place the -T40308- on the drive axle.
cardiagn.com
– Drive in the new seal with the -T50038- in the clutch housing
until it stops.
– Remove the -T40308- .

2 Special Tools
♦ Pressure Stand - T40099-
cardiagn.com
♦ Dual Clutch Lifting Device - T40123A- and Dual Clutch Lifting
Device - Sleeve - T40123A/2-
♦ Puller - Clutch Module - T40176-
2. Special Tools 17
♦ Guide Pins - Gearbox - T40288-
cardiagn.com
♦ Assembly Sleeve - T40308-

♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/

2-
cardiagn.com
2. Special Tools 19
34 – Controls, Housing
1 Selector Mechanism
All Selector Mechanism Procedures Can Be Found in the Repair
Manual »7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL«
Refer to ⇒ Rep. Gr. 34 ; Selector Mechanism .
cardiagn.com
20 Rep. Gr.34 - Controls, Housing

2 Transmission, Transporting
♦ Lifting Tackle - 3033-
♦ Hook And Support Tool - 3311- with Hook And Support Tool -
Bolt - 3311/1-
♦ Retaining Strap - T40155-
Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Risk of damaging the transmission by mixing ATF and trans‐
mission fluid (MTF) through the same bleeder.
♦ The transmission is filled with ATF and MTF transmission
fluid, the transmission can only be tilted a maximum of 15°
in lateral and longitudinal direction.
♦ If more of an incline is needed, then the ATF and MTF
cardiagn.com
transmission fluids must be drained.
♦ Draining the ATF. Refer to ⇒ 7-Speed Dual Clutch Trans‐
mission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; ATF; ATF, Draining
and Filling .
♦ Draining the transmission fluid. Refer to ⇒ 7-Speed Dual
Clutch Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; Trans‐
mission Fluid; Transmission Fluid, Draining and Filling .
– Secure the transmission on the -3311- (use new longer bolts

-3311/1- ).
2. Transmission, Transporting 21
– Guide the -T40155- around the transmission and secure on

the -3033- .
– Secure the -T40155- on the transmission end with a commer‐
cially available M10 bolt -arrow-.
– Using the -3033- and the -VAS6100- the transmission can be
lifted and transported.
cardiagn.com
Note
To prevent damaging the transmission fluid pump -A- when plac‐

ing the transmission on the oil pan -C-, for support a commercially
available M10 bolt approximately 100 mm long -B- must be in‐
stalled on the rear of the transmission housing.

3 Securing on Engine and Transmis‐

sion Holder
♦ Engine and Gearbox Bracket - VAS6095A-
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-
♦ Gearbox Support - T40206- and Gearbox Support - Drilling
Template - T40206/3-
♦ Lifting Eyebolt - 3368-
Procedure
– Assemble the -T40206- as follows:
• The connection area -arrow A- points upward.
• The lettering “B” points upward -arrow B-.
cardiagn.com
– Place the -T40206/3- on the - T40206- .

– Make an additional 12 mm hole -arrow- in the -T40206- .
– Install the bolts as follows in the holes:
♦ M10x80 in the hole 15
♦ M10x50 in the new hole 5b
3. Securing on Engine and Transmission Holder 23

Caution

♦ The ATF and transmission fluid must be drained.
– Draining the ATF. Refer to ⇒ 7-Speed Dual Clutch Transmis‐

sion 0CJ, 0CK, 0CL; Rep. Gr. 34 ; ATF; ATF, Draining and
Filling .
– Draining the transmission fluid. Refer to ⇒ 7-Speed Dual
Clutch Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; Transmis‐
sion Fluid; Transmission Fluid, Draining and Filling .
– Secure the -3368- with the -10-222A/12- on the transmission
cardiagn.com
housing as shown.
– Secure the -T40155- on the -10-222A/12- and on the left
flange shaft -arrow-.
– Lift the transmission with the -VAS6100- and secure on the -
T40206- as shown.

4 Transmission, Disassembling and

Assembling
⇒ “4.1 Overview - Transmission”, page 25
⇒ “4.2 Overview - Gear Set”, page 29
⇒ “4.3 Transmission, Disassembling and Assembling”,
page 32
4.1 Overview - Transmission

⇒ “4.1.1 Overview - Transmission, FWD
permitted Vehicles”,
unless authorised bypage 25AUDI AG does not guarantee or accept any liability
AUDI AG.
⇒ “4.1.2 Overview - Transmission, AWD Vehicles”, page 27
4.1.1 Overview - Transmission, FWD Vehicles
1 - Gear Set
❑ Removing and instal‐
ling. Refer to
⇒ “4.2.1 Overview -
cardiagn.com
Gear Set, FWD Vehi‐
cles”, page 29 .
2 - Hydraulic Pressure Reser‐
voir
❑ Observe the safety
notes. Refer to
⇒ “1.3 ATF Pump, De‐
activating and Draining
the Hydraulic Pump
Reservoir”, page 4 .
ling. Refer to
⇒ “4.3.2 Gear Actuator
Module and Hydraulic
Pressure Reservoir, Re‐
page 42 .
❑ Disposal. Refer to
⇒ “4.3.3 Hydraulic Pres‐
sure Reservoir, Dispos‐
ing”, page 45 .
3 - Dual Clutch
ling. Refer to
page 9 .
4 - Flywheel
ling. Refer to
page 7 .
6 - Seal
❑ Always replace
7 - Transmission Housing Bolt
❑ Always replace
4. Transmission, Disassembling and Assembling 25

8 - Transmission Fluid Pump

❑ Removing and installing. Refer to ⇒ 7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ;
Transmission Fluid Circuit; Transmission Fluid Pump, Removing and Installing .
9 - Bolt
10 - Transmission Housing
❑ Removing an installing. Refer to ⇒ “4.3 Transmission, Disassembling and Assembling”, page 32 .
11 - Circlip
❑ Always replace
12 - Oil Guide Piece Drive Axle
13 - Cap
❑ Always replace
15 - Seal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
cardiagn.com
16 - Bolt
❑ 15 Nm + 90°
❑ Always replace
❑ With seal
Transmission Housing Tightening Specification and Sequence.

– Tighten the bolts in three steps in the sequence shown:
Step Bolts Tightening Specification
1. -1 to 9- Install by hand evenly until the bolt
head contact the transmission hous‐
ing.
2. -1 to 9- Tighten one after the other to 10 Nm
+ 90°
3. -Arrow- Tighten the remaining bolts clockwise
to 10 Nm + 90°
Wheel Set Tightening Specification and Sequence.

– Push the centering bracket -A- all the way in.
Note
Bolt -6- without centering bracket.
– Tighten the bolts in two steps in the sequence shown:

ing.
+ 90°

4.1.2 Overview - Transmission, AWD Vehicles
1 - Gear Set
ling. Refer to
⇒ “4.2.2 Overview -
Gear Set, AWD Vehi‐
cles”, page 30 .
2 - Hydraulic Pressure Reser‐
voir
❑ Observe the safety
notes. Refer to
⇒ “1.3 ATF Pump, De‐
activating and Draining Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
the Hydraulic Pump permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Reservoir”, page 4 . with respect to the correctness of information in this document. Copyright by AUDI AG.
Refer to
cardiagn.com
page 42 .
❑ Disposal. Refer to
⇒ “4.3.3 Hydraulic Pres‐
sure Reservoir, Dispos‐
ing”, page 45 .
3 - Dual Clutch
ling. Refer to
page 9 .
4 - Flywheel
ling. Refer to
page 7 .
6 - Seal
❑ Always replace
7 - Transmission Housing Bolt
❑ Always replace
9 - Bolt
10 - Transmission Housing
11 - Seal
❑ Always replace

12 - Oil Guide Piece Drive Axle

13 - Differential Housing Bolt
14 - Circlip
❑ Always replace
16 - Seal
❑ Always replace
17 - Bolt
❑ 15 Nm + 90° Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace with respect to the correctness of information in this document. Copyright by AUDI AG.
Transmission Housing Tightening Specification and Sequence.

– Tighten the bolts in three steps in the sequence shown:
cardiagn.com
ing.
+ 90°
3. -Arrow- Tighten the remaining bolts clockwise
to 10 Nm + 90°
Wheel Set Tightening Specification and Sequence.

– Push the centering bracket -A- all the way in.
Note
Bolt -6- without centering bracket.

ing.
+ 90°

4.2 Overview - Gear Set

⇒ “4.2.1 Overview - Gear Set, FWD Vehicles”, page 29
⇒ “4.2.2 Overview - Gear Set, AWD Vehicles”, page 30
4.2.1 Overview - Gear Set, FWD Vehicles
1 - Oil Pipe
2 - Bolt
❑ 3 Nm + 90°
❑ Always replace
❑ M6 × 30
3 - Gear Positioner with:
❑ Transmission Input
Speed Sensor 1 - G632-
❑ Gear Position Distance
cardiagn.com
Sensor 1 - G487-
Sensor 2 - G488-
Sensor 3 - G489-
❑ Gear PositionProtected
Distanceby copyright. Copying for private or commercial purposes, in part or in whole, is not
Sensor 4 - G490-
Refer to
page 42 .
4 - Seal
❑ Always replace
5 - Oil Pan
❑ Always replace
6 - Bolt
❑ 3 Nm + 90°
❑ Always replace
❑ M6 × 30
7 - Seal
❑ Always replace
8 - Hydraulic Pressure Reservoir
❑ Observe the safety notes. Refer to
⇒ “1.3 ATF Pump, Deactivating and Draining the Hydraulic Pump Reservoir”, page 4 .
❑ Disposal. Refer to ⇒ “4.3.3 Hydraulic Pressure Reservoir, Disposing”, page 45 .
9 - Bolts
❑ 3 Nm + 90°
❑ Always replace
❑ M6 × 30

10 - Gear Set
❑ Removing and installing. Refer to ⇒ “4.3 Transmission, Disassembling and Assembling”, page 32 .
11 - Bolts
❑ 6 Nm + 30°
❑ Gearshift rail gear positioner module
❑ M6 × 50
Gear Positioner and Pressure Reservoir Tightening Sequence
Note
Replace the bolts.

Step M6 × 30 Bolts Tightening Specification
1. -1 to 8- 3 Nm
cardiagn.com
2. -1 to 8- 90°
4.2.2 Overview - Gear Set, AWD Vehicles

1 - Oil Pipe
2 - Bolt
❑ 3 Nm + 90°
❑ Always replace
❑ M6 × 30
3 - Gear Positioner with:
Sensor 1 - G487-
Sensor 2 - G488-
Sensor 3 - G489-
Sensor 4 - G490-
cardiagn.com
Refer to
page 42 .
❑ Observe the tightening
sequence. Refer to
⇒ Fig. ““Gear Positioner,
Pressure Reservoir and
Gear Carrier Tightening
Sequence”“ ,
page 32 .
4 - Seal
❑ Replacing
5 - Oil Pan
❑ Replacing
6 - Bolts
❑ 3 Nm + 90°
❑ Always replace
❑ M6 × 30
7 - Needle Bearing
8 - Seal
❑ Always replace
9 - Hydraulic Pressure Reservoir
❑ Observe the safety notes. Refer to
⇒ “1.3 ATF Pump, Deactivating and Draining the Hydraulic Pump Reservoir”, page 4 .
❑ Removing an installing. Refer to
⇒ “4.3.2 Gear Actuator Module and Hydraulic Pressure Reservoir, Removing and Installing”,
page 42 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Disposal. Refer to ⇒ “4.3.3with
Hydraulic
respect to thePressure Reservoir,
correctness of Disposing”,
information in this pageby45
document. Copyright . AG.
AUDI
❑ Observe the tightening sequence. Refer to

⇒ Fig. ““Gear Positioner, Pressure Reservoir and Gear Carrier Tightening Sequence”“ , page 32 .
10 - Bolts
❑ Always replace


11 - Bearing Bracket with Roller Bearing
12 - Gear Set
❑ Removing and installing. Refer to ⇒ “4.3 Transmission, Disassembling and Assembling”, page 32 .
13 - Needle Bearing
14 - Bolts
❑ 6 Nm + 30°
❑ Gearshift rail gear positioner module
❑ M6 × 50
Gear Positioner, Pressure Reservoir and Gear Carrier Tightening

Sequence
– Tighten the bolts in four steps in the sequence shown:
cardiagn.com
1. -1 to 9- 3 Nm
2. -1 to 6- 90° (M6 × 30)
3. -7 to 9- 5 Nm
4. -7 to 9- 120° (M6 × 40)
4.3 Transmission, Disassembling and As‐

sembling
⇒ “4.3.1 Gear Set, Removing and Installing”, page 32
⇒ “4.3.2 Gear Actuator Module and Hydraulic Pressure Reservoir,
Removing and Installing”, page 42 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “4.3.3 Hydraulic Pressure Reservoir, Disposing”, page 45
WARNING

♦ Refer to
⇒ “1.3 ATF Pump, Deactivating and Draining the Hydraulic
Pump Reservoir”, page 4 .
4.3.1 Gear Set, Removing and Installing


♦ Press Tool - T40323-

♦ Assembly Tool - T40305-
♦ Slide Hammer Set - VW771-
♦ Gearbox Assembly Tool - T40213/1/2/3-
♦ Puller - Grease Cap - VW637/2-
♦ Wiring Harness
permitted unless Repair
authorised Set
by AUDI AG.-AUDI
HotAGAir Blower
does - VAS1978/14A-
not guarantee or accept any liability
Caution

♦ The ATF and transmission fluid must be drained.
cardiagn.com
Removing
– Draining the ATF. Refer to ⇒ 7-Speed Dual Clutch Transmis‐
sion 0CJ, 0CK, 0CL; Rep. Gr. 34 ; ATF; ATF, Draining and
Filling .
– Draining the transmission fluid. Refer to ⇒ 7-Speed Dual
Clutch Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; Transmis‐
– Remove the clutch. Refer to
– Turn the transmission on the -T40206- 180°.
FWD Vehicles
– Remove the end cover to do so chisel the center of the cover
and remove using the -VW637/2- as shown.

– Remove the oil catch tray -1-.
AWD Vehicles
– Remove the all wheel drive clutch/self-locking center differen‐
tial.
Refer to ⇒ 7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL,
0DN; Rep. Gr. 39 ; Center Differential; Center Differential, Re‐
moving and Installing .
cardiagn.com
0DN; Rep. Gr. 39 ; All Wheel Drive Clutch; All Wheel Drive Clutch,
Removing and Installing .
– Remove the oil catch tray -1-.
All Vehicles
– Remove the circlip -1-.
– Remove the bolts -1 to 6-.

– Remove the five centering bushings -arrow- using the -

VW771- .
cardiagn.com
Note
Bolt -6- does not have a centering bushing.
– Remove the bolts for the transmission housing.

– Remove the transmission housing with the -T40323- .
– Prepare the 1/4 inch tool with TORX® T30 and flexible exten‐
cardiagn.com
sion as shown.
– Remove the bolts for the gear positioner -arrows-.

– Remove the bolt for the Transmission Input Speed Sensor 1 -

G632- -A- and remove the line from the oil pan -B-.
– Secure the -T40155- and -10-222A/12- on the gear set as
cardiagn.com
shown and slowly and carefully remove with the -VAS6100-
from the transmission housing.
Note
For transmissions with a self-locking center differential, make

sure that both bearings -arrows- do not fall when removing.

Installing
– Bring the gear positioner into the basic setting.
– Push the gear positioner by hand and turn at the same time it
until it engages and determine the current backlash.
Transmission with Self-Locking Center Differential:
cardiagn.com
– Check if the needle bearing -arrow- is installed.
All Transmissions:
– Carefully remove the gear set.
– Guide together the bearing area and gear positioner
-arrows- evenly.

Transmission with Self-Locking Center Differential:

– Install the needle bearing -arrow-.
All Transmissions:
– Install the gear positioner -arrows- hand-tight.
cardiagn.com
• When the gear positioner is installed correctly the dimension
-X- is approximately 2 mm.
– Tighten the bolts for the gear positioner to the tightening spec‐
ification. Refer to
⇒ “4.2.1 Overview - Gear Set, FWD Vehicles”, page 29 .

– Install the Transmission Input Speed Sensor 1 - G632- and

tighten the bolt -A-. Refer to
⇒ “4.2.1 Overview - Gear Set, FWD Vehicles”, page 29 .
– Install the wire in the bracket -B- at the same time pay attention
to the correct routing.
– Install the -T40213A- on the transmission.
cardiagn.com
Note
This step is necessity to that the bearing “E” in the transmission

housing can be mounted correctly on the shaft.
– Install the spindle from the -T40213A- by hand until the input
shaft has raised approximately 2 to 3 Copying
Protected by copyright. mm and there
for private is a small
or commercial purposes, in part or in whole, is not
resistance when turning.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Position the new seal and check if both centering pins are in‐
stalled.
– Warm the inner race of the bearing “E” -arrow- with the -
VAS1978/14A- to a maximum of 100° C (212 °F).
Caution
Risk of damaging the bearing seal.

♦ Only warm up the inner bearing race.

– Guide the transmission housing with the transmission.

– Install the new circlip -1- for the bearing “E”.
Note
♦ The circlips have different installed dimensions.

♦ If the bearing “E” is not replaced, a circlip with the same di‐
mension as the old circlip must be installed.
♦ For a new bearing “E” the largest possible circlip to be installed
must be used.
– Remove the -T40213A- from the transmission.

– Tighten the transmission housing with new bolts. Tightening
sequence and tightening specification. Refer to
⇒ “4.1.1 Overview - Transmission, FWD Vehicles”, page 25 .
– Tighten the bolts for the transmission housing to the tightening

sequence. Refer to
⇒ Fig. ““Transmission Housing Tightening Specification and
cardiagn.com
Sequence.”“
Protected , page
by copyright. 26for.private or commercial purposes, in part or in whole, is not
Copying
– Push in the centering bracket -A- for the gear set all the way.
Note
Bolt -6- without centering sleeve.
– Tighten the new bolts for the gear set -1 to 6- with the tight‐
ening sequence. Refer to
⇒ Fig. ““Wheel Set Tightening Specification and Sequence.”“ ,
page 26 .
Transmission with FWD or All Wheel Drive Clutch

– Install the oil catch tray -1-.

– Press in the new end cover with the -T40323- .
Caution
Oil loss due to improper assembly.

♦ The end cover is installed “dry”. Never use retaining com‐
pound.
♦ Let the end cover be tensioned 10 minutes with the -
T40323- .
Transmission with Self-Locking Center Differential
cardiagn.com
– Install the oil catch tray -1-.
– Install the self-locking center differential/all wheel drive clutch:
0DN; Rep. Gr. 39 ; Center Differential; Center Differential, Re‐
0DN; Rep. Gr. 39 ; All Wheel Drive Clutch; All Wheel Drive Clutch,
All Vehicles
– Install the clutch. Refer toProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fill the ATF. Refer to ⇒ Rep. Gr. 34 ; ATF; ATF, Draining and
Filling .
– Fill the transmission fluid. Refer to ⇒ Rep. Gr. 34 ; Transmis‐
4.3.2 Gear Actuator Module and Hydraulic

Pressure Reservoir, Removing and In‐
stalling
– Remove the transmission fluid pan. Refer to
⇒ “9.5 Transmission Fluid Pan, Removing and Installing”,
page 56 .
– Remove the gear set. Refer to
⇒ “4.3.1 Gear Set, Removing and Installing”, page 32 .

– Disconnect the connector -arrow- using the -T40305- .
FWD
with Vehicles
respect to the correctness of information in this document. Copyright by AUDI AG.
cardiagn.com
– Loosen the bolts -arrow- for the hydraulic pressure reservoir
but do not remove.
Note
♦ If the hydraulic pressure reservoir lifts when loosening the

bolts the ATF system is still under pressure.
♦ In this case the bolts from the Mechatronic must be minimally
loosened to reduce the pressure in the ATF system via the
sealing surfaces.
♦ Also, refer to
– Remove the bolts -arrows- and the hydraulic pressure reser‐

voir.
AWD
– Loosen the bolts -arrow- for the hydraulic pressure reservoir
and bearing bracket but do not remove.
Note
♦ If the hydraulic pressure reservoir lifts when loosening the

bolts the ATF system is still under pressure.
♦ In this case the bolts from the Mechatronic must be minimally
loosened to reduce the pressure in the ATF system via the
sealing surfaces.
♦ Also, refer to
– Remove the bolts -arrows-, the bearing bracket and the hy‐
draulic pressure reservoir.

All Vehicles
– Remove the bolts -1 through 6- and remove the gear positioner
module.
Installing
– Insert the gear positioner module and tighten the bolts in the
sequence -1 to 6- hand-tight.
cardiagn.com
– Before installing the hydraulic pressure reservoir, coat the
seals and oil filler hole with ATF.
– Guide the hydraulic pressure reservoir carefully and evenly
into the oil filler hole, and tighten the bolts -arrow- hand-tight.
– Tighten the gear actuator and the pressure reservoir to the
tightening specification - FWD vehicle. Refer to
⇒ Fig. ““Gear Positioner and Pressure Reservoir Tightening
Sequence”“ , page 30 .
– Tighten the gear actuator and the pressure reservoir to the
tightening specification - AWD vehicle. Refer to
⇒ Fig. ““Gear Positioner, Pressure Reservoir and Gear Carrier
Tightening Sequence”“ , page 32 .
– Bring the gear positioner into the basic setting.

– Push the gear positioner by hand and turn at the same time it
until it engages and determine the current backlash.
– Install the gear set. Refer to

– Install the connector with the -T40305- .

– Install the transmission fluid pan. Refer to
page 56 .
• After installing the gear actuator the calibration of the Gear
Position Distance Sensor 1 to 4 - G487/G488/G489/G490-
must be performed using the Vehicle Diagnostic Tester .
Procedure
– Connect the Vehicle Diagnostic Tester . by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– Select Diagnostic mode and start the
withdiagnostics.
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Drivetrain
cardiagn.com
♦ ⇒ Distance sensor calibration
4.3.3 Hydraulic Pressure Reservoir, Dispos‐

ing
Note
♦ The installed hydraulic pressure reservoir is around a closed

hollow body; that is impinged on by the prefilled working gas
(nitrogen) with an inner pressure
♦ Because it is prohibited to scrap a closed hollow body, the
hydraulic pressure reservoir must be drained before disposal.
– Remove the hydraulic pressure reservoir. Refer to

⇒ “4.3 Transmission, Disassembling and Assembling”,
page 32 .
WARNING

♦ Wear protective eyewear and hearing protection when
engaging the pressure reservoir.
♦ When the drill bit passes through in the gas space due to
the internal pressure the shavings can be flung around.

– Tension the hydraulic pressure reservoir in the vise.

– Completely drill out approximately 25 mm -dimension x- from
the square deck area with a 3 mm drill bit.
– The pressureless hydraulic pressure reservoir can then be
scrapped.
cardiagn.com

5 Transmission Fluid Circuit

⇒ “5.1 Overview - Transmission Fluid Circuit”, page 47
⇒ “5.2 Transmission Fluid Pump, Removing and Installing”, page
47
5.1 Overview - Transmission Fluid Circuit
1 - Plug
❑ 8 Nm +30°
❑ Replace after removing.
❑ For the ATF check and
fill hole
2 - Plug
❑ 35 Nm
❑ For transmission fluid
inspection and fill hole
cardiagn.com
(MTF Pump) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ With seal welded on with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Must be removed for

draining the transmis‐
sion fluid (MTF).
❑ Replace the transmis‐
sion fluid pump if the
seal is damaged.
ling. Refer to ⇒ Rep.
Gr. 34 ; Transmission
Fluid Circuit; Transmis‐
sion Fluid Pump, Re‐
4 - Bolt
❑ 3 Nm +90°
5 - Drain Plug
❑ 35 Nm
❑ For the ATF
5.2 Transmission Fluid Pump, Removing

and Installing
Chapter: transmission fluid pump, removing and installing can be
found in the repair manual »7-Speed Dual Clutch Transmission
0CJ, 0CK, 0CL«
Refer to ⇒ Rep. Gr. 34 ; Transmission Fluid Circuit; Transmission
Fluid Pump, Removing and Installing .
5. Transmission Fluid Circuit 47

6 ATF Circuit
All ATF circuit work can be found in the repair manual »7-Speed
Dual Clutch Transmission 0CJ, 0CK, 0CL«
Refer to ⇒ 7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL;
Rep. Gr. 34 ; ATF Circuit .
cardiagn.com

7 Transmission Fluid
All transmission fluid work can be found in the repair manual »7-
Speed Dual Clutch Transmission 0CJ, 0CK, 0CL«
Rep. Gr. 34 ; Transmission Fluid .
cardiagn.com
7. Transmission Fluid 49
8 ATF
All work for checking the ATF level and draining and filling can be
found in the repair manual »7-Speed Dual Clutch Transmission
0CJ, 0CK, 0CL«.
Rep. Gr. 34 ; ATF; ATF Level, Checking .
Rep. Gr. 34 ; ATF; ATF, Draining and Filling .
cardiagn.com

9 Mechatronic
⇒ “9.1 Overview - Mechatronic”, page 51
⇒ “9.2 Overview - Valve Body”, page 53
⇒ “9.4 Overview - Transmission Control Module J217 ”,
page 56
page 56
⇒ “9.6 Mechatronic, Removing and Installing”, page 59
⇒ “9.7 Transmission Control Module J217 , Removing and In‐
stalling”, page 65
⇒ “9.9 Hydraulic Pressure Sensor 1 G545 and Hydraulic Pres‐
sure Sensor 2 G546 , Removing and Installing”, page 71
⇒ “9.10 Transmission Fluid Auxiliary Hydraulic Pump V552 , Re‐
moving and Installing”, page 73
9.1 Overview - Mechatronic
cardiagn.com
1 - Transmission Fluid Pan
ling. Refer to
⇒ “9.5 Transmission
Fluid Pan, Removing
and Installing”,
page 56 .
2 - Bolt
❑ Tightening specification
and sequence. Refer to
⇒ Fig. ““Transmission
Fluid Pan - Tightening
Specification and Se‐
quence”“ , page 53 .
❑ M6 × 30
3 - Seal
4 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Fig. ““ Hydraulic Pres‐
sure Sensor 1 -G545-
and Hydraulic Pressure
Sensor 2 -G546- - Tight‐
ening Specification and
Sequence”“ ,
page 53 .
5 - Bracket
6 - Hydraulic Pressure Sensor
1 - G545- and Hydraulic Pres‐
sure Sensor 2 - G546-
ling. Refer to
⇒ “9.9 Hydraulic Pressure Sensor 1 G545 and Hydraulic Pressure Sensor 2 G546 , Removing and
Installing”, page 71 .
9. Mechatronic 51
7 - Seals
8 - Contact Element
9 - Bolt
❑ 3 Nm + 90°
❑ Replacing
❑ M6 × 25
10 - O-ring
11 - Bleed Pipe
12 - Dust Ring
13 - Seals
14 - Seal
❑ Depending on the model
cardiagn.com
❑ For vehicles with Parking Lock Solenoid - N486-
15 - Mechatronic
❑ Removing an installing. Refer to ⇒ “9.6 Mechatronic, Removing and Installing”, page 59 .
16 - Mechatronic Bolts
❑ Refer to ⇒ Fig. ““Mechatronic - TighteningProtected
Specification
by copyright.and Sequence”“
Copying , page purposes,
for private or commercial 53 in part or in whole, is not
❑ M6 × 90 with respect to the correctness of information in this document. Copyright by AUDI AG.
17 - Bolt
❑ 3 Nm + 90°
❑ For vehicles with Parking Lock Solenoid - N486-
❑ M6 × 22
18 - Seal
19 - Transmission Control Module - J217-
20 - Oil Pipe
❑ Depending on the model
❑ Foe vehicles with Parking Lock Solenoid - N486-
21 - Wiring Guide
22 - Seals
23 - ATF Pipe
24 - Seals

Transmission Fluid Pan - Tightening Specification and Sequence

Step Bolts Tightening Specification/Additional
Turn
1. -1 through 25- Install all the way by hand
2. -1 through 25- 3 Nm
3. -1 through 25- 90° additional turn
Mechatronic - Tightening Specification and Sequence

Turn
1. -1 to 7- Install all the way by hand
2. -1 to 7- 8 Nm
3. -1 to 7- 120° additional turn
cardiagn.com
Hydraulic Pressure Sensor 1 - G545- and Hydraulic Pressure
Sensor 2 - G546- - Tightening Specification and Sequence
Turn
2. -1 to 7- 8 Nm
9.2 Overview - Valve Body
9. Mechatronic 53
1 - Low Pressure Filter Hous‐

ing
2 - Bolt
❑ M6 × 20
❑ Quantity: 4
3 - Seal
4 - Suction Filter
5 - Bolt
❑ M5 × 18
❑ Quantity: 2
6 - Bolt
❑ Quantity: 3
❑ M6 × 20
7 - High Pressure Filter Hous‐
ing
8 - High Pressure Filter
cardiagn.com
9 - Seal
10 - Seal
11 - Valve Units
ling. Refer to
⇒ “9.11 Solenoid Valves
and Pressure Regulat‐
ing Valves in Valve
Body, Removing and In‐
stalling”, page 76 .
12 - Valve Unit Retainer
13 - Bolt
❑ M4 × 35
❑ Quantity: 8
14 - Bleed Pipe Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Seal with respect to the correctness of information in this document. Copyright by AUDI AG.
16 - Seal
17 - Transmission Fluid Auxiliary Hydraulic Pump - V552- Motor
❑ Removing and installing. Refer to
⇒ “9.10 Transmission Fluid Auxiliary Hydraulic Pump V552 , Removing and Installing”, page 73 .
18 - Cover
19 - Bolt
❑ 4 Nm + 45°
❑ M5 × 22
❑ Quantity: 4
20 - Transmission Fluid Auxiliary Hydraulic Pump - V552- Pump
❑ Removing and installing. Refer to
⇒ “9.10 Transmission Fluid Auxiliary Hydraulic Pump V552 , Removing and Installing”, page 73 .

21 - Seal
22 - Seal
23 - Valve Body
❑ Removing and installing Transmission Control Module - J217- removing. Refer to
⇒ “9.7 Transmission Control Module J217 , Removing and Installing”, page 65 .
24 - Seal
25 - Seal
26 - Low Pressure Switch
9.3 Overview - Solenoid Valves and Pressure Regulating Valves in Valve Body
1 - Automatic Transmission
Pressure Regulating Valve 1 -
N215-
❑ Clutch pressure valve 1
cardiagn.com
N216-
❑ Clutch pressure valve 2
3 - Solenoid Valve 2 - N89-
❑ Gear Actuator 2-R
❑ Gear Actuator 1-3
❑ Clutch safety valve
6 - Solenoid Valve 5 - N92- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ For clutch cooling valve
7 - Clutch Cooling Valve
Note
♦ Do not remove the clutch cooling

valve it remains in the valve
body!
♦ The height of the accurate fit pre‐
vents reinstalling and the valve
body is damaged at the same
time.

10 - Automatic Transmission Pressure Regulating Valve 3 - N217-
❑ Gear actuator module valve
9. Mechatronic 55
Note
Check before the repair, if the necessary replacement parts are

available. Refer to the Parts Catalog.
Refer to
⇒ “9.11 Solenoid Valves and Pressure Regulating Valves in Valve
Body, Removing and Installing”, page 76
9.4 Overview - Transmission Control permitted

Module unless -authorised
J217-
by AUDI AG. AUDI AG does not guarantee or accept any liability
1 - Seal
2 - Seal
3 - Valve Body
❑ Refer to
⇒ “9.2 Overview - Valve
Body”, page 53 .
cardiagn.com
4 - Bolt
❑ 5 Nm +20°
❑ Always replace
❑ Quantity: 3
5 - Cover
6 - Transmission Control Mod‐
ule - J217-
ling. Refer to
Control Module J217 ,
Removing and Instal‐
ling”, page 65 .
7 - Bolt
❑ 3 Nm +90°
❑ Always replace
❑ Quantity: 4
9.5 Transmission Fluid Pan, Removing and

Installing
♦ Engine Bung Set - VAS6122-
♦ Used Oil Collection and Extraction Unit - SMN372500-

Removing
Note
♦ General repair instructions. Refer to

⇒ “1 Repair Information”, page 1 .
♦ Guidelines for clean working conditions when working on the
dual-clutch transmission. Refer to
WARNING

• Deactivate the ATF pump and drain the hydraulic pressure
reservoir before removing the transmission fluid pan!
• Refer to
cardiagn.com
Caution
Risk of damaging the transmission.

♦ Do not run engine or tow vehicle when the transmission
fluid pan is removed or without transmission fluid.
– Remove the subframe crossbrace. Refer to ⇒ Suspension,

Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe Cross‐
brace, Removing and Installing .
– Using the Vehicle Diagnostic Tester in the Transmission Con‐
trol Module - J217- empty the ATF pressure reservoir and
disable the Transmission Fluid Auxiliary Hydraulic Pump -
V552- . Refer to
Pump Reservoir”, page 4 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Drain the ATF. Refer to ⇒ 7-Speed Dual Clutch Transmission

0CJ, 0CK, 0CL; Rep. Gr. 34 ; ATF; ATF, Draining and Filling .
– Remove the bolts -arrows-.
Note
The coolant hose -2- stays connected to the ATF cooler.
9. Mechatronic 57
– Remove the bolts -arrows- and remove the protective plate

-1-.
– Place the -SMN372500- underneath.
– Only loosen bolts -2- and remove the bolts -1 and 3-.
cardiagn.com
– Remove the ATF cooler -2- from the transmission fluid pan and
hang it to the side. Make sure that the ATF line -1- stays in‐
stalled in the transmission fluid pan while doing this.
– Remove the ATF line -1- from the transmission fluid pan.
– Seal the open lines and connections with clean plugs from the
-VAS6122- .
– Remove the bolts in the sequence -25 to 1- and remove the

transmission fluid pan.
Installing
Install in the reverse order of removal while noting the following:
Note
Replace the seal and the ATF line.

Note
♦ For vehicles with an aluminum transmission fluid pan, a plastic

transmission fluid pan is available as a replacement part.
♦ During the conversion both the centering pins -arrows- must
be removed from the transmission housing.
♦ At the same time pay attention that the sealing surface is not
damaged.
– Install the ATF cooler. Refer to ⇒ 7-Speed Dual Clutch Trans‐

mission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; ATF Circuit; ATF Cooler,
– Fill with ATF. Refer to ⇒ 7-Speed Dual Clutch Transmission
Tightening Specifications Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Refer to with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ Fig. ““Transmission Fluid Pan - Tightening Specification and
Sequence”“ , page 53
cardiagn.com
♦ Subframe crossbrace. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Subframe Crossbrace, Remov‐
ing and Installing .
9.6 Mechatronic, Removing and Installing

♦ Oil Sump Assembly Pin - T40199-
♦ Electronic Torque Wrench 3-60Nm - VAS6583-
♦ Cover - T40322/1-4-
♦ Support - T40321-
Removing
Note

WARNING

reservoir before removing the Mechatronic!
• Refer to
9. Mechatronic 59
Caution
There is a risk of destroying the transmission control module

(Mechatronic) with static discharge.
♦ Always “discharge” the static electricity before working
with connectors. Do this by touching a grounded object,
for example vehicle ground, the heater, or the hoist.
nector with hands.
The Transmission is Installed

– Remove the noise insulations -1 and 2-. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Noise Insulation .
– Drain the ATF. Refer to ⇒ 7-Speed Dual Clutch Transmission
– Turn off the ignition and remove the key.
cardiagn.com
– Disconnect the connector -1- by pressing the locking mecha‐
nism -arrow B- and pull the locking bracket -2- in the direction
of -arrow A-.

– Remove the protective cap -arrow-.

page 56 .
– Disconnect the connector using the -T40305- .
cardiagn.com
9. Mechatronic 61
WARNING
The system may be under pressure.

♦ Make sure that the ATF pressure reservoir is discharged.
Refer to
♦ When the system status is not clear, for example the
cause of a faulty transmission control module, only loosen
the mechatronic bolts to a minimal degree, so that the oil
pressure in the hydraulic pressure reservoir can decrease
slowly.
♦ Wear protective eyewear.
– Loosen the bolt in the sequence -1 to 7- a 1/2 turn.

– Remove the bolts -2 and 5- and install the two -T40199- in their
place.
cardiagn.com
– Remove the remaining bolts -1, 3, 4, 6 and 7-.
Caution
Risk of causing damage to the Mechatronic.

♦ Only bolts -1 through 7- may be loosened.
♦ If other bolts are loosened, this may impair the function of
the Mechatronic unit or it may come apart.
Note
♦ The Mechatronic fits partially inside the transmission.

♦ If the Mechatronic must be removed, then a second technician
will be needed to keep it from falling. Another alternative, the
bolts -1 and 2- can be installed slightly to hold the Mechatronic
in place while it is being removed.
Caution
Risk of causing damage to the Mechatronic.

♦ Lay the Mechatronic with the bolt head side facing down
only.
– Remove the Mechatronic.

Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Contamination damages the Mechatronic.

♦ A clean work environment is required for working on the
Mechatronic.
• Place the removed Mechatronic on a clean surface and cover

it. Use foil or lint-free cloths.

– Seal off the ATF channels with the -T40322/1-4- .

Installing
Caution
♦ The pump for the Transmission Fluid Auxiliary Hydraulic

Pump - V552- can start up on a non-deactivated control
module immediately after installing the connector. Refer
to
cardiagn.com
♦ From this the pump can be damaged, or the residual oil
can flow out under high pressure.
♦ To prevent this install the transmission control module
connector after installing the oil pan and the transmission
filled with ATF.
• Only install clean parts: Remove the new Mechatronic from

the packaging immediately prior to installation.
– Replace the seals -1 through 4-.
Note
-1- is only for vehicles with a Parking Lock Solenoid - N486- .
• Install the two -T40199- hand-tight as illustrated.
Note
The -T40199- prevent

unless authorised the Mechatronic
by AUDI AG. AUDI AG doesfrom tiltingorwhen
not guarantee accept it
anyisliability
being
permitted
installed.
9. Mechatronic 63
– Replace the Mechatronic evenly and install the bolts

-6 and 7- hand-tight.
– Install the remaining bolts according to the tightening se‐
quence. Refer to
⇒ Fig. ““Mechatronic - Tightening Specification and Se‐
quence”“ , page 53 . .
cardiagn.com
page 56 .
Install the oil pan with a new seal and tighten to the tightening
specification. Refer to
⇒ Fig. ““Transmission Fluid Pan - Tightening Specification and
Sequence”“ , page 53 .
– Tighten the ATF drain plug.

– Fill 3.5 liters (3.7 quarts) of AFT in the transmission using the
-VAS6617- . Refer to ⇒ 7-Speed Dual Clutch Transmission
Note
The ATF level can be adjusted after operating the control module.
• For the following components after replacing a set up must be

performed:
♦ Transmission Control Module - J217- . Refer to ⇒ page 70 .
♦ Valve Bodypermitted
. Refer to ⇒
unless page by
authorised 70AUDI
. AG. AUDI AG does not guarantee or accept any liability
♦ Dual-Clutch Transmission Mechatronic - J743- . Refer to
⇒ page 70 .
♦ Drive Position Sensor - G676- . Refer to ⇒ Rep. Gr. 34 ;
Selector Mechanism .
♦ Transmission Fluid Auxiliary Hydraulic Pump - V552- . Refer
to ⇒ page 76 .
cardiagn.com
♦ Gear Position Distance Sensors 1 to 4 - G487/G488/G489/
G490- . Refer to ⇒ page 45 .
♦ Automatic Transmission Pressure Regulating Valve 1 and 2 -
M215/N216- . Refer to ⇒ page 73 .
♦ Solenoid Valves and Pressure Regulating Valves in Valve
Body . Refer to ⇒ page 80 .
Procedure
– Select Diagnostic mode and start the diagnostic.
♦ Drivetrain
– Checking the ATF level. Refer to ⇒ 7-Speed Dual Clutch
Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; ATF; ATF Level,
Checking .
– Install the subframe crossbrace. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe Cross‐
brace, Removing and Installing .
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
66 ; Noise Insulation .
9.7 Transmission Control Module - J217- ,

Removing and Installing
♦ Cover - T40322/1-4-
9. Mechatronic 65
Removing
WARNING

♦ Refer to
⇒ “1.3 ATF Pump, Deactivating Protected
and Draining the Hydraulic
by copyright. Copying for private or commercial purposes, in part or in whole, is not

Note

cardiagn.com
♦ Disable the ATF pump and drain the pressure reservoir. Refer
to
Caution
Risk of destroying Transmission Control Module - J217- with

static discharge.
♦ Always “discharge” the static electricity before working
with connectors. Do this by touching a grounded object,
for example vehicle ground, the heater or the hoist.
nector with hands.

page 56 .

– Release the connector for the Hydraulic Pressure Sensor 1 -

G545- -1- and Hydraulic Pressure Sensor 2 - G546- -2- at the
retaining tabs -arrows- and disconnect from the Transmission
Control Module - J217- .
– Secure the connector as shown in the designated transporta‐
tion safeguard.
– Remove the Mechatronic. Refer to
⇒ “9.6 Mechatronic, Removing and Installing”, page 59 .
Caution

Mechatronic.
– Seal off the ATF channels with the -T40322/1-4- .
cardiagn.com
– Secure the Mechatronic on the Retaining Bracket .
9. Mechatronic 67
– Release the cover -1- for the sensor from the retaining tabs
-arrows- and remove.
– Remove the bolts in the sequence -3 to 1-.
cardiagn.com
– Pivot the Transmission Fluid Auxiliary Hydraulic Pump Rotor

Position Sensor - G847- -1- to the side to the engagement
position.
– Engage the connector for the Gear Position Distance Sensor

1 - G487- and Gear Position Distance Sensor 2 - G488- in the
transportation safeguard in direction of -arrow- and loosen the
bolts in the sequence -4 to 1-.
– Remove the Transmission Control Module - J217- from the
valve body.
Installing
Note
Before installing clean the control module threaded holes of oil

and debris.

– Push the control module evenly on the valve body and tighten
the bolts in the sequence -1 to 4- to the tightening specification.
Note
♦ A protector is located on the ATFbypump.

permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Pay attention to the correct assembly.
cardiagn.com
– Push in the sensor arm -1- on the ATF pump -2- by hand and
tighten the bolts -arrows- hand-tight.
Caution
There is a risk of damaging the ATF pump.

♦ The sensor arm -1- must make contact when attaching the
ATF pump -2-.
– Tighten the bolts to the specification in the following sequence:

-1 through 3-.
9. Mechatronic 69
– Install the cover -1- for the sensor arm -arrows-.
– Install the Hydraulic Pressure Sensor 1 - G545- and Hydraulic

Pressure Sensor 2 - G546- .
Note
♦ Do not switch the connectors,

♦ Make sure that the connection is correct as shown -1 and 2-.
cardiagn.com
♦ Refer to
⇒ “9.9 Hydraulic Pressure Sensor 1 G545 and Hydraulic
Pressure Sensor 2 G546 , Removing and Installing”,
page 71 .
– Install the Mechatronic. Refer to

Tightening Specifications: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Refer to ⇒ “9.1 Overview - Mechatronic”, page 51
Refer to ⇒ “9.2 Overview - Valve Body”, page 53
Refer to
⇒ “9.4 Overview - Transmission Control Module J217 ”, page 56
• If the Transmission Control Module - J217- was replaced, the
function “control module replacing” must be performed using
the Vehicle Diagnostic Tester .
• If the valve body is replaced, the “valve body, replacing” func‐
tion must be performed using the Vehicle Diagnostic Tester .
Procedure
♦ Drivetrain
♦ 02 - Control module/Mechatronic, replacing or 02 - Valve body,
replacing

9.8 Valve Body, Removing and Installing

• The same as: Transmission Control Module - J217- removing
and installing. Refer to
⇒ “9.7 Transmission Control Module J217 , Removing and
9.9 Hydraulic Pressure Sensor 1 - G545-

and Hydraulic Pressure Sensor 2 -
G546- , Removing and Installing
Note
The Mechatronic remains installed.
WARNING

cardiagn.com
♦ Refer to

page 56 .
– Release the catches -arrows- from the connector for the Hy‐
draulic Pressure Sensor 1 - G545- -1- and Hydraulic Pressure
Sensor 2 - G546- -2- and disconnect from the Transmission
Control Module - J217- .
9. Mechatronic 71
– Disconnect the connector using the -T40305- .
– Loosen the bolts in the sequence -7 to 1-.

cardiagn.com
– Remove the Hydraulic Pressure Sensor 1 - G545- -1- and Hy‐
draulic Pressure Sensor 2 - G546- with the retaining plate
-arrow A- and wiring guide -arrow B-.
Installing
Note
Replace the wiring guide -2-.
– Coat the new seal -1- with ATF and install in the valve body
as shown.
– Install the wiring guide -2- with both bolts -arrows- hand-tight.
– Install the Hydraulic Pressure Sensor 1 - G545- -1- and Hy‐

draulic Pressure Sensor 2 - G546- with the retaining plate
-arrow A- and bolts -1 to 5- hand-tight.

– Clip in the Hydraulic Pressure Sensor 1 - G545- -1- and Hy‐

draulic Pressure Sensor 2 - G546- in the wiring guide and
engage on the Transmission Control Module - J217- .
Note
♦ Pay attention that the cable routing is even.

♦ The cables must not stick out or be kinked.
♦ Adapt the cable routing by turning the pressure sensors
-arrows- as shown.
– Tightening specification and sequence. Refer to

⇒ “9.1 Overview - Mechatronic”, page 51 .
cardiagn.com
page 56 .
– After replacing the Hydraulic Pressure Sensor 1 - G545- -1-
and Hydraulic Pressure Sensor 2 - G546- the calibration of the
clutch valve must be performed in the Transmission Control
Module - J217- .
Procedure
♦ Drivetrain
♦ 02 - Transmission electronics,
Protected functions
♦ ⇒ Clutch valve calibration
9.10 Transmission Fluid Auxiliary Hydraulic

Pump - V552- , Removing and Installing
♦ Locking Pin - T10492-
9. Mechatronic 73
WARNING

• Refer to
Caution

Mechatronic.
Removing
cardiagn.com
– Remove the Transmission Control Module - J217- . Refer to
⇒ “9.7Protected
Transmission Control Module J217 , Removing and
Installing”, page 65the.correctness of information in this document. Copyright by AUDI AG.

with respect to
– Secure the Mechatronic on the vise as shown using the -

T40321- .
– Remove the bolts -arrows-.

– Remove the ATF motor -1- with the ATF pump -2- downward
at the same time pay attention that the ATF pump -2- does not
fall down.
Installing
Caution

Mechatronic.
– Place the ATF pump on the ATF motor at the same time pay
cardiagn.com
attention to the correct alignment of the anti-twist mechanism
-arrows-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9. Mechatronic 75
– Drive the ATF motor and ATF pump using the - T10492- in the
valve body.
– With the -T10492- install and tighten the bolts evenly all the
way.
Tightening specification. Refer to
⇒ “9.2 Overview - Valve Body”, page 53 .
– Install the Transmission Control Module - J217- . Refer to
• After replacing the Transmission Fluid Auxiliary Hydraulic
Pump - V552- the function “calibrating the fluid auxiliary hy‐
draulic pump” must be performed. Refer to Vehicle Diagnostic
Tester .
Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

cardiagn.com
♦ Drivetrain
♦ ⇒ Calibrating the auxiliary hydraulic pump
– Checking the ATF level. Refer to ⇒ 7-Speed Dual Clutch
Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; ATF; ATF Level,
Checking .
9.11 Solenoid Valves and Pressure Regulat‐

ing Valves in Valve Body, Removing and
Installing
♦ Cover - T40322/1-4-
♦ Ruler (2 pc.) - T40100-
Note
Check before the repair, if the necessary replacement parts are

available. Refer to the Parts Catalog.

WARNING

• Also refer to
Caution

♦ Pay attention to absolute cleanliness when working on
hydraulic control.
♦ Even a small amount of debris can lead to system mal‐

functions.
♦ Remove the replacement parts from their packaging just
cardiagn.com
prior to installing them.
♦ Protect open oil channels from debris.
Note
Electric allocation of the pressure regulating valves and solenoid

valves. Refer to ⇒ “1 Transmission Control”, page 98 .
Removing
• Check before the repair, if the necessary replacement parts
are available. Refer to the Parts Catalog.
Note
♦ Do not remove the clutch piston valve -arrow- it remains in the

valve body.
♦ The height of the accurate fit prevents reinstalling and the
valve body is damaged at the same time.

– Remove the Transmission Control Module - J217- . Refer to
9. Mechatronic 77
– Remove bolts -arrows- and remove the contact element.
Note
♦ Hold the Solenoid Valve 5 - N92- -1- when removing the

mounting rail.
♦ The clutch cooling valve -2- and the spring -3- must remain in
the valve body.
cardiagn.com
– Remove the bolts -arrows- and remove the mounting rail.
– Remove the valves if necessary carefully pry out as shown in

direction of -arrows-.

Installing
– Coat the valve surface with ATF and push in the valves all the
way.
– Hold the Solenoid Valve 5 - N92- in direction of -arrow-.
– Using the -T40100- align the connection evenly as shown.
– Connect the contact element evenly.
cardiagn.com
– Install the bolts in direction of -arrows- and tighten to the tight‐
ening specification.
9. Mechatronic 79
– Tighten the bolts -arrows- to the tightening specification.

Tightening specification:
⇒ “9.2 Overview - Valve Body”, page 53 .
– Install the Transmission Control Module - J217- . Refer to
– Install the Mechatronic. Refer to
• After replacing the Solenoid Valves
permitted unless the function
authorised by AUDI AG.“Calibrating
AUDI AG does not guarantee or accept any liability
valves” must be performed usingto the
with respect VehicleofDiagnostic
the correctness Test‐
information in this document. Copyright by AUDI AG.
er .
Procedure
cardiagn.com
♦ Drivetrain
♦ ⇒ Cooling oil/clutch valve calibration
9.12 Valve Body Filter, Removing and Instal‐

ling
♦ Cover - T40322/1-4-
• Check before the repair, if the necessary replacement parts
are available. Refer to the Parts Catalog.
Caution

♦ Pay attention to absolute cleanliness when working on
hydraulic control.
♦ Even a small amount of debris can lead to system mal‐
functions.
♦ Remove the replacement parts from their packaging just
prior to installing them.
♦ Protect open oil channels from debris.


1 - Valve Body
❑ Removing and installing
Transmission Control
Module - J217- remov‐
ing. Refer to
Control Module J217 ,
Removing and Instal‐
ling”, page 65 .
2 - Seal
❑ Always replace
3 - Low Pressure Switch
❑ Always replace
4 - Seal
❑ Always replace
5 - Filter Cover
❑ Always replace
6 - Bolts
cardiagn.com
❑ 8 Nm + 60°
⇒ Fig. ““Filter Cover
Tightening Specification
and Sequence”“ ,
page 82 .
❑ Always replace
❑ M6 x 20
7 - Seal
❑ Replace
8 - Suction Filter
❑ Always replace
9 - Bolts
❑ Always replace
❑ M5 x 18
10 - Bolts
❑ Tightening specification and sequence. Refer to
⇒ Fig. ““Filter Cover Tightening Specification and Sequence”“ , page 82 .
❑ Always replace
❑ M6 x 20
11 - Filter Cover
❑ Always replace
permitted ❑unlessPay attention
authorised by AUDItoAG.the
AUDIassembly instructions.
AG does not guarantee or acceptRefer to
any liability
⇒the
with respect to Fig. ““Filter
correctness Cover Tightening
of information Specification
in this document. Copyright by AUDIand
AG. Sequence”“ , page 82 .
12 - Seal
❑ Always replace
13 - High Pressure Filter
❑ Always replace
14 - Seal
❑ Always replace
9. Mechatronic 81
Filter Cover Tightening Specification and Sequence

High Pressure Filter Cover -A-
Note
Pay attention to the -arrows-!

Turn
2. -1 to 3- 8 Nm
Low Pressure Filter Cover -B-
Turn
2. -1 to 4- 8 Nm
cardiagn.com

10 Special Tools
♦ Locking Pin - T10492-
cardiagn.com
♦ Ruler (2 pc.) - T40100-
10. Special Tools 83

♦ Oil Sump Assembly Pin - T40199-
♦ Gearbox Support - T40206- and Gearbox Support - Drilling

Template - T40206/3-
cardiagn.com
♦ Gearbox Assembly Tool - T40213/1/2/3-

♦ Cover - T40322/1-4-
cardiagn.com
♦ Engine and Gearbox Bracket - VAS6095A-

♦ Engine Bung Set - VAS6122-
cardiagn.com
♦ Puller - Grease Cap - VW637/2-
♦ Slide Hammer Set - VW771-

♦ Lifting Tackle - 3033-
cardiagn.com
♦ Hook And Support Tool - 3311- with Hook And Support Tool -
Bolt - 3311/1-
♦ Lifting Eyebolt - 3368-
♦ Not illustrated:
♦ Press Tool - T40323-
♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

35 – Gears, Shafts
1 Gears and Shafts, Disassembling
and Assembling
1.1 Gear Set, Disassembling and Assem‐

bling
⇒ “1.1.1 Overview - Input Shaft 1”, page 88
⇒ “1.1.2 Input Shaft 1, Disassembling and Assembling”,
page 89
1.1.1 Overview - Input Shaft 1
Note
cardiagn.com
Range of repairs currently possible.
1 - Thrustpermitted
Washer unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - 7th Gear Wheel
3 - 7th Gear Bearing Inner
Race
4 - 7th Gear Needle Bearing
5 - 7th Gear Synchronizer Ring
6 - Synchronizer Hub
7 - Thrust Pieces
8 - Locking Collar
10 - 5th Gear Wheel
11 - Thrust Washer
Race
❑ Remains on the input
shaft
88 Rep. Gr.35 - Gears, Shafts

1.1.2 Input Shaft 1, Disassembling and As‐

sembling
♦ Two-Arm Puller - VAS251001-
♦ Seal Installer - Shaft Seal - T10431/1-
♦ Wishbone Rubber Mount Assembly Tool - T10219/1-
♦ Press Plate - VW401-
Disassembling:
Note
For vehicles with AWD, the bearing inner race "F" must be re‐
moved before the gear set is removed.
cardiagn.com
AWD Vehicles:
– Remove the transmission housing. Refer to

– Remove the circlip -arrow-.
– Remove the "F" bearing inner race -arrow- using the -

VAS251001- and -T10431/1- .
All Vehicles:
– Remove the gear set and place it on a clean work station. Re‐
fer to ⇒ “4.3.1 Gear Set, Removing and Installing”, page 32 .
– Remove the bolt -arrow- and remove the shift forks 4/6 and
5/7 together.
1. Gears and Shafts, Disassembling and Assembling 89

Caution
Input shaft damage

♦ When removing the input shaft 1, the 7th gear wheel may
already be loosened and can fall.
– Remove the input shaft from the gear set.
cardiagn.com
Caution
Damage to input shaft 1 components

♦ Individual components may fall out when removing.
– Remove the synchronization with the gear wheel and 5th/7th

gear bearing.
Note
Make sure that the sensor wheel -1- is not damaged.
The following components can now be removed:
Note
Label the installation position of the individual components if necessary.

1 - Thrust Washer
Note
♦ Deposits and debris on the thrust

washer are not critical.
♦ Clean the thrust washer before
installing if necessary.
2 - 7th Gear Wheel

Race
6 - Synchronizer Hub
7 - Thrust Pieces
8 - Locking Collar
cardiagn.com
10 - 5th Gear Wheel
11 - Thrust Washer
Race
❑ Remains on the input
shaft
Assembling: with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install the 5th gear wheel -1- with the synchronizer ring -2- and
position the synchronizer hub -3- with the lettering facing up‐
ward.

– Install the bearing inner race while positioning the fluid holes
-arrows- at an approximately 90° offset.
– Using the Wishbone Rubber Mount Assembly Tool - T10219- ,

press the bearing inner race -1- with the synchronizer hub
-2- up to approximately two-thirds of the way on before the
stop.
– Lift the 5th gear synchronizer ring with the 5th gear wheel -3-
until the synchronizer ring anti-twist mechanism joins with the
synchronizer hub cut-out in direction of -arrows-.
– At the same time, install the bearing inner race -1- and syn‐
cardiagn.com
chronizer hub -2- until they stop.
– Use the flywheel -1- as an assembly stand for input shaft 1

-2- as shown.
– Insert the three thrust pieces -arrows-.

– Push the double-toothed locking collar onto the opening

-arrow A- with the lettering facing upward.
– Press the tops of the thrust pieces in slightly by hand when
installing.
– Mount the synchronizer ring -1- with the 7th gear needle bear‐
cardiagn.com
ing -2- and 7th gear wheel -3-.
Note
♦ Deposits and debris on the thrust washer -1- are not critical.
♦ Clean the thrust washer before installing if necessary.
– Install the thrust washer -1- using the -T10219- .


– Carefully guide the input shaft 1 into the gear set -arrow-. While
doing so, make sure the needle bearings -A and B- are instal‐
led correctly.
– Install the shift forks and tighten the bolt -arrow- to 6 Nm +30°.
cardiagn.com
AWD Vehicles:
– Warm the "F" bearing inner race using the -VAS1978/14A- and
slide it on downward -arrow A- with the collar until it stops.

– Install the circlip -arrow-.

All Vehicles:
– Install the gear set. Refer to
cardiagn.com

2 Special Tools
♦ Wishbone Rubber Mount Assembly Tool - T10219/1-
♦ Seal Installer - Shaft Seal - T10431/1-
cardiagn.com
♦ Two-Arm Puller - VAS251001-

cardiagn.com
2. Special Tools 97
39 – Final Drive, Differential

1 Transmission Control
⇒ “1.1 Component Location Overview - Transmission Control”,
page 98
1.1 Component Location Overview - Transmission Control
1 - DSG Transmission Mecha‐

tronic - J743-
2 - Transmission Fluid Tem‐
perature Sensor - G93- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Temperature Sensor In permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Control Module - G510-

4 - Transmission Control Mod‐

ule - J217-
5 - Transmission Input Speed
cardiagn.com
Sensor 2 - G612-
6 - Transmission Input Speed
Sensor 1 - G632-
7 - Gear Position Distance
Sensor 4 - G490-
Sensor 3 - G489-
9 - Transmission Electric
Pump 2 - V553-
10 - Transmission Fluid Tem‐
perature Sensor 2 - G754-
Sensor 2 - G488-
Sensor 1 - G487-
98 Rep. Gr.39 - Final Drive, Differential

1 - Transmission Fluid Auxili‐

ary Hydraulic Pump - V552-
2 - Transmission Fluid Auxili‐
ary Hydraulic Pump Rotor Po‐
sition Sensor - G847-
3 - Drive Position Sensor 2 -
G869-
4 - Drive Position Sensor -
G676-
N217-
cardiagn.com
N216-
N215-
14 - Hydraulic Pressure Sen‐
sor 1 - G545-
15 - Hydraulic Pressure Sen‐
sor 2 - G546-
1. Transmission Control 99
2 Seals
⇒ “2.1 Component Location Overview - Gaskets”, page 100
⇒ “2.2 Left Seal, Replacing”, page 101
⇒ “2.3 Right Seal, Replacing”, page 103
2.1 Component Location Overview - Gaskets
1 - Flywheel
Refer to
page 7 .
2 - Left Flange Shaft Seal
⇒ “2.2 Left Seal, Replac‐
ing”, page 101 .
cardiagn.com
3 - Front Differential
4 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Final Drive Cover
❑ Tightening specifica‐
tions and sequence. Re‐
fer to
⇒ Fig. ““Final Drive Cov‐
er - Tightening Specifi‐
cation and Sequence”“ ,
page 106
6 - Right Flange Shaft
ling. Refer to
⇒ “3.3 Right Flange
Shaft, Removing and In‐
7 - Right Flange Shaft Seal
ling. Refer to
⇒ “2.3 Right Seal, Re‐
placing”, page 103 .
8 - Selector Lever
ling. Refer to ⇒ 7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; Selector Mechanism .
9 - Selector Shaft Seal
❑ Replacing. Refer to ⇒ 7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL; Rep. Gr. 34 ; Selector Mech‐
anism .
10 - Left Flange Shaft
❑ Removing and installing. Refer to ⇒ “3.2 Left Flange Shaft, Removing and Installing”, page 106 .
11 - Clutch Cover Seal
❑ Replacing. Refer to ⇒ “1.5 Input Shaft Seal, Replacing”, page 15 .

2.2 Left Seal, Replacing

♦ Puller - Camshaft Seal - 3240-
♦ Seal Installer - Flange Shaft - T40164-
♦ Puller - Flanged Shaft - T10037-
♦ Sealing Grease - G 052 128 A1-
Removing
– Remove the left and right drive axle. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Re‐
– Remove the left flange shaft slightly from the transmission but
do not remove completely. Refer to
page 106 .
– Remove the right flange shaft. Refer to
⇒ “3.3 Right Flange Shaft, Removing and Installing”,
page 108 .
cardiagn.com
Remove the bolts -arrows- and the final drive cover.
Caution
Danger of causing damage to the differential.

♦ Slowly and carefully remove final drive cover from trans‐
mission housing. Otherwise differential can fall out of
transmission.
♦ A differential that has fallen out can no longer be installed.
If the differential falls out, transmission must be replaced.
– Carefully remove the front final drive cover. At the same time
some transmission fluid will drain out.
– Carefully remove the differential -arrow- and lay it on a soft

support.
2. Seals 101
– Position the inner section of the -3240- flush with the outer
section and lock the inner section using the knurled bolt
-arrow-.
– Lubricate the puller threads, position, and using strong pres‐
sure insert the puller - camshaft seal as far as possible in the
seal until the seal turns.
– Turn the puller - camshaft seal further and at the same time
pull until the seal is removed.
– Tension the puller - camshaft seal on the flat side in a vise and
remove the seal using pliers.
– Check the seal in the transmission housing for damage and
rework if necessary.
– Clean the contact and sealing surface.
Installing
Install in reverse order of removal while noting the following:
– Always clean the transmission housing in the area where the
differential is accessed -arrow A- and the shaft seal seat
-arrow B-.
cardiagn.com
– Lightly coat the new seal on the outside with oil and install it
using the -T40164- .
• The open side of the seal faces the -T40164- .
– Install the shaft seal all the way. Be careful not to bend it.
– Fill the space between the sealing/dust lip halfway with Seal‐
ing Grease - G 052 128 A1- .

– Install the differential -arrow-.
– Replace the O-ring -A- on the front final drive cover and coat
it with transmission fluid.
cardiagn.com
– Insert the final drive cover and tighten the bolts -arrows-. Tight‐
ening specification.
Protected by copyright. Refer
Copying for private or to purposes, in part or in whole, is not
commercial
⇒ Fig. ““Final Drive Cover - Tightening Specification and
Se‐
quence”“ , page 106 .
– Install the left flange shaft. Refer to
page 106 .
– Install the right flange shaft. Refer to
page 108 .
2.3 Right Seal, Replacing

Removing
• The transmission is installed.
– Remove the right flange shaft. Refer to
page 108 .
– Pry out the flange shaft seal.
2. Seals 103
Installing
Install in reverse order of removal and note the following:
– Lightly oil the new gasket on the outer edge.
– Drive in the seal all the way without tilting using the -T40163- .
ing Grease - G 052 128 A1- .
– Install the right flange shaft. Refer to
page 108 .
cardiagn.com

3 Differential
⇒ “3.1 Overview - Differential”, page 105
⇒ “3.2 Left Flange Shaft, Removing and Installing”, page 106
⇒ “3.3 Right Flange Shaft, Removing and Installing”, page 108
3.1 Overview - Differential
1 - Left Flange Shaft Seal

⇒ “2.2 Left Seal, Replac‐
ing”, page 101 .
2 - Shim
❑ Behind the taper roller
bearing outer race
3 - Taper Roller Bearing Outer
Race
4 - Front Differential
cardiagn.com
5 - Bolt
⇒ Fig. ““Final Drive Cov‐
er - Tightening Specifi‐
cation and Sequence”“ ,
page 106 .
6 - Circlip
❑ Always replace
7 - Right Flange Shaft
ling. Refer to
⇒ “3.3 Right Flange
Shaft, Removing and In‐
8 - Right Flange Shaft Seal
9 - Final Drive Cover
ling. Refer to
10 - O-ring
❑ Always replace
Protected byafter removing.
copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Shim with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Behind the taper roller bearing outer race
12 - Taper Roller Bearing Outer Race
13 - Left Flange Shaft
❑ Removing and installing. Refer to ⇒ “3.2 Left Flange Shaft, Removing and Installing”, page 106 .
14 - Bolt
❑ 10 Nm + 90°
❑ Quantity: 3
3. Differential 105
15 - Gear Carrier
❑ Attached to the left flange shaft with the bearing -16- and the circlip -17-
16 - Bearings
❑ For the left flange shaft
17 - Circlip
❑ For the left flange shaft bearing
Final Drive Cover - Tightening Specification and Sequence

– Tighten the bolts in steps according to the specified sequence:
Turn
1. -1 to 12- 3 Nm
2. -1 to 12- 20 Nm
cardiagn.com
3.2 Left Flange Shaft, Removing and Instal‐
ling
♦ Engine and Gearbox Jack - VAS6931-
♦ Sealing Grease. Refer to the Parts Catalog.
Removing
• Thepermitted
transmission is installed.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Drain the transmission fluid. Refer to ⇒ 7-Speed Dual Clutch
Transmission 0CJ, 0CK, 0CL 0DN; Rep. Gr. 34 ; Transmis‐
– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
– Remove the left drive axle heat shield. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle Heat
Shield, Removing and Installing .
– Remove the left shock absorber fork. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Suspension, Upper Control
Arm; Tower Brace, Removing and Installing .
– Remove the bolts -arrows- from the flange shaft mounting
bracket.

– Remove the lower cover -arrow- from the transmission.
WARNING
Risk of damaging the seal between the final drive and the
transmission housing when removing the flange shaft.
♦ If the flange shaft -arrow- is not held in a central position,
the seal on the flange shaft spline will be damaged.
cardiagn.com
♦ A seal must be replaced if it is damaged.
– To avoid damaging the seal, support and guide the flange

shaft out of the opening in the transmission.
– Remove the left flange shaft from the transmission in the di‐
rection of -arrow A-.
Note
Ignore items -1 and 3- and -arrow B-.
Installing
Note
Replace the bolts that were tightened with an additional turn.

3. Differential 107
WARNING
Risk of damaging the seal between the final drive and the
transmission housing when installing the flange shaft.
♦ If the flange shaft -arrow- is not held in a central position,
the seal on the flange shaft spline will be damaged.
♦ A seal must be replaced if it is damaged.
– To avoid damaging the seal when inserting the flange shaft,

support and guide the flange shaft into the opening in the
transmission.
– Slide the left flange shaft -2- into the transmission in the di‐
rection of -arrow B-. When doing this, insert the flange shaft
centrally into the seal on the front differential -arrow 3-.
– Install the shock absorber fork. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Suspension, Upper Control
Arm; Shock Absorber Fork, Removing and Installing .
cardiagn.com
Tightening Specification
♦ Refer to ⇒ “3.1 Overview - Differential”, page 105
♦ Upper control arm and coupling rod. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Suspension Strut and Upper
Control Arm; Overview - Suspension Strut and Upper Control
Arm .
♦ Drive Axle. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 40 ; Drive Axle; Overview - Drive Axle .
♦ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive
Axle; Drive Axle Heat Shield, Removing and Installing .
3.3 Right Flange Shaft, Removing and In‐

stalling
♦ Circlip Pliers - VAS5503A-
Removing
– Remove the right drive axle. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
– Remove the right drive axle heat shield. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle
Heat Shield, Removing and Installing .
– Place the -SMN372500- under the transmission.

– Remove right flange shaft by fastening -T10037- to transmis‐

sion housing -arrow-.
Installing
Note
Replace the circlip after removing.
cardiagn.com
– Insert the circlip -1- with the -VAS5503A- .
– Check the right flange shaft seal for damage and replace if
necessary.
ing Grease - G 052 128 A1- .
– Insert the right flange shaft.
– Fill the transmission fluid and check the fluid level. Refer to ⇒
7-Speed Dual Clutch Transmission 0CJ, 0CK, 0CL 0DN; Rep.
Gr. 34 ; Transmission Fluid; Transmission Fluid, Draining and
Filling .
Tightening Specifications
Axle; Overview - Drive Axle .
Axle; Drive Axle Heat Shield, Removing and Installing .
3. Differential 109
4 Center Differential
⇒ “4.1 Overview - Center Differential”, page 110
⇒ “4.2 Center Differential, Removing and Installing”, page 111
⇒ “4.3 Transmission Output Shaft Seal, Replacing”, page 113
⇒ “4.4 Transmission Output Shaft Ball Bearing, Replacing”, page
115
⇒ “4.5 Center Differential Ball Bearing, Replacing”, page 118
4.1 Overview - Center Differential
1 - Center Differential
2 - Bearing
❑ For self-locking center
differential
3 - Pressure Spring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Circlip
cardiagn.com
❑ Secures the ball bearing
in the self-locking center
differential housing
5 - Circlip
❑ Secures the transmis‐
sion output shaft
6 - Ball Bearing
❑ For the transmission
output shaft.
7 - Housing
❑ For the center differen‐
tial
8 - Bolt
❑ 10 Nm + 90°
❑ Always replace
❑ M8 × 40
9 - Transmission Output Shaft
10 - Shaft Seal
11 - Dust Ring
12 - Balance Weight
❑ Installed, depending on
the version
13 - Bolt
❑ 30 Nm

Center Differential Housing - Tightening Specification and Se‐

quence
Note
Replace the bolts that were tightened with an additional turn.
– Tighten the bolts in three steps and in the sequence shown:

Turn
1. -1- and -11- 3 Nm
2. -1 to 11- 10 Nm
4.2 Center Differential, Removing and In‐

stalling
Removing
cardiagn.com
Note

⇒ “1.1 General Repair Information”, page 1 .
♦ Guidelines for clean working conditions. Refer to
– Remove the driveshaft. Refer to ⇒ Rear Final Drive; Rep. Gr.

39 ; Driveshaft; Driveshaft, Removing and Installing .
– Drain the transmission fluid. Refer to ⇒ 7-Speed Dual Clutch
Transmission 0CJ, 0CK, 0CL 0DN; Rep. Gr. 34 ; Transmis‐
Caution
Transmission components could be damaged.

♦ The self-locking center differential is pretensioned with a
pressure spring.
♦ Carefully remove the center differential housing from the
transmission toward the rear. Otherwise the center differ‐
ential could fall out of the transmission.
4. Center Differential 111

– Remove the bolts from the self-locking center differential

housing in the following sequence: -11 to 1-.
– Remove the oil guide piece.
cardiagn.com
– Secure the center differential -1- so it does not fall out or re‐
move it toward the rear from the input shaft.
Installing
– Position the center differential on the input shaft splines. Ro‐
tate the center differential slightly when doing this.
– Install the oil guide piece.

– Install the driveshaft. Refer to ⇒ Rear Final Drive; Rep. Gr.
Filling .
Tightening Specifications
♦ Refer to
⇒ Fig. ““Center Differential Housing - Tightening Specification
and Sequence”“ , page 111

4.3 Transmission Output Shaft Seal, Re‐

placing
⇒ “4.3.1 Vehicle with Self-Locking Center Differential”,
page 113
⇒ “4.3.2 Vehicle with All Wheel Drive Clutch”, page 114
4.3.1 Vehicle with Self-Locking Center Differ‐

ential
♦ Puller - Crankshaft/Power Steering Seal - T20143/1-
♦ Seal Installer - Output Shaft - T40239-
♦ Sealing Grease
permitted - authorised
unless G 052 128 A1-
by AUDI AG. AUDI AG does not guarantee or accept any liability
Procedure
Note
cardiagn.com
⇒ “1.1 General Repair Information”, page 1 .
♦ Guidelines for clean working conditions. Refer to

– Pry off the dust ring -1-.
Note
The dust ring cannot be removed without destroying it.
– Remove the seal for the transmission output shaft with splines.
– Clean the contact and sealing surface.
– Coat outer edge of the seal with gear oil.

– Mount the -T40239/1- , -1- on the transmission output shaft.

ing Grease - G 052 128 A1- .
– Install the seal -2- over the guide sleeve -1- and onto the
transmission output shaft.
• Installed position: The open side of the seal faces the trans‐
mission housing.
– Install the seal all the way using the -T40239- , -item 1-. Do
not tilt the seal.
Note
Remove the -T40239/1- from the seal carefully so that the sealing
lip does not fold over.
cardiagn.com
– Install a new dust ring -1-.
4.3.2 Vehicle with All Wheel Drive Clutch

Gearshift Shaft Seal, Removing Protected
and Installing,
by copyright.Transmission In‐
Copying for private or commercial purposes, in part or in whole, is not
stalled permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Assembly Device - Sleeve - T40367/1-
♦ Assembly Device - Thrust Piece - T40367/2-
♦ Puller - Crankshaft/Power Steering Seal 2 - T20143/2-
♦ Sealing Grease Allocate according to the Parts Catalog.
Removing
– Remove the all wheel drive clutch. Refer to ⇒ Rear Final Drive;
Rep. Gr. 39 ; All Wheel Drive Clutch; All Wheel Drive Clutch,

– Pry out the output shaft seal using the -T20143/2- .
Installing
– Lightly coat the outer edge of the seal.
– Fill the space between the sealing lip and the dust lip halfway
with Sealing Grease .
– Place the seal with the - T40367/1- .
cardiagn.com
– Press in the seal all the way using the -T40367/2- .

– Install the all wheel drive clutch. Refer to ⇒ Rear Final Drive;
Rep. Gr. 39 ; All Wheel Drive Clutch; All Wheel Drive Clutch,
4.4 Transmission Output Shaft Ball Bearing,

Replacing
♦ Press Piece - Rod - VW409-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Front Control Arm - 2040-
Procedure
– Remove the center differential housing. Refer to
⇒ “4.2 Center Differential, Removing and Installing”,
page 111 .

– Remove the locking ring -A- on the transmission output shaft

with splines and the ball bearing circlip -B-.
– Remove the transmission output shaft from the center differ‐

ential housing using the -VW409- .
cardiagn.com
– Pry out the seal.
Note
To protect the housing lay for example an extractor lever -A- un‐
derneath.
– Remove the transmission output shaft ball bearing with

splines.

– Install the transmission output shaft ball bearing with splines.

• The shoulder on the -VW415A- -arrow- faces the -VW412- .
– Install the ball bearing circlip -B-.
Note
Ignore -item A-.
cardiagn.com
– Install the transmission output shaft into the center differential
housing using the -VW412- .
– Install the locking ring -arrow- into the groove in the transmis‐
sion output shaft.
– Install the center differential housing. Refer to
page 111 .
– Install the seal for the transmission output shaft with splines.
Refer to
⇒ “4.3 Transmission Output Shaft Seal, Replacing”,
page 113 .
Filling .

4.5 Center Differential Ball Bearing, Replac‐

ing
♦ Press Piece - Bushing - 50mm Diameter - VW432-
♦ Bearing Installer - Carrier Bearing - 3350-
♦ Splitter - VAS251411-
Procedure
– Remove the center differential housing. Refer to
page 111 .
– Remove the center differential -1- from the output shaft.
cardiagn.com
– Removing the ball bearing from the center differential

A - -VAS251411-
• The -VW432- faces the ball bearing.
– Installing the ball bearing onto the center differential

5 Special Tools
♦ Puller - Crankshaft/Power Steering Seal - T20143/1-
cardiagn.com
♦ Puller - Crankshaft/Power Steering Seal 2 - T20143/2-

♦ Seal Installer - Output Shaft - T40239-
♦ Circlip Pliers - VAS5503A-
cardiagn.com
♦ Splitter - VAS251411-
♦ Engine and Gearbox Jack - VAS6931-

cardiagn.com
♦ Press Piece - 60mm - VW415A- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Press Piece - Bushing - 50mm Diameter - VW432-
♦ Press Piece - Front Control Arm - 2040-
cardiagn.com
♦ Puller - Camshaft Seal - 3240-
♦ Bearing Installer - Carrier Bearing - 3350-

6 Revision History
DRUCK NUMBER: A005AI01721
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Check
Edi‐ tion ck ed By
tion
05.2 12/19 Cor‐ MRP Removal Process Tom
018 /2018 rec‐ Perry
tion
05.2 10/19 Fac‐ N/A 05.2018 is the correct edi‐ Eric P.
018 /2018 tory tion here.
Up‐
date
09.2 09/27 Fac‐ 138 Performed Factory update. Juan
018 /2018 tory 266 Added trans code 0HL S.
Up‐ 4
date
05.2 07/17 Fac‐ N/A Updated metadata Eric P.
018 /2018 tory
cardiagn.com
Up‐
date
02.2 04/24 Fac‐ N/A Performed Factory update. Juan
018 /2018 tory S.
Up‐
date
05.2 10/04 Feed 128 Corrected illustration
permitted Juan
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
017 /2017 back 645 A30-10330 duetotothenew
with respect tool ofS.information in this document. Copyright by AUDI AG.
correctness
4 and illustration A30-10391.
05.2 09.01 Fac‐ 128 Performed Factory update; Juan
017 .2017 tory 011 update includes fixes for S.
Up‐ 1 feedback.
date
12.2 07/11 Link N/A Link checking for FY Eric P.
016 /2017 Chec
king
12.2 03/20 Fac‐ N/A Added F5 and FY to meta‐ Eric P.
016 /2017 tory data
Up‐
date
12.2 02/07 Fac‐ N/A Eric P.
016 /2017 tory
Up‐
date
09.2 11/11 Fac‐ N/A Eric P.
016 /2016 tory
Up‐
date
03.2 4/5/2 Quali N/A Jim H.
016 016 ty
Trac
king
03.2 3/31/ Fac‐ N/A Added MRPs and deleted Jim H.
016 2016 tory tool names from text
Up‐
date
09.2 03/28 Link N/A Tom
015 /2016 Chec Perry
king
6. Revision History 123

Fac‐ Edit Job Fee Notes Quality

tory Edi‐ Type dba Check
Edi‐ tion ck ed By
tion
09.2 03/01 Cor‐ N/A Changed obergrup to Driv‐ Eric P.
015 /2016 rec‐ etrain
tion
09.2 02/18 Fac‐ 115 Updated warning for better Eric P.
015 /2016 tory 219 clarity in Transmission ,
Up‐ 9 Transporting
date
09.2 10/19 Fac‐ N/A Added 8W content Eric P.
015 /2015 tory
Up‐
date
08.2 5/4/2 Cor‐ 109 Jim H.
014 015 rec‐ 481
tion 1
08.2 2/20/ Cor‐ N/A Jim H.
014 2015 rec‐
tion
cardiagn.com
08.2 1/15/ Title N/A Jim H.
014 2015 Cha
nge
08.2 10/01 Fac‐
Protected N/A Copying for private or commercial purposes,
by copyright. Eric P.or in whole, is not
in part
014 /2014 toryunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
New

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in
this manual, we suggest you leave such repairs to an authorized Audi retailer or other qualified
shop. We especially urge you to consult an authorized Audi retailer before beginning repairs on
any vehicle that may still be covered wholly or in part by any of the extensive warranties issued by
Audi.
•= Disconnect the battery negative terminal (ground strap)whenever you work on the fuel system or
the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved
fire extinguisher handy.
•= Audi is constantly improving its vehicles and sometimes these changes, both in parts and
specifications, are made applicable to earlier models. Therefore, part numbers listed in this
manual are for reference only. Always check with your authorized Audi retailer parts department
cardiagn.com
for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be
necessary to reestablish Transmission Control Module (TCM) basic settings using the VAG 1551
Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose.
Do not support a vehicle on cinder blocks, hollow tiles or other props that may crumble under
continuous load. Never work under a vehicle that is supported solely by a jack. Never work under
the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before
disconnecting the battery or removing the radio. If the wrong code is entered when the power is
restored, the radio may lock up and become inoperable, even if the correct code is used in a later
attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block
the wheels to keep the vehicle from rolling. Disconnect the battery negative terminal (ground
strap) to prevent others from starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to
yourself and others if you are tired, upset or have taken medicine or any other substances that
may impair
permitted you
unlessor keep by
authorised youAUDIfrom being
AG. AUDI AG fully alert.
does not guarantee or accept any liability
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work
with acid. Wear goggles, gloves and other protective clothing whenever the job requires working
with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when
you work near machine tools or running engines. If your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
=Page 1 of 3
© 2002 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual
property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be
modified or reposted to other sites, without the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are
designed to be used only once and are unreliable and may fail if used a second time. This
includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the
recommendations in this manual - replace these fasteners with new parts where indicated, and
any other time it is deemed necessary by inspection.
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or
under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create
dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and
asbestos dust. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and
may result in death.
•= Fingerwithrings
respectshould be removed
to the correctness so that
of information in this they cannot
document. cause
Copyright electrical
by AUDI AG. shorts, get caught in running
machinery, or be crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read
cardiagn.com
all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to the work
and use only replacement parts meeting Audi specifications. Makeshift tools, parts and
procedures will not make good repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage
containers that might mislead someone into drinking from them. Store flammable fluids away from
fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn
spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these
tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque listed.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping
hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper
way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or
lake. Consult local ordinances that govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C
system should be serviced only by trained automotive service technicians using approved
refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect
the battery negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive
heat will increase system pressure and may cause the system to burst.
=Page 2 of 3
Version 1.0
Cautions & Warnings
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the
Transmission Control Module (TCM), the ABS control module, and the trip computer. In cases
where one or more of these components is not separately fused, disconnect the control module
connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system
(SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag is operated
by an explosive device. Handled improperly or without adequate safeguards, it can be accidentally
activated and cause serious personal injury. To guard against personal injury or airbag system
failure, only trained Audi Service technicians should test, disassemble or service the airbag
system.
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed
16.5 volts at the battery with the boosting cables attached. Wait at least one minute before
boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be
tested by trained Audi Service technicians using the VAG 1551 Scan Tool (ST) or an approved
equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.
cardiagn.com
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that
may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of
ignition away from the tire repair area. Inflate and deflate the tire at least four times before
breaking the bead from the rim. Completely remove the tire from the rim before attempting any
repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or
lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of
injury in an accident.
I have read and I understand these Cautions and Warnings.

=Page 3 of 3
Version 1.0

0cj Audi Dupla Embreagem Audi q5

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

0cj Audi Dupla Embreagem Audi q5

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Audi AG, Ingolstadt D4B804AF0CA

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

00 – General, Technical Data

1.1 General Repair Information

♦ Before installing, lightly lubricate shaft seal outer circumfer‐

2 Rep. Gr.00 - General, Technical Data

♦ Check for burrs or damage. Only install flawless shims.

There is a risk of destroying the transmission control module

♦ Do not touch connector terminals in the transmission con‐

1.2 Contact Corrosion

♦ Original replacement parts are recommended because they

1.3 ATF Pump, Deactivating and Draining

The system is under pressure.

ATF Pump, Deactivating and Draining the Hydraulic Pump Res‐

4 Rep. Gr.00 - General, Technical Data

2 Rules for Cleanliness when Working

2. Rules for Cleanliness when Working on DSG® Transmission 5

1.1 Overview - Flywheel and Dual Clutch

6 Rep. Gr.30 - Clutch

1.2 Flywheel, Removing and Installing

♦ There is a normal »clicking« in the dual mass flywheel with

• Secure the transmission on the -VAS6095- . Refer to

To prevent the flywheel from tilting, counterhold it underneath as

differential is accessed -arrow A- and the shaft seal

Replace the shaft seal between the differential and transmission

8 Rep. Gr.30 - Clutch

– Clean the input shaft -arrow-.

Special tools and workshop equipment required

– Remove the bolts -1 to 12-.

– Secure the Dual Clutch Lifting Device - T40123A- and Dual

When removing, the engaging bearing and both alignment

♦ The dual clutch is extensively calibrated on the engaging bear‐

10 Rep. Gr.30 - Clutch

There is a risk of damaging the dual clutch from mishandling.

It Can Be Checked by Measuring the Height Dimension If the

Depending on the version the three bolts -arrows- may not be

– Check if the sleeves -1 and 2- are installed.

Depending on the version the three bolts -arrows- may not be

12 Rep. Gr.30 - Clutch

♦ Pay attention that the engaging bearing is installed correctly

• Before installing the clutch the dimension -x- must be deter‐

If the dimension -x- is outside of the tolerance, the clutch must be

– Place the dual clutch as shown in the transmission housing.

– Tighten the bolts -1 to 12- for the clutch cover diagonally in

1.4 Input Shaft Seal, Replacing

14 Rep. Gr.30 - Clutch

• Clutch, engaging bearing and slave cylinder removed. Refer

– A waved washer -arrow- is located behind the seal, it does not

– Drive in the new seal to the stop using the -T40300- .

1.5 Input Shaft Seal, Replacing

There is a risk of damaging the clutch from mishandling.

Do not damage the contact surface on the shaft.

– Place the -T40308- on the drive axle.

16 Rep. Gr.30 - Clutch

♦ Pressure Stand - T40099-

♦ Puller - Clutch Module - T40176-

♦ Guide Pins - Gearbox - T40288-

♦ Thrust Piece - T40300-

♦ Thrust Piece - T50038-