SM 22 Unlocked

Service
Repair Manual
Audi A4 2008 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ ,
Audi A6 China 2012 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤
cardiagn.com
Servicing - 7-Speed Dual Clutch Transmission 0B5 (S
tronic)
Edition 12.2018
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 D3E8045FFC4

Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Servicing - 7-Speed Dual Clutch Transmission 0B5 (S tronic) - Edition 12.2018
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Overview - Flywheel and Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Flywheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 DSG Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Dual Clutch, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
cardiagn.com
1.1 Overview - Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Oil Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 ATF Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Mechatronic, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Overview - Mechatronic Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.6 Mechatronic Circuit Board, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.7 ATF Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Transmission, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2 Sensor Module , with integrated transmitters and sensors G612 , G632 , G676 and Circuit
Board 3 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3 Oil Pump and Suction Jet Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4 Transmission Housing Separator Seals, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 Automatic Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1 ATF Drain Plug, Fill Plug and Check Plug Assembly Overview . . . . . . . . . . . . . . . . . . . . . . 62
5.2 ATF, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Input Shaft Ball Bearing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1 Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.1 Overview - Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.1 Overview - Transmission Drain and Inspection Plug for Transmission Fluid . . . . . . . . . . . . 75
2.2 Transmission
Protected Fluid;
by copyright. Copying for Transmission
private or commercialFluid, Draining
purposes, in part or in and
whole,Filling
is not ...................... 75
2.3 Transmission
permitted Fluid
unless authorised Temperature
by AUDI AG. AUDI AG does Sensor 2 G754
not guarantee or accept, Removing
any liability and Installing . . . . . . . . . . . . 78
3 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.2 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Contents i
3.3 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.1 Left Flange Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2 Left Flange Shaft Ball Bearing Pre-Tension, Checking and Adjusting . . . . . . . . . . . . . . . . 85
4.3 Left Flange Shaft Ball Bearing Mounting Bracket, Removing and Installing . . . . . . . . . . . . 91
4.4 Right Flange Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5 Center Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.1 Overview - Self-Locking Center Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2 Self-Locking Center Differential, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.3 Center Differential Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.4 Transmission Output Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
cardiagn.com
ii Contents
00 – General, Technical Data

1 Repair Information
(Edition 12.2018)
⇒ “1.1 Guidelines for Clean Working Conditions”, page 1
⇒ “1.2 General Repair Information”, page 1
⇒ “1.3 Contact Corrosion”, page 3
1.1 Guidelines for Clean Working Condi‐

tions
♦ Always clean the connection locations and the area around
them before loosening.
♦ Clean the transmission and transmission components using
Cleaning Solution - D 009 401 04- .
♦ Use lint-free cloths when cleaning, for example, the “WYPALL
X70/WORKHORSE” cloth made by Kimberly-Clark Professio‐
cardiagn.com
nal.
♦ Seal all open lines and connections immediately with clean
plugs or caps from the Engine Bung Set - VAS6122- .
♦ Place removed parts on a clean surface and cover them. Use
foil or lint-free cloths.
♦ Cover or plug unpacked components if repairs cannot be per‐
formed immediately.
♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them.
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
1.2 General Repair Information

Using the Repair Manual
Refer to the “7-speed DSG transmission (S tronic)” repair manual
for all special procedures with the transmission installed, depend‐
ing on the model. The servicing repair manual either does not
describe them or describes them only partially. Both repair man‐
ual are needed for a successful repair.
Carefulness, cleanliness and the correct tools are required for
transmission repairs to be successful. The usual basic safety pre‐
cautions also, naturally apply when carrying out vehicle repairs.
Some general repair information that applies to several proce‐
dures throughout this manual is summarized here. They apply to
this repair manual.
permittedOil, Environmental
unless authorised by AUDI and Disposal
AG. AUDI AG does notRegulations
guarantee or accept any liability
♦ Handle ATF, transmission fluid and other oils carefully.
♦ Dispose of the drained fluids properly.
♦ Follow the legal environmental and disposal regulations.
♦ Follow the information provided on oil packaging.
Special Tools and Equipment
For a complete list of special tools used in the repair manual. Re‐
fer to Workshop Equipment and Special Tools.
1. Repair Information 1
Transmission
♦ Follow all the guidelines for clean working conditions. Refer to
⇒ “1.1 Guidelines for Clean Working Conditions”, page 1 .
♦ If installing parts that can be used again, clean and check them
and replace if necessary.
♦ During installation, make sure that the alignment bushings are
fitted correctly.
O-Rings, Shaft Seals, Seals
♦ O-rings, shaft seals and seals must be replaced.
♦ After removing gaskets, examine contact surface on housing/
shaft for burr resulting from removal or for other signs of dam‐
age.
♦ Clean the housing separating surface thoroughly before as‐
sembling.
♦ Before installing, lightly lubricate shaft seal outer circumfer‐
ence and sealing lips with ATF or gear oil, depending on
installation location.
♦ Coat O-rings lightly with ATF or transmission fluid before in‐
cardiagn.com
stalling them. This prevents them crimping when being instal‐
led.
♦ Always only use approved ATF. Other types of lubrication
cause faults to occur in the transmission hydraulics.
♦ The open side on the shaft seals faces the fluid to be sealed
off.
♦ After installing, check and correct the ATF
permitted unlesslevel or the
authorised trans‐
by AUDI AG. AUDI AG does not guarantee or accept any liability
mission fluid level (MTF) with the transmission
with respect to the installed.
correctness ofRefer
information in this document. Copyright by AUDI AG.
to ⇒ S tronic Transmission; Rep. Gr. 34 ; Automatic Trans‐
mission Fluid; ATF Level, Checking or⇒ S tronic Transmis‐
sion; Rep. Gr. 39 ; Transmission Fluid; Transmission Fluid
Level, Checking . Specification. Refer to the Parts Catalog.
Bolts and Nuts
♦ Loosen the bolts opposite the tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
tightened in steps according to the specified tightening se‐
quence and method.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened crosswise in stages if no tightening
sequence is specified.
♦ Always replace self-locking nuts and bolts.
♦ If nothing else is specified: Use a wire brush to clean the
threads of bolts that were screwed in with locking compound.
Use locking fluid when installing the bolts. Refer to the Parts
Catalog.
♦ Threaded holes with self-locking bolts or bolts coated with
locking fluid must be cleaned, for example using a thread tap.
Otherwise there is a risk that the bolts will shear the next time
they are removed.
♦ The tightening specifications stated apply to non-oiled nuts
and bolts.
Circlips, Snap Rings
♦ Do not overstretch the circlips.
♦ Replace damaged or stretched circlips.
♦ The circlips must fit completely inside the groove.
2 Rep. Gr.00 - General, Technical Data

Bearings
♦ Install needle bearings with lettered side (thicker metal) racing
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.
Adjusting Shims
♦ Measure the adjusting shims at several locations with a mi‐
crometer. Different shim thicknesses make it possible to select
the required thickness precisely; install two shims if necessa‐
ry.
♦ Check for burrs and damage. Only install perfect shims.
Mechatronic
Caution
cardiagn.com
There is a risk of destroying the transmission control module
(Mechatronic) with electrostatic discharge.
♦ Always discharge “static electricity” before working with
connectors or the Mechatronic. Do this by touching a
grounded object, for example vehicle ground, the vehicle
or the hoist.
♦ Do not touch contacts in transmission connector with
hands.
1.3 Contact Corrosion

Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating may
be installed.
In addition, rubber or plastic
permittedparts and adhesive
unless authorised by AUDI AG.are made
AUDI AG doesof not
ma‐guarantee or accept any liability
terials that do not conduct
with electricity.
respect to the correctness of information in this document. Copyright by AUDI AG.
If there are doubts about whether parts can be used or not, then
use new parts. Refer to the Parts Catalog.
Note
♦ Original replacement parts are recommended because they

have been tested.
♦ The use of Audi accessories is recommended.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
1. Repair Information 3
30 – Clutch
1 Clutch
⇒ “1.1 Overview - Flywheel and Dual Clutch”, page 4
⇒ “1.2 Flywheel, Removing and Installing”, page 5
⇒ “1.3 DSG Clutch, Removing”, page 7
⇒ “1.4 Dual Clutch, Installing”, page 9
1.1 Overview - Flywheel and Dual Clutch
1 - Flywheel
❑ Refer to the Parts Cata‐
log because there are
different versions de‐
pending on the date of
manufacture.
❑ Removing and instal‐
cardiagn.com
ling. Refer to
⇒ “1.2 Flywheel, Re‐
moving and Installing”,
page 5 .
2 - Clutch Cover
❑ There are different ver‐
sions depending on the
date of manufacture,
with or without a thrust
washer (-item 7-
⇒ Item 7 (page 5) ),
allocation. Refer to the
Parts Catalog.
❑ Removing. Refer to
⇒ “1.3 DSG Clutch, Re‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
moving”, page 7 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Installing. Refer to
⇒ “1.4 Dual Clutch, In‐
stalling”, page 9 .
3 - Bolt
❑ Tightening specification
and sequence. Refer to
⇒ Fig. ““Clutch Cover
Tightening Specification
and Sequence”“ ,
page 5
4 - O-Ring
❑ Always replace
5 - Dual Clutch
❑ Refer to the Parts Catalog because there are different versions depending on the date of manufacture.
❑ Removing. Refer to ⇒ “1.3 DSG Clutch, Removing”, page 7 .
❑ Installing. Refer to ⇒ “1.4 Dual Clutch, Installing”, page 9 .
• Perform the relevant “Guided Function” using the Vehicle Diagnostic Tester after replacing the dual clutch.
Refer to ⇒ S tronic Transmission; Rep. Gr. 39 ; Transmission Control .
4 Rep. Gr.30 - Clutch

6 - Transmission Housing
7 - Thrust Washer
❑ Depending on the date of manufacture, clutch cover allocation. Refer to the Parts Catalog.
8 - Ball Bearing
❑ For the dual clutch
❑ Replacing. Refer to ⇒ “1.1 Input Shaft Ball Bearing, Replacing”, page 67 .
9 - Locking Ring
❑ Always replace
❑ For ball bearing
10 - Locking Ring
❑ Always replace
❑ For the dual clutch Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Shaft Seal with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For the input shaft

❑ Replacing. Refer to ⇒ “1.2 Input Shaft Seal, Replacing”, page 69 .
12 - Bolt
cardiagn.com
❑ 60 Nm
❑ Always replace
Clutch Cover Tightening Specification and Sequence

– Tighten the bolts in three steps in the sequence shown:
Step Bolts Tightening Specification
1. -1 to 5- Install by hand evenly until the bolt
head contact the clutch cover.
2. -1 to 5- Tighten one after the other in 90°
steps until the clutch cover contact the
transmission housing.
3. -1 to 5- 10 Nm
1.2 Flywheel, Removing and Installing

Special tools and workshop equipment required
♦ Puller - Clutch Module - T40176-
♦ Clutch Disc Shaft Spline Lubricant - G 000 100-
♦ Grease. Refer to the Parts Catalog.
Removing
• Secure the transmission on the Engine And Transmission
Holder - VAS6095- . Refer to
⇒ “4 Securing on Engine and Transmission Holder”,
page 61 .
– Remove the left flange shaft. Refer to
⇒ “4.1 Left Flange Shaft, Removing and Installing”,
page 83 .
– Attach the Puller - Clutch Module - T40176- to the flywheel
-A- with the nut -B- -arrow-.
1. Clutch 5
– Turn the Puller - Clutch Module - T40176- upward.
Note
To prevent the flywheel from tilting, counterhold it underneath as

illustrated.
– Remove the flywheel from the input shaft -arrow-. Do not tilt
the flywheel when doing this.
Installing
Install in reverse order of removal. Note the following:
– Always clean the transmission housing in the area where the
differential is accessed -arrow A- and the shaft seal
-arrow B-.
cardiagn.com
Note
Replace the shaft seal between the differential and transmission

housing -arrow B- if it is damaged. Refer to
⇒ “3.1 Left Seal, Replacing”, page 80 .
– Fill the space between the sealing- and dust lip half way with
sealing grease. Refer to the Parts Catalog.
– 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.

– Remove the Puller - Clutch Module - T40176- from the fly‐

wheel -A-.
– Install the left flange shaft. Refer to
page 83 .
1.3 DSG Clutch, Removing

♦ Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/
2-
♦ Shop Crane - VAS6100-
♦ Pulling Hook - T20143/2-
cardiagn.com
♦ Dual Clutch Lifting Device - T40123A-
♦ Oil Sump Assembly Pin - T40199-
Removing
page 61 .
– Remove the flywheel. Refer to
⇒ “1.2 Flywheel, Removing and Installing”, page 5 .
– Drain the ATF. Refer to
⇒ “5.2 ATF, Draining and Filling”, page 62 .
– Pry out the input shaft seal with the Pulling Hook - T20143/2- .
– Remove the bolts -1 through 5-.
1. Clutch 7
– Turn the inside the Engine and Gearbox Jack - VAS6931- so

that it is vertical.
– Place the Dual Clutch Lifting Device Sleeve - T40123A/1- on
the drive axle.
– Place the Dual Clutch Lifting Device - T40123A- on the drive
axle.
• The edge -arrow- of the lifting device must grip under the Dual
Clutch Lifting Device Sleeve - T40123A/1- .
– Close the lifting device and tighten the knurled nut -1- to ap‐
proximately 20 Nm.
– Make sure the lifting device fits securely on the input shaft.
– Connect the Dual Clutch Lifting Device - T40123A- with the

Engine Support Bridge - Additional Hooks (2 pc.) - 10-222A/
2- and engage in the Shop Crane - VAS6100- .
– Carefully remove the dual clutch out of the transmission hous‐
ing.
cardiagn.com
– Lay the dual clutch and cover on a soft surface so that the thin
rib -arrow A- does not get damaged.
– Remove the locking ring -arrow- with locking ring pliers.

– Remove the clutch cover -2- from the dual clutch -1-.
cardiagn.com
Note
♦ If the clutch cover does not come off, gently strike the input
shaft with a rubber hammer while a second technician lifts the
clutch cover by hand.
♦ Be careful not to damage the thin rib -arrow A- when doing
this.
1.4 Dual Clutch, Installing

Note
Replace the O-ring and the circlip.
– Clean the sealing surface on the clutch cover.

– Turn the rectangular rings -B- on the hub and check for ease
of movement and axial play.
Note
If the rectangular rings do not move easily, then the dual clutch
must not be installed.
1. Clutch 9
– Clean the transmission housing around the dual clutch and the
sealing surface.
Note
Make sure no dirt can fall into the transmission while cleaning.
– Install the Oil Sump Assembly Pin - T40199- into the threaded
hole in the transmission housing as illustrated.
– Check the hole -arrow- in the transmission for wear grooves.
cardiagn.com
– Coat the O-ring -C- and hub -B- on the dual clutch with ATF.
– Install the dual clutch into the transmission housing. Using

short lifting/turning motions, allow the input shaft to engage
into the ATF pump splines and transmission shafts as illustra‐
ted.
• The dual clutch is installed correctly when the clutch cover O-
ring noticeably contacts the edge of the transmission housing.

Caution
♦ Do not let the O-ring get caught when installing.

♦ Always follow the tightening sequence when tightening
the clutch cover bolts -1 through 5-. Refer to
( ⇒ Fig. ““Clutch Cover Tightening Specification and Se‐
quence”“ , page 5 ).
– Tighten the clutch cover bolts -1 through 5- to the tightening

specification and sequence. Refer to
⇒ Fig. ““Clutch Cover Tightening Specification and Se‐
quence”“ , page 5 .
– Replace the input shaft seal. Refer to
⇒ “1.2 Input Shaft Seal, Replacing”, page 69 .
– Install the flywheel. Refer to
– Fill with ATF after the transmission is installed:
cardiagn.com
– After installing the transmission, fill the ATF. Refer to ⇒ S
tronic Transmission; Rep. Gr. 34 ; Automatic Transmission
Fluid; ATF, Draining and Filling .
• Perform the relevant “Guided Function” using the vehicle di‐
agnostic tester after replacing the dual clutch. Refer to ⇒ S
tronic Transmission; Rep. Gr. 39 ; Transmission Control .
1. Clutch 11
2 Special Tools
Special tools and workshop

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

2-
♦ Pulling hook - T20143/2-
♦ Dual Clutch Lifting Device - T40123A-
♦ Oil Sump Assembly Pin - T40199-

♦ Puller - Clutch Module - T40176-
♦ Clutch Disc Shaft Spline Lubricant - G 000 100-
cardiagn.com
2. Special Tools 13
34 – Controls, Housing
1 Mechatronic
⇒ “1.1 Overview - Mechatronic”, page 14
⇒ “1.2 Oil Pan, Removing and Installing”, page 18
⇒ “1.3 ATF Filter, Removing and Installing”, page 19
⇒ “1.4 Mechatronic, Removing and Installing”, page 20
⇒ “1.5 Overview - Mechatronic Circuit Boards”, page 28
⇒ “1.6 Mechatronic Circuit Board, Removing and Installing”, page
31
⇒ “1.7 ATF Filter, Removing and Installing”, page 34
1.1 Overview - Mechatronic
1 - ATF Drain Plug
cardiagn.com
-item 1-
⇒ Item 1 (page 62) .
2 - Seal
❑ Always replace
3 - Bolt
⇒ Fig. ““ATF Oil Pan,
page 17
❑ Always replace
4 - Expanding Rivet
❑ For attaching the gasket
to the ATF oil pan
❑ Not required for installa‐
tion
5 - Magnet
❑ Insert into the depres‐
sion in the ATF oil pan
❑ Make sure the entire
surface contacts oil pan
❑ Quantity: 2
6 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Tightening specification with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ Fig. ““ Mechatronic,
page 17
❑ Always replace
7 - O-Rings
❑ Always replace
8 - ATF Pressure Pipes (Coupling Pressure)
❑ Always replace
14 Rep. Gr.34 - Controls, Housing

❑ Depending on the date of manufacture, versions may be different. The ATF pressure pipe (clutch pres‐
sure) in transmissions of the new version are a single unit and made out of plastic.
❑ Plastic ATF pressure pipes are backward compatible.
9 - Retaining Plate
❑ Only for the ATF pressure pipe (clutch pressure) made out of metal
10 - Bolt
❑ 10 Nm
❑ Only for the ATF pressure pipe (clutch pressure) made out of metal
11 - O-Rings
❑ Always replace
12 - O-Rings
❑ Always replace
13 - ATF Pipes
❑ Different versions, depending on date of manufacture
14 - O-Rings
❑ Always replace
cardiagn.com
15 - O-Ring
❑ Always replace
❑ Different versions, depending on date of manufacture
16 - ATF Filter Housing
❑ For transmissions with an ATF filter
❑ Replace components that do not have a factory-installed anti-twist mechanism after removing them.
Refer to ⇒ page 27
17 - O-Ring
❑ Always replace
❑ For transmissions with a replaceable ATF filter
18 - ATF Filter Cover
❑ 8 Nm
❑ Note that there are different versions
19 - ATF Filter
❑ Replace each time the ATF is changed and after performing a repair on the transmission
❑ Pay attention to the allocation. Refer to the Parts Catalog is also called a filter
to ⇒ “1.7
❑ ReferProtected ATF Filter,
by copyright. Removing
Copying for and Installing”,
private or commercial page
purposes, in part 34 is not
or in whole,
20 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 10 Nm
❑ Quantity: 3
21 - O-Rings
❑ Always replace
22 - ATF Return Pipe
❑ Removing and installing. Refer to ⇒ S tronic Transmission; Rep. Gr. 34 ; ATF Circuit; ATF Pipes,
Removing and Installing
23 - ATF Supply Pipe
1. Mechatronic 15
24 - Bolt
❑ Tightening specification. Refer to ⇒ S tronic Transmission; Rep. Gr. 34 ; ATF Circuit; Overview - ATF
Circuit
25 - Bolt
❑ 10 Nm
❑ For transmissions with an ATF pipe filter
❑ Quantity: 3
26 - ATF Return Pipe
27 - Bolt
❑ Tightening specification. Refer to ⇒ S tronic Transmission; Rep. Gr. 34 ; ATF Circuit; Overview - ATF
Circuit
cardiagn.com
28 - O-Rings
❑ Always replace
29 - ATF Pipe Connection
30 - ATF Pipe Filter
❑ Replace when replacing the transmission or if the ATF is extremely dirty.
❑ Removing and Installing. Refer to ⇒ 7-Speed Dual Clutch Transmission; Rep. Gr. 34 ; ATF Circuit; ATF
Filter, Removing and Installing .
31 - ATF Fill and Check Plug
❑ Tightening specification -item 4- ⇒ Item 4 (page 62) .
32 - O-Rings
❑ Always replace permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
33 - Bolt
❑ 8 Nm
34 - Connector Housing
– To remove, remove the bolt -33- and turn the connector housing counter-clockwise.
36 - O-Rings
❑ Always replace
37 - ATF Pipes
❑ Always replace
❑ Depending on the date of manufacture, versions may be different. The ATF pipes in transmissions for
the new version are a single unit and made out of plastic.
❑ Plastic ATF pressure pipes are backward compatible.
38 - Bolt
❑ 8 Nm
❑ Quantity: 5

39 - Wiring Set for the Sensor Module

❑ Removing and installing. Refer to
⇒ “3.2 Sensor Module , with integrated transmitters and sensors G612 , G632 , G676 and Circuit Board
3 , Removing and Installing”, page 42 .
❑ Replace if the Sensor Module is replaced.
40 - O-Ring
❑ Always replace
41 - ATF Suction Filter
❑ Removing and installing. Refer to ⇒ “1.3 ATF Filter, Removing and Installing”, page 19 .
42 - DSG Transmission Mechatronic - J743-
❑ Removing and installing. Refer to ⇒ “1.4 Mechatronic, Removing and Installing”, page 20 .
❑ Tightening specification and sequence
⇒ Fig. ““ Mechatronic, Tightening Specification and Sequence”“ , page 17 .
• Perform the relevant “Guided Function” using the vehicle diagnostic tester after replacing the DSG Trans‐
mission Mechatronic - J743- . Refer to ⇒ S tronic Transmission; Rep. Gr. 39 ; Transmission Control .
❑ Remove the circuit board from the DSG Transmission Mechatronic - J743- . Refer to
⇒ “1.5 Overview - Mechatronic Circuit Boards”, page 28 .
43 - Seal
cardiagn.com
❑ Always replace
❑ Installing. Refer to ⇒ page 18 .
44 - ATF Pan
❑ Removing and installing. Refer to ⇒ “1.2 Oil Pan, Removing and Installing”, page 18 .
ATF Oil Pan, Tightening Specification and Sequence

– Tighten the bolts in two stages as described below.
1. Install the bolts -arrows- hand-tight.
2. Tighten the screws -1 through 15- diagonally to 10 Nm and
in steps.
Mechatronic, Tightening Specification and Sequence

– Tighten the bolts to 10 Nm in the sequence -1 to 6-.
1. Mechatronic 17
1.2 Oil Pan, Removing and Installing

Removing
Note
♦ General Repair Instructions. Refer to

⇒ “1 Repair Information”, page 1 .
♦ Rules for cleanliness when working on the DSG transmission.
Refer to
The Transmission is Installed.

It is also possible to remove and install the ATF pan when the
transmission is installed. Depending on the vehicle model and the
engine version, additional work may be required to be able to
reach the ATF pan. Refer to ⇒ S tronic Transmission; Rep. Gr.
34 ; Mechatronic
Transmission Removed.
cardiagn.com
– The transmission is secured to the engine/transmission
Protected by copyright.hold‐
Copying for private or commercial purposes, in part or in whole, is not
er. Refer to permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
page 61 .
– Place the Used Oil Collection and Extraction Unit -
SMN372500- under the transmission.
– Diagonally Loosen the screws -1 through 15-.

– Remove the bolts and the ATF pan.
Note
Ignore -arrows-.
Installing
– Clean the sealing surfaces.
– Replace the ATF oil pan bolts and gasket.
– Insert the guides -arrow- on the new gasket -2- into the ATF
fluid pan -1-.
– Attach the gasket (if equipped) and expanding rivets -3- to the
ATF pan.
Note
Clips item -3- are only used for assembly help during production.

– Clean the magnets -arrows- in the ATF pan.

– Make sure the magnets completely contact the depressions in
the ATF oil pan.
– Tighten the ATF oil pan screws. Refer to

⇒ Fig. ““ATF Oil Pan, Tightening Specification and Se‐
– After installing the ATF pan, fill with ATF. Refer to ⇒ S tronic
Transmission; Rep. Gr. 34 ; Automatic Transmission Fluid;
ATF, Draining and Filling
cardiagn.com
1.3 ATF Filter, Removing and Installing
♦ Used Oil Collection and Extraction Unit - SMN372500-
Removing
Note

Refer to

– Remove the ATF oil pan. Refer to
⇒ “1.2 Oil Pan, Removing and Installing”, page 18 .
– Carefully pull the ATF suction filter to the rear and off the Me‐
chatronic in direction of -arrow-.
1. Mechatronic 19
Installing
– Install the O-ring -2- on the rear support on the ATF suction
filter -1-.
– Install the ATF suction filter suction collar all the way into the
opening in the transmission fluid pump.
• The support with the O-ring must fit into the hole inside the
– Install the ATF pan. Refer to
– After installing the transmission, fill with ATF. Refer to ⇒ S
tronic Transmission;
Protected byRep. Gr.Copying
copyright. 34 ; for
Automatic Transmission
private or commercial purposes, in part or in whole, is not
Fluid; ATF, Draining and authorised
permitted unless Filling by AUDI AG. AUDI AG does not guarantee or accept any liability
1.4 Mechatronic, Removing and Installing

cardiagn.com
Removing
Note
♦ General repair instructions. Refer to

Refer to
Caution

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

The Transmission is Installed.

– Remove the noise insulations -1 and 2-. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Noise Insulation; Noise Insulation, Re‐
moving and Installing .
Caution
Danger of Causing Damage to the Transmission.

♦ Do not start the engine if there is no ATF in the transmis‐
sion or if the DSG Transmission Mechatronic - J743- is
removed.
– Move the selector lever into “P”.

– Turn off the ignition and remove the key.
– Turn the twist lock counter-clockwise in direction of -arrow-
cardiagn.com
and disconnect the connector from the transmission.
Transmission, Removed or Installed
– Remove the ATF oil pan. Refer to
– Remove the bolt -1-.
– Turn the connector housing -2- counter-clockwise in direction

of -arrow- and remove it.
Vehicles with an ATF Pipe Filter
– Remove the bolts -arrows- and remove the connecting piece

for the ATF pipes. Refer to ⇒ S tronic Transmission; Rep. Gr.
34Protected
; ATFbyCircuit .
copyright. Copying for private or commercial purposes, in part or in whole, is not
Vehicles with ATF Filter
1. Mechatronic 21
– Remove the bolts -arrows- and remove the ATF filter housing.
Refer to ⇒ S tronic Transmission; Rep. Gr. 34 ; ATF Circuit
All Vehicles
Note
♦ The ATF pipes -2- cannot remain attached to the mechatronic,

because these would otherwise block the removal.
♦ Always replace the seals -3 and 4-.
cardiagn.com
– Carefully pull the ATF filter to the rear and off the Mechatronic
in direction of -arrow-.
Caution



hoist.
hands.
– Pull the retainer in direction of -arrow 1-, push the release

down in direction of -arrow 2- and disconnect the connector.

– Remove the bolts in reverse order: -6 to 1-.
Caution
Risk of causing Damage to the Mechatronic.

♦ Only bolts -6 to 1- may be loosened.
♦ If other bolts are loosened, this may affect the function of
the Mechatronic unit or it may come apart.
Note
♦ The sealing surface must not be damaged.

♦ 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.
cardiagn.com
– Remove the Mechatronic.
Caution
Danger of Damaging the Sensor on the Back Side of the Me‐

chatronic.
♦ Lay the Mechatronic with the bolt head side facing down
only.
Installing
Note
♦ The ATF pressure pipes -1 through 5- are made out of plastic

on the newer version of the transmission.
♦ The bracket for the ATF pressure pipes -1 and 2- is not present
in this case.
♦ The metal ATF pressure pipes can be replaced with plastic
ATF pressure pipes. To do so, remove the bolt -arrow- and
remove the bracket.
♦ Coat the seals with ATF before installing.
– If equipped, remove the bolt for the ATF pressure pipe bracket
-arrow-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Replace the ATF pressure pipes (clutch pressure) -1 and 2-.

– Replace the ATF pipes -3 through 5-.
– If equipped, tighten the bolt without the ATF pressure pipe
bracket -arrow-.
• Tightening specifications. Refer to
⇒ “1.1 Overview - Mechatronic”, page 14 .
1. Mechatronic 23
Note
Make sure all shift forks and gear positions are in the center po‐
sition before installing the DSG transmission Mechatronic -
J743- .
Adjust the Shift Forks

– First check the shift positions for the shift forks -1 through 4-
by hand.
Each shift fork has three positions:
♦ -G- is engaged
♦ Idle -N- (center position)
♦ -G- is engaged
– Move all four shift forks one time into each position -arrows-
one after the other.
– After doing this, move the shift forks back into the center po‐
sition -N-.
cardiagn.com

Adjust the Gear Selector:
Caution

hoist.
hands.
♦ Do not pry out the plunger on the sensors.
The gear shifter must be adjusted differently depending on the

date of manufacture of the Mechatronic.
The date of manufacture is located only on the Mechatronic iden‐
tification -arrow-.
cardiagn.com
The Mechatronic identification consists of: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Mecha‐ Example “L31B1138”

tronic
identifi‐
cation
L3 B 1
1 1 3
8
L Year of manufacture:
L = 2010
K = 2009
J = 2008
... etc.
3 Calendar week in the year of manufacture
1
B Manufacturer day shift identification:
1 Monday: Shift 1 = A1, Shift 2 = B1, Shift 3 = C1
Tuesday: Shift 1 = D1, Shift 2 = E1, Shift 3 = F1
Wednesday: Shift 1 = G1, Shift 2 = H1, Shift 3 = I1
... etc.
1 Running manufacturing number of the shift per day,
3 here, the 138 Mechatronic from shift B1
8
The gear positions must be adjusted to a different adjustment
value from Mechatronic “L31B1138”.
Note
♦ A Mechatronic with the identification. “L31A1140” was built

before Mechatronic “L31B1138” because it was built by the 1st
shift (A1) on a Monday.
♦ A Mechatronic with the identification “L31C1009” was built af‐
ter Mechatronic “L31B1138” because it was built by the 3rd
shift (C1) on Monday.
1. Mechatronic 25
– Move the gear position back and forth and set the 4 gear po‐
sitions on the back of the Mechatronic in the center position to
dimension -a-.
For Mechatronic with Identification Through “L31B1137”:
• Dimension -a- = 28 mm
For Mechatronic with Identification From “L31B1137”:
• Dimension -a- = 32 mm.
– Align the gear selector yokes -arrows- so that they engage into
cardiagn.com
the eyes in the shift fork when being installed.
– Insert the Mechatronic into the transmission housing.

• The Mechatronic and its bolts must fit easily into the holes in
the transmission.
• If the Mechatronic does not go in easily, then it is possible that
a shift fork or a gear selector is not in its center position. Check
the center position and adjust if necessary.

After installing the Mechatronic:

– Using a flashlight, check all the gear selectors through the
opening between the Mechatronic and the transmission hous‐
ing.
• All four gear selector yokes must fit correctly in the shift fork
eyes.
– Tighten the Mechatronic bolts. Refer to
⇒ Fig. ““ Mechatronic, Tightening Specification and Se‐
Install in reverse order, paying attention to the following:
Caution

hoist.
cardiagn.com
hands.
– Make suretothe
with respect connector
the correctness is correctly
of information connected
in this document. to the
Copyright Mecha‐
by AUDI AG.
tronic.
– Install the ATF suction filter. Refer to
⇒ “1.3 ATF Filter, Removing and Installing”, page 19 .
– Install the ATF pan. Refer to
– Install the ATF filter housing or ATF line connecting pieces
(depending on the version). Refer to ⇒ S tronic Transmission;
Rep. Gr. 34 ; ATF Circuit
Note
Replace the filter housing without a factory-installed anti-twist

mechanism -arrow-
1. Mechatronic 27
Caution
Danger of leaks!
♦ Always replace the seals on the oil lines and on the filter
housing and coat with ATF.
♦ Ensure a clean sealing surface.
Transmission Removed
– Install the transmission. Refer to ⇒by AUDI
S tronic Transmission;
permitted unless authorised AG. AUDI AG does not guarantee or accept any liability
Rep. Gr. 34 ; Transmission,
with respect to theRemoving and Installing;
correctness of information Trans‐
in this document. Copyright by AUDI AG.
mission, Installing .
The Transmission Is Installed
– Fill with ATF. Refer to ⇒ S tronic Transmission; Rep. Gr. 34 ;
Automatic Transmission Fluid; ATF, Draining and Filling .
• Perform the relevant “Guided Function” using the vehicle di‐
agnostic tester after replacing the DSG Transmission Mecha‐
tronic - J743- . Refer to ⇒ S tronic Transmission; Rep. Gr.
cardiagn.com
39 ; Transmission Control .
1.5 Overview - Mechatronic Circuit Boards
Note
A protector must be installed before installing the circuit boards.

Refer to ⇒ page 30 .

1 - DSG Transmission Mecha‐

tronic - J743-
ling. Refer to
⇒ “1.4 Mechatronic, Re‐
page 20 .
• Perform “Guided Func‐
tions” using the Vehicle Di‐
agnostic Tester after re‐
placing the DSG Transmis‐
sion Mechatronic - J743- .
Refer to ⇒ S tronic Trans‐
mission; Rep. Gr. 39 ;
Transmission Control
2 - Protector. Refer to
⇒ page 30 .
3 - Protector. Refer to
⇒ page 30 .
4 - Circuit Board 1
cardiagn.com
ling. Refer to
⇒ “1.6 Mechatronic Cir‐
cuit Board, Removing
and Installing”,
page 31 .
❑ The contact springs on
the circuit board can be
connected one time on‐
ly. A circuit board cannot
be used again once it
has been removed.
5 - Bolt
⇒ Fig. ““Circuit board 1 -
Tightening Specification and Sequence”“ , page 30
6 - Connector
❑ Use a 3.5 mm screwdriver to unlock the connector. Refer to ⇒ page 32
7 - Circuit Board 2
⇒ “1.6 Mechatronic Circuit Board, Removing and Installing”, page 31 .
❑ The contact springs on the circuit
Protected board can
by copyright. Copyingbeforconnected one time
private or commercial only.
purposes, Aorcircuit
in part in whole,board
is not cannot be used
again once it has been removed.
8 - Bolt
❑ Tightening specification and sequence. Refer to
⇒ Fig. ““Circuit board 2 - Tightening Specification and Sequence”“ , page 30
9 - Connector
❑ Use a 3.5 mm screwdriver to unlock the connector. Refer to ⇒ page 32
1. Mechatronic 29
Circuit board 1 - Tightening Specification and Sequence

– Tighten the bolts to 3 Nm in the following sequence: -1 to 5-.
Circuit board 2 - Tightening Specification and Sequence

– Tighten the bolts to 3 Nm in the following sequence: -1 to 5-.
cardiagn.com
Overview - Protectors

1 - Protector
❑ Rectangular
❑ Quantity: 2
2 - Protector
❑ Cap
❑ Quantity: 2
3 - Protector
❑ Cross-shaped
❑ Quantity: 6
cardiagn.com
1.6 Mechatronic Circuit Board, Removing

and Installing
Removing
– Remove the DSG Transmission Mechatronic - J743- . Refer
to ⇒ “1.4 Mechatronic, Removing and Installing”, page 20 .
– Place the Mechatronic on a clean, soft surface.
Caution

(Mechatronic) with electrostatic discharge.
hoist.
1. Mechatronic 31
Caution
Using an inappropriate tool can damage the transmission con‐

trol module (Mechatronic).
♦ The Mechatronic must be replaced if the locking mecha‐
nism for the connectors gets damaged while unlocking
and disconnecting the connectors.
♦ Use a screwdriver -a- = maximum 3.5 mm to unlock the
connector.
– Unlock the connectors -1 and 2- on the Mechatronic carefully

using a screwdriver -3- in direction of -arrow A- and disconnect
them in direction of -arrow B-.
– Loosen the screws -1, 2 and 3- on the small circuit board -A-
approximately 5 mm.
cardiagn.com
– Remove the screws -4 and 5- completely and move the wiring
guide to the side.
Caution
There is a danger of an insufficient contact connection.

♦ The contact springs on the circuit board can be connected
one time only. A circuit board cannot be used again once
it has been removed.

– Pull circuit board 2 just far enough until the contact springs
-2- on the circuit board are free from the contacts -1- on the
valves.
– Remove the screws -1, 2 and 3- carefully and remove circuit
board 2.
– Loosen the screws -1 through 5- on the large circuit board

-B- approximately 5 mm.
Caution
There is a danger of an insufficient contact connection.

♦ The contact springs on the circuit board can be connected
cardiagn.com
one time only. A circuit board cannot be used again once
it has been removed.
– Pull circuit board 1 just far enough until the contact springs
-2- on the circuit board are free from the contacts -1- on the
valves.
– Remove the screws -1 through 5- completely and remove cir‐

cuit board 1.
Installing
Note
♦ A protector must be installed before installing the circuit

boards. Refer to ⇒ page 30 .
♦ Install a protector in the transmission if the transmission did
not have one installed before.
1. Mechatronic 33
– Position the new circuit board 1 -B- carefully on the Mecha‐

tronic.
– Install the screws -1 to 5- approximately 2 turns as a guide.
– Push circuit board 1 carefully onto the contacts.
– Install the screws -1 to 5- all way hand-tight and then tighten
them to the tightening specification.
– Position the new circuit board 2 -A- carefully on the Mecha‐

tronic.
– Install the screws -1, 2 and 3- approximately 2 turns as a guide.
– Push circuit board 2 carefully onto the contacts.
– Position the wiring guide on the alignment sleeves on the small
circuit board.
cardiagn.com
– Install the screws -1 to 5- all way hand-tight and then tighten
them to the tightening specification. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect the connectors so that they click into place.with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install the Dual-Clutch Transmission Mechatronic - J743- .
Refer to
⇒ “1.4 Mechatronic, Removing and Installing”, page 20 .
1.7 ATF Filter, Removing and Installing

Note
♦ There are two different ATF filter versions depending on the

engine and the date of manufacture.
♦ Replace the ATF line filter -arrow- only when replacing a trans‐
mission. Removing and installing. Refer to ⇒ S tronic Trans‐
mission; Rep. Gr. 34 ; ATF Circuit .

Note
The ATF filter -A- must be changed each time the ATF is changed.
Removing the ATF Filter
Note
♦ Refer to
♦ Always clean the ATF lines and ATF cooler with compressed
air (maximum 10 bar (145 psi)) and then flush with ATF before
installing a replacement transmission.

– If equipped loosen the securing strap -3- and remove the anti-
twist mechanism -1-.
cardiagn.com
– Remove the cover for the ATF filter -1- and drain the ATF.
– Remove the ATF filter -2- in direction of -arrow- and remove

from below.
Installing
Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
Danger of leaks!
♦ Always replace the seals on the oil lines and the filter
housing and coat with ATF.
♦ Ensure a clean sealing surface.
Install in reverse order of removal. At the same time pay attention

to the following:
There are two different versions of ATF filter housing.
1. Mechatronic 35
If the factory installed anti-twist mechanism -arrow- is not present,

install an ATF-filter cover with upgradable anti-twist mechanism.
Note
The retrofittable anti-twist mechanism and the related ATF filter

cover are available from 07/2014. Refer to the Parts Catalog.
Caution
Leaking ATF filter.

♦ Only use the assigned respective ATF-filter cover for the
respective ATF filter housing/
Allocation of the ATF-Filter Cover to the ATF Filter Housing
Note
cardiagn.com
Position of the part number for the ATF filter housing.
ATF Fil‐ Its ATF-Filter Cover: Anti-Twist Mechanism:

ter Hous‐
ing:
0B5.325. 0B5.325.240.C Retrofitted
060.B Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
0B5.325. 0B5.325.240.B with respectFactory Installed
to the correctness of information in this document. Copyright by AUDI AG.
060.C
Note
♦ Replace the O-ring on the ATF filter cover.

♦ Replace the ATF filter.
Caution
Danger of causing damage to the transmission.

The new ATF filter must not come in contact with water. Even
the smallest amount of water, such as a drip of water from the
engine compartment or moisture from hands will cause the
surface of the ATF filter to swell up. Small paper particles from
the filter can come loose and contaminate the Mechatronic.

– Coat the O-ring -2- on the new ATF filter -1- with ATF before
installing.
– Coat the O-ring -2- on the ATF filter cover -1- with ATF.
cardiagn.com
– Install the ATF filter cover -1- and tighten to tightening speci‐
fications.
1. Mechatronic 37
Vehicles without A Factory Installed Anti-Twist Mechanism:
Caution
Filter housing leak.

♦ On filter housing without a factory installed anti-twist
mechanism the filter cover must always be replaced with
upgradable anti-twist mechanism -1-.
– Secure the anti-twist mechanism -1- on the ATF-filter cover

-2- with the securing strap -3-.
Note
The anti-twist mechanism retaining tab -arrow- must touch the

filter housing as shown.
– Clean the transmission and attachments.

Tightening Specification. Refer to
cardiagn.com
⇒ “1.1 Overview - Mechatronic”, page 14 .
Automatic Transmission Fluid; ATF, Draining and Filling .

2 Transmission, Transporting
♦ Hook And Support Tool - T40197-
♦ Hook and Support Tool - T40294-
DANGER!
Do not use the Hook And Support Tool T40197 for the repair
(Refer to
⇒ “3.2 Sensor Module , with integrated transmitters and sen‐
sors G612 , G632 , G676 and Circuit Board 3 , Removing and
Installing”, page 42 ) - There is a risk of injury.
Only use the Hook and Support Tool T40294 for this operation.
Procedure
cardiagn.com
• The transmission is removed.
Caution
Transmission components could be damaged if they are not

set down correctly.
♦ Do not set the transmission on the ATF pan.
– Engage the Hook And Support Tool - T40197- in the holes on

the right side of the transmission and secure it to the left side
of the transmission with the knurled bolt -arrow-.
– Lift and transport the transmission with the Shop Crane -
VAS6100- .
2. Transmission, Transporting 39
3 Transmission, Disassembling and

Assembling
⇒ “3.1 Overview - Transmission”, page 40
⇒ “3.2 Sensor Module , with integrated transmitters and sensors
G612 , G632 , G676 and Circuit Board 3 , Removing and Instal‐
ling”, page 42
⇒ “3.3 Oil Pump and Suction Jet Pump, Removing and Installing”,
page 54
⇒ “3.4 Transmission Housing Separator Seals, Replacing”, page
57
3.1 Overview - Transmission
1 - Oil Guide
2 - Transmission Intermediate
Housing
cardiagn.com
❑ With wheel set
3 - Gear Position Seal
❑ Only replace if damaged
ling. Refer to
⇒ Fig. ““Replace the
Gear Position Seal”“ ,
page 42 .
4 - Front Oil Catch Tray
❑ Replace after removal
❑ Clipped onto the Sensor
Module
5 - Sensor Module
❑ With integrated Trans‐
mission Input Speed
Sensor 2 - G612- ,
Transmission Input
Speed Sensor 1 -
G632- , Drive Position
Sensor - G676- and Cir‐
cuit Board 3
❑ Refer to the Parts Cata‐
log because there are
different versions de‐
pending on the date of
manufacture.
ling. Refer to
⇒ “3.2 Sensor Module ,
with integrated transmit‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ters and sensors G612 , permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
G632 , G676 and Circuit Board 3 ,with
Removing
respect to theand Installing”,
correctness page
of information 42document.
in this . Copyright by AUDI AG.
6 - Bolt
❑ 8 Nm
❑ Refer to the Parts Catalog because there are different versions depending on the date of manufacture.
7 - Bolt
❑ 4.5 Nm

8 - O-Ring
❑ Always replace
9 - O-Ring
❑ Always replace
10 - Bolt
❑ 25 Nm
❑ Quantity: 5
11 - Oil Pump
⇒ “3.3 Oil Pump and Suction Jet Pump, Removing and Installing”, page 54 .
12 - Suction Jet Pump
❑ Replace the small O-ring (not shown in the illustration)
13 - Shaft Seal
❑ The Double seal is connected
❑ For the separating wall inside the transmission housing
❑ Replacing. Refer to ⇒ “3.4 Transmission Housing Separator Seals, Replacing”, page 57 .
cardiagn.com
14 - Connector Housing for the Sensor Module
⇒ “3.2 Sensor Module , with integrated transmitters and sensors G612 , G632 , G676 and Circuit Board
3 , Removing and Installing”, page 42 .
16 - Oil Guide
❑ To the front final drive
17 - Bolt
⇒ Fig. ““Transmission Intermediate Housing on the Transmission Housing - Tightening Specification and
Sequence”“ , page 42
❑ Always replace
18 - Side Shaft
❑ With helical gear wheel
19 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 150 Nm +90° with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Always replace
❑ For the side shaft to the pinion
20 - Spur Gear
21 - Needle Bearing
3. Transmission, Disassembling and Assembling 41

Replace the Gear Position Seal
Caution
There is a risk of damaging the gear position

♦ Do not use any sharp-edged tools when removing the
seals.
– Remove the seal by hand from the respective gear position

-2-.
– Coat the new seal -1- with MTF and install on the Seal Installer
- Gear Selector - T40291- .
– Place the Seal Installer - Gear Selector - T40291- on the re‐
spective gear position -2- and insert the seal -1-.
Transmission Intermediate Housing on the Transmission Hous‐

ing - Tightening Specification and Sequence
cardiagn.com
Note
Replace the bolts.
– Tighten the bolts in two stages as described below:

Step Bolts Tightening Specification/Additional
Turn
1. -Arrows- 8 Nm diagonally
2. -Arrows- 120° additional turn diagonally
3.2 Sensor Module , with integrated trans‐

mitters and sensors -G612- , -G632- , -
G676 - and Circuit Board 3 , Removing
and Installing
♦ Counterhold - Side Shaft - T40217-
♦ Sensor Module Tool - T40228-
♦ Sealant. Refer to the Parts Catalog.
DANGER!
Caution:
Do not use the Hook And Support Tool T40197 for the following
described work procedures - There is a risk of injury.

Note
♦ The Transmission Input Speed Sensor 2 - G612- , Transmis‐

sion Input Speed Sensor 1 - G632- , Drive Position Sensor -
G676- and Circuit Board 3 are integrated in the Sensor
Module . The components can only be replaced as a single
Sensor Module unit.
♦ Replace the wiring set for the sensor module (-item 39-
⇒ Item 39 (page 17) ) when replacing the Sensor Module .
Removing
page 61 .
– Remove the dual clutch. Refer to
⇒ “1.3 DSG Clutch, Removing”, page 7 .
cardiagn.com
– Remove the oil pump and the suction jet pump. Refer to
⇒ “3.3 Oil Pump and Suction Jet Pump, Removing and Instal‐
ling”, page 54 .
Note
The wiring set for the sensor module must be replaced when re‐
placing the Sensor Module .
– Loosen the bolts -arrows- on the wiring set for the sensor
module.
– Loosen the bolt -1-.
– Pull the fastener in direction of -arrow A- and remove the con‐
nector in direction of -arrow B- to disconnect the connector
from the Sensor Module .

– Remove the wiring set for the sensor module.

– Mount the Sensor Module Tool - T40228- on the connector
housing, turn it all the way to the left in direction of -arrow A-
and then remove the connector housing for the Sensor Mod‐
ule .
– Remove the connector housing for the Sensor Module in di‐
cardiagn.com
rection of -arrow B-.
– Remove the center differential housing and center differential.
Refer to
⇒ “5.2 Self-Locking Center Differential, Removing and Instal‐
ling”, page 99 .
– Remove the oil guide for the input shaft -arrow-.

– Loosen the twelve-point bolt -A- for the side shaft -B- on the
pinion as follows:
– Mount a twelve-point socket -C- (21 mm) with an extension
-D- over the twelve-point bolt -A-.
– Insert the Counterhold - Side Shaft - T40217- with the outer
splines -arrow 1- into the inner splines -arrow 2- on the side
shaft.
– Tighten thewithCounterhold - Side ofShaft
respect to the correctness - T40217-
information on the
in this document. trans‐
Copyright by AUDI AG.
mission intermediate housing -arrows-.
cardiagn.com
DANGER!
Do not use the Hook And Support Tool T40197 for the following
described work procedure - There is a risk of injury.
– Remove the bolt -1- and the side shaft -2-.
Note
The bolt has a high loosening torque.

– Remove the spur gear -1- and needle bearing -2- from the
output shaft -3-.
– Wrap the splines for the outer drive axle with adhesive tape in
direction of -arrow-, so that the inner surfaces of the suction
jet pump are not damaged when removing or installing.
– Coat the tape lightly with grease.
cardiagn.com
– Adjust the transmission housing on the engine/transmission
holder so that it is vertical.
• The clutch side faces down.
– Remove the bolts -arrows- all around for the transmission in‐
termediate housing.
– Install the Three Guide Pins - Gearbox - T40288- in a distance
of approximately 120° in the transmission housing bolt holes.
Note
The Guide Pins - Gearbox - T40288- improve the removal of the

transmission housing and prevent damage to the seals and com‐
ponents.

– Engage the transmission intermediate housing -1- with the

wheel set on the Shop Crane - VAS6100- as shown in the
illustration.
WARNING
There is the risk of an accident if the support bridge parts are

loose.
♦ Install each threaded connection on the Lifting Eyebolt -
3368- and the Slide Hammer Set - Adapter 40 -
VW771/40- until stop to make sure they are secure.
♦ Secure the hooks and locking pins on the Engine Sling -
2024A- with cotter pins.
– Lift the transmission intermediate housing slowly and carefully

off the transmission housing.
– Place the transmission intermediate housing on a workbench.
– Remove the bolt -arrow-, and then remove the Sensor Module
cardiagn.com
-2-.
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The front oil catch tray -1- is engaged to the Sensor Module and
will also be removed.
– Release the tabs to remove the front oil catch tray -1- from the
Sensor Module .
Installing
⇒ “3.1 Overview - Transmission”, page 40 .
Note
♦ Replace any bolts that were tightened with an additional turn.

♦ There are different versions of the sensor module and screw,
depending on the date of manufacture. Allocation. Refer to the
Parts Catalog.
jet pump are not damaged when installing.

– Remove the shaft seal for the separator in the transmission

housing starting from the transmission side with a screwdriver
in direction of -arrow-.
Note
♦ Both of the shaft seals for the separator in the transmission

housing must always be replaced.
♦ To prevent damaging the seals there are pushed in after as‐
sembling the transmission housing with the intermediate hous‐
ing.
– Insert the Sensor Module into the guide openings and tighten
cardiagn.com
it -arrow-.
– Replace the oil catch tray.
– Insert the front oil catch tray into the holes in the gear carrier
and into the guide on the Sensor Module -arrows-.
• The oil catch tray must click into place.

Prepare the connector for the Sensor Module for installation:
Note
It is necessary to replace the O-ring on the connector -2- for the

Sensor Module if the Sensor Module is not being replaced.
– Check whether the connector -2- is secured on the bracket

-1- for the Sensor Module .
– Push the connector housing -3- onto the connector until it
clicks into place. Do not turn it.
– Coat the gear position seals with MTF -item 3-
⇒ Item 3 (page 40) . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check if the retaining tabs
within -4- to
respect can be pushed
the correctness in.
of information in this document. Copyright by AUDI AG.
– Check the oil catch tray seating.

– Check the seating of the sensor module seals -5-.
– Adjust the transmission housing on the engine/transmission
cardiagn.com
holder so that it is vertical.
– Move the gearshift lever all the way in direction of travel in

direction of -arrow-.

– Make sure the alignment sleeves -1 and 2- are installed inside

the transmission housing.
Note
♦ The transmission housing sealing surface must be lightly

roughened before the assembly.
♦ While doing so, make sure that no debris gets into the trans‐
mission.
♦ Suitable abrasive for example 3M bristle disk
– Coat the transmission housing flange -arrow- evenly and light‐

ly with sealant. Refer to the Parts Catalog.
– Make sure the magnet -arrow- is installed inside the transmis‐

sion housing.
cardiagn.com
– Insert the front final drive oil guide into the transmission hous‐
ing.
• The oil guide must be inserted into the holes in the transmis‐
sion housing at three locations -arrows-.
– Install the Guide Pins - Gearbox - T40288- in the threaded
holes approximately 120° offset.


– Engage the transmission intermediate housing -1- with the

wheel set on the Shop Crane - VAS6100- as shown in the
illustration.
WARNING
There is the risk of an accident if the support bridge parts are

loose.
♦ Install each threaded connection on the Lifting Eyebolt -
3368- and the Slide Hammer Set - Adapter 40 -
VW771/40- until stop to make sure they are secure.
♦ Secure the hooks and locking pins on the Engine Sling -
2024A- with cotter pins.
– Lower the transmission intermediate housing into the trans‐
cardiagn.com
mission housing slowly and carefully.
Caution
There is a danger of damaging the Sensor Module .

♦ When installing the transmission intermediate housing,
pay close attention that the Sensor Module is not on the
oil guide -1- and will not be damaged.
There is a risk of damaging the shift fork seal -item 3-
⇒ Item 3 (page 40) .
♦ When guiding the transmission intermediate housing pay
special attention not to contact the shift fork seal.
– When lowering the transmission intermediate housing guide it

so that the connector -1- from the Sensor Module is guided in
the hole -arrow- on the transmission housing without tilting.
Note
The procedure from the transmission intermediate housing side

is shown. The procedure from the transmission housing side must
also be performed.

– Guild the transmission intermediate housing completely on the

transmission housing and secure it. Refer to
⇒ Fig. ““Transmission Intermediate Housing on the Transmis‐
sion Housing - Tightening Specification and Sequence”“ ,
page 42 .
– Check if the connector retaining tabs for the sensor module
are engaged in the transmission housing.
– Connect the Sensor Module Tool - T40228- flush with the con‐
nector housing for the Sensor Module .
Note
The tabs for the Sensor Module Tool - T40228- must securely
mesh into the openings on the connector housing for the Sensor
Module .
cardiagn.com
– Turn the connector housing with the Sensor Module Tool -
T40228- 180° in the clockwise direction of -arrow- lock it into
place. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install the shaftwith
seal fortothe
respect separator
the correctness in the transmission
housing. Refer to
⇒ “3.4 Transmission Housing Separator Seals, Replacing”,
page 57 .
– Install the oil pump and the suction jet pump. Refer to
ling”, page 54 .
Note
♦ The wiring set for the sensor module must be replaced when
replacing the Sensor Module .
♦ Bolt tightening specification: position -item 38-
⇒ Item 38 (page 16) .
– Tighten the bolts -arrows- on the wiring set for the sensor
module.

– Carefully press the connector on the Sensor Module com‐

pletely opposite the direction of -arrow B-.
– Secure the fastener opposite the direction of -arrow A-.
– Make sure that the connector is secured and fastened cor‐
rectly on the Sensor Module .
– Tighten the bolt -1-.
Note
Bolt tightening specification: position -item 38-

⇒ Item 38 (page 16) .
– Mount the needle bearing -2- and spur gear -1- on the output
cardiagn.com
shaft -3-.
– Insert the side shaft -2- with the bolt -1- into the transmission
intermediate housing.
– Insert the side shaft -B- all the way onto the pinion and into the
transmission cover.
Tighten the twelve-point bolt -A- for the side shaft -B- on the pinion
as follows:
– Mount a twelve-point socket -C- (21 mm) with an extension
-D- over the twelve-point bolt -A-.
– Insert the Counterhold Protected
- Side by Shaft - T40217-
copyright. Copying for with
privatethe outer purposes, in part or in whole, is not
or commercial
splines -arrow 1- into the innerunless
permitted splines -arrow
authorised 2-AG.
by AUDI onAUDI
theAG sidedoes not guarantee or accept any liability
shaft. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Tighten the Counterhold - Side Shaft - T40217- on the trans‐

mission intermediate housing -arrows-.
– Tighten the bolt for the side shaft.
– Mount the oil guide for the input shaft -arrow-.

Installation is performed in reverse order of removal.
– Install the center differential housing and the center differen‐
tial. Refer to
ling”, page 99 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install the DSG Transmission Mechatronic

with respect to the- correctness
J743- . Refer to in this document. Copyright by AUDI AG.
cardiagn.com
of information
– Push the separator shaft seal in the transmission housing.
Refer to
⇒ “3.4 Transmission Housing Separator Seals, Replacing”,
page 57 .
– Install the dual clutch. Refer to
⇒ “1.4 Dual Clutch, Installing”, page 9 .
3.3 Oil Pump and Suction Jet Pump, Re‐

moving and Installing
Removing
page 61 .

jet pump are not damaged when removing or installing.
– Remove the bolts -arrows- and push the oil pump forward on
the input shaft.
cardiagn.com
– Remove the bolts -arrows- for the suction jet pump -2- on the
back of the oil pump -1-.
Note
The oil pump is shown removed.
– Remove the oil pump and suction jet pump separately from
the input shaft.

Installing
⇒ “3.1 Overview - Transmission”, page 40 .
Note
♦ Replace any bolts that were tightened with an additional turn.

♦ Replace the O-rings.
jet pump are not damaged when installing.
– Push the O-ring -2- onto the seal seat on the suction jet pump
-1-.
cardiagn.com
– Check the sealing surface -arrow- on the inside of the large
opening in the suction jet pump for damage and replace if
necessary.
– Check that the small O-rings -1- are in the correct places on
the suction jet pump.

– Push the suction jet pump -2- and oil pump -1- separately onto
the input shaft.
Note
The oil pump is shown removed.
– Position the suction jet pump on the oil pump and tighten the
bolts -arrows-.
– Tighten the oil pump -arrows-.
cardiagn.com
– Remove the adhesive tape.
– Install the DSG Transmission Mechatronic - J743- . Refer to
3.4 Transmission Housing Separator Seals,

Replacing
♦ Seal Installer - Clutch Housing - T40260-
Procedure
page 61 .


– Remove the oil pump and the suction jet pump. Refer to
ling”, page 54 .
Caution

• In the following procedures, the input shaft surface must
not come in contact with hard objects. Damage to the
sealing surface on the input shaft will result in leaks.
– Place a punch on the shaft seal and drive in a small hole

-arrow-.
cardiagn.com
– Install a screw -arrow- with a large head into the hole in the
shaft seal.
– Remove the outer shaft seal using a wide screwdriver in di‐

rection of -arrow-.
– Remove the inner shaft seal the same way.
Caution
There is the danger of causing damage to the roller bearing

behind the inner shaft seal.
• Do not hit the punch too hard when making the hole in the
inner shaft seal otherwise the bearing cage for the roller
bearing behind it will get damaged.

Note
Remove both shaft seals from the transmission side using a

screwdriver in direction of -arrow- with the transmission disas‐
sembled.
– Position the new shaft seals for installation.
cardiagn.com
Note
The shaft seals -1- and -2- are supplied as one part, and must be
coated with MTF before installing.
• The spiral spring -arrow A- on the outer shaft seal -1- must
face the dual clutch.
• The spiral spring -arrow B- on the inner shaft seal -2- must face
the transmission.
Caution
Risk of leaks due to incorrect assembly.

♦ Before installing the shaft seal, wrap the outer input shaft
splines with tape.
♦ After the shaft seal is pushed over the splines, make sure
that the sealing lips have not turned inside out.
– Clip the shaft seals together and slide them over the input
shaft.

– Install the shaft seals flush from the clutch side using the Seal
Installer - Clutch Housing - T40260- .
Note
The Seal Installer - Clutch Housing - T40260- can be extended

using the Press Piece - 60mm - VW415A- .

– Install the oil pump. Refer to
ling”, page 54 .
– Install the DSG Transmission Mechatronic - J743- . Refer to
cardiagn.com

4 Securing on Engine and Transmis‐

sion Holder
♦ Engine And Transmission Holder - VW6095-
♦ Holding Plate - VW309A-
DANGER!
Do not use the Hook And Support Tool T40197 for the repair
(Refer to
⇒ “3.2 Sensor Module , with integrated transmitters and sen‐
sors G612 , G632 , G676 and Circuit Board 3 , Removing and
Installing”, page 42 ) - There is a risk of injury.
cardiagn.com
Procedure
• Hold the transmission with the Shop Crane - VAS6100- . Refer
to ⇒ “2 Transmission, Transporting”, page 39 .
– Attach the Holding Plate - VW309A- to the Hook And Support
Tool - T40197- .
– Place the transmission using the Shop Crane - VAS6100- in

the Engine And Transmission Holder - VAS6095- .
Note
The vents for the transmission housing and final drive must be
closed before turning a filled transmission with oil pan upward on
the engine and transmission holder.
4. Securing on Engine and Transmission Holder 61

5 Automatic Transmission Fluid

⇒ “5.1 ATF Drain Plug, Fill Plug and Check Plug Assembly Over‐
view”, page 62
⇒ “5.2 ATF, Draining and Filling”, page 62
5.1 ATF Drain Plug, Fill Plug and Check Plug Assembly Overview
1 - ATF Drain Plug

❑ 45 Nm
2 - Seal
❑ Always replace
❑ For the ATF drain plug
3 - Transmission Fluid (MTF)
fill and Check Plug
45 Nm
❑ Inside the manual trans‐
cardiagn.com
mission, front final drive
and transfer case Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - ATF Fill and Check Plug with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 45 Nm
Drain Plug
❑ Drain plug tightening
specification 45 Nm
and transfer case
❑ Depending on the date
of manufacture, Trans‐
mission Fluid Tempera‐
ture Sensor 2 - G754-
may also serve as the
transmission fluid drain
plug; tightening specifi‐
cation for Removing and
installing. Refer to
⇒ “2.3 Transmission
Fluid Temperature Sen‐
sor 2 G754 , Removing
and Installing”,
page 78 .
5.2 ATF, Draining and Filling

ATF Level, Checking and Correcting: The ATF level can be
checked and corrected only if the transmission is installed. Refer
to ⇒ S tronic Transmission; Rep. Gr. 34 ; Automatic Transmission
Fluid; ATF Level, Checking
♦ Protective eyewear

ATF, Draining
Transmission Installed:
• The engine is off.
• Move vehicle onto a four-pillar workshop hoist or over a work
pit so that it is absolutely horizontal.
• The selector level is in “P”.
• The parking brake button should be activated to set the elec‐
tromechanical parking brake.
– Remove the rear noise insulation -2-. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 66 ; Noise Insulation; Noise Insulation, Remov‐
ing and Installing .
Caution

♦ Engine must not be started if only a small amount or no
ATF is in the transmission after repair work or after signif‐
icant ATF loss.
cardiagn.com
• The transmission is secured to the engine/transmission hold‐
er. Refer to
page 61 .
Transmission, Removed or Installed:

WARNING
Danger of eye injury.

♦ Wear protective eyewear.
– Remove the ATF drain plug -arrow- and let the ATF drain out.
Note
♦ Follow the disposal requirements.

♦ Replace the ATF drain plug seal.
– Tighten the ATF drain plug.
5. Automatic Transmission Fluid 63

On Transmissions with an ATF Filter -2-:
Caution

• Always replace the ATF filter -2- every time the ATF is
changed.
– Replace the ATF filter. Refer to

⇒ “1.7 ATF Filter, Removing and Installing”, page 34 .
Continuation for All Transmissions:
Fill the Transmission with ATF.
Caution

♦ Only use replacement part ATF for the DSG transmission
0B5.
cardiagn.com
♦ Allocation. Refer to the Parts Catalog.
♦ Using other types of ATF can result in the malfunctions or
transmission failure.
♦ The ATF filler tool must be clean and the ATF must not be
mixed with any other oils.

Automatic Transmission Fluid; ATF, Draining and Filling

6 Special Tools
cardiagn.com
♦ Engine And Transmission Holder - VW6095-
6. Special Tools 65
♦ Holding Plate - VW309A-
cardiagn.com
♦ Seal Installer - Clutch Housing - T40260-

35 – Gears, Shafts
1 Input Shaft
⇒ “1.1 Input Shaft Ball Bearing, Replacing”, page 67
⇒ “1.2 Input Shaft Seal, Replacing”, page 69
1.1 Input Shaft Ball Bearing, Replacing

♦ Press Plate - VW401-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Puller - 3046-
Removing
cardiagn.com
– Remove the dual clutch -1-. Refer to
– Remove the locking ring -arrow- from the removed clutch cov‐
er.
1. Input Shaft 67
– Remove the dual clutch ball bearing.
cardiagn.com
Note
♦ There may still be a thrust washer -2- behind the ball bearing
-3- depending on the clutch cover date of manufacture. If there
is, then replace the old one with a new one when installing the
new ball bearing.
♦ Replace the ball bearing -3-.
Installing
– Replace the O-ring and locking rings. Refer to
⇒ “1.1 Overview - Flywheel and Dual Clutch”, page 4 .
Note
The clutch cover may have or may not have a thrust washer -2-,
depending on the date of manufacture. Allocation. Refer to the
Parts Catalog.
– If it was there during the removal, then insert a thrust washer

-2- into the cover -1-.
68 Rep. Gr.35 - Gears, Shafts

– Install the new dual clutch ball bearing all the way.
• Position the Press Piece - 60mm - VW415A- with the thin
shoulder facing up.
– Install the new ball bearing circlip -arrow-.
cardiagn.com
– Clean the sealing surface on the clutch cover.
1.2 Input Shaft Seal, Replacing

♦ Pulling Hook - T20143/2-
♦ Seal Installer - Input Shaft - T40198-
Procedure
page 61 .
1. Input Shaft 69
– Pry out the input shaft seal with the Pulling Hook - T20143/2- .
– Place the Seal Installer - Input Shaft Guide Sleeve - T40198/1-

on the drive axle.
– Lightly coat the outer circumference of the new shaft seal with
oil.
sealingwithgrease.
respect toRefer to theofParts Catalog.
the correctness information in this document. Copyright by AUDI AG.
– Install the shaft seal on the guide sleeve.
cardiagn.com
• Installed position: Open side of shaft seal faces transmission.
– Drive in the shaft seal with the Seal Installer - Input Shaft -
T40198- until it stop without tilting.

2 Special Tools

equipment required
cardiagn.com
♦ Puller - 3046-
2. Special Tools 71
♦ Puller - Crankshaft/Power Steering Seal - T20143-
♦ Seal Installer - Input Shaft - T40198-
cardiagn.com

39 – Final Drive, Differential

1 Final Drive
⇒ “1.1 Overview - Final Drive”, page 73
1.1 Overview - Final Drive
1 - Flywheel
ling. Refer to
⇒ “1.2 Flywheel, Re‐
page 5 .
2 - Shaft Seal
❑ For the left flange shaft
❑ Between the final drive
and the transmission
housing
cardiagn.com
❑ Replacing. Refer to
⇒ “3.1
Protected Left Seal,
by copyright. CopyingReplac‐
for private or commercial purposes, in part or in whole, is not
ing”, page 80 .
3 - Shim
❑ Behind the taper roller
bearing outer race
4 - Taper Roller Bearing Outer
Race
5 - Differential
6 - Bolt
⇒ Fig. ““Tightening
Specification and Se‐
quence, Front Final
Drive Cover”“ ,
page 74
❑ Quantity 10
7 - Locking Ring
❑ Always replace
8 - Right Flange Shaft
ling. Refer to ⇒ “4.4 Right Flange Shaft, Removing and Installing”, page 92 .
9 - Shaft Seal
❑ For the right flange shaft
❑ Replacing. Refer to ⇒ “3.2 Right Seal, Replacing”, page 81 .
10 - Front Final Drive Cover
❑ Removing and installing. Refer to ⇒ “3.1 Left Seal, Replacing”, page 80 .
11 - O-Ring
❑ Always replace
❑ On the front final drive cover
12 - Shim
❑ Behind the taper roller bearing outer race
1. Final Drive 73
13 - Taper Roller Bearing Outer Race

14 - Spring Pin
15 - Gearshift Lever
16 - Shaft Seal
❑ For the selector shaft
❑ Replacing. Refer to ⇒ S tronic Transmission; Rep. Gr. 34 ; Selector Mechanism; Selector Shaft Seal,
Replacing
17 - Bolt
❑ 10 Nm + 45°
❑ Quantity: 3
18 - Left Flange Shaft
❑ Removing and installing. Refer to ⇒ “4.1 Left Flange Shaft, Removing and Installing”, page 83 .
19 - Bracket
❑ Attached to the left flange shaft with the ball bearing -20- and the circlip -21-
❑ Check for traces of wear on the bearing bracket and check the pre-tension on the ball bearing for the left
flange shaft. Refer to
⇒ “4.2 Left Flange Shaft Ball Bearing Pre-Tension, Checking and Adjusting”, page 85
cardiagn.com
20 - Ball Bearing
❑ For the left flange shaft
❑ Left Flange Shaft Ball Bearing Pre-Tension, Checking. Refer to
⇒ “4.2 Left Flange Shaft Ball Bearing Pre-Tension, Checking and Adjusting”, page 85
❑ Replacing. Refer to
⇒ “4.3 Left Flange Shaft Ball Bearing Mounting Bracket, Removing and Installing”, page 91 .
21 - Locking Ring
❑ Always replace
❑ For the left flange shaft bearing
22 - Shaft Seal
❑ Replacing. Refer to ⇒ “1.2 Input Shaft Seal, Replacing”, page 69 .
Tightening Specification and Sequence, Front Final Drive Cover
Note
Replace any bolts that were tightened with an additional turn.
– Tighten the bolts in three steps in the sequence shown:

Step Bolts Tightening Specification/Additional
Turn
1. -1 to 10- 3 Nm
2. -1 to 10- 20 Nm
3. -1 to 10- Tightenpermitted
an additional 90° by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
74 Rep. Gr.39 - Final Drive, Differential

2 Transmission Fluid
⇒ “2.1 Overview - Transmission Drain and Inspection Plug for
Transmission Fluid”, page 75
⇒ “2.2 Transmission Fluid; Transmission Fluid, Draining and Fill‐
ing”, page 75
⇒ “2.3 Transmission Fluid Temperature Sensor 2 G754 , Re‐
moving and Installing”, page 78
2.1 Overview - Transmission Drain and Inspection Plug for Transmission Fluid
The gear set, the manual transmission and the transfer case in
the DSG transmission 0B5 share a common transmission fluid
chamber, which is checked and filled by a single plug.
1 - ATF Drain Plug

45 Nm
2 - Seal
cardiagn.com
❑ Always replace
❑ For the ATF drain plug
Fill and Check Plug
❑ 45 Nm
and transfer case
4 - ATF Fill and Check Plug
45 Nm
Drain Plug
❑ 45 Nm
and transfer case
❑ Depending on the date
of manufacture, Trans‐
mission Fluid Tempera‐
ture Sensor 2 - G754-
may also serve as the
transmission fluid drain
plug; tightening specifi‐
cation for Removing and
installing. Refer to
⇒ “2.3 Transmission
Fluid Temperature Sen‐
sor 2 G754 , Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
and Installing”, permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
page 78 . with respect to the correctness of information in this document. Copyright by AUDI AG.
2.2 Transmission Fluid; Transmission Fluid,

Draining and Filling
Transmission Fluid Level, Checking and Filling: The transmission
fluid level (MTF) can be checked and corrected only if the trans‐
2. Transmission Fluid 75
mission is installed. Refer to ⇒ S tronic Transmission; Rep. Gr.

39 ; Transmission Fluid; Transmission Fluid Level, Checking
cardiagn.com

Procedure
Note

Refer to
• Gear oil at about 20 ℃ (68 °F) (room temperature).

• Move vehicle onto a four-pillar workshop hoist or over a work
pit so that it is absolutely horizontal.
Caution
cardiagn.com
Without any or with too little manual transmission fluidunless
permitted insideauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
the transmission: with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Do not start the engine and

♦ Do not tow the vehicle
er. Refer to
page 61 .-
WARNING
Danger of eye injury.

♦ Wear protective eyewear.
Note
♦ Place a cloth over the tunnel crossmember to prevent trans‐

mission fluid (MTF) from getting into the cast pockets on the
top.
♦ In the following description, vehicles with drain plugs for trans‐
mission fluid (MTF) are differentiated from vehicles with Trans‐
mission Fluid Temperature Sensor 2 - G754- in place of drain
plugs for transmission fluid (MTF).
– Place a cloth over the tunnel crossmember.
Vehicles with a Transmission Fluid (MTF) Drain Plug -arrow-:
Note
The drain plug for the transmission fluid is located behind the
transmission fluid pan.
– Remove the transmission fluid (MFT) drain plug -arrow- on the

bottom of the transmission housing.
– Drain the transmission fluid (MTF).
– Tighten the transmission fluid drain plug (MTF) -arrow-.
• Tightening specification. Refer to
Transmission Fluid”, page 75 .
Vehicles with Transmission Fluid Temperature Sensor 2 - G754-

-1- Instead of a Transmission Fluid (MTF) Drain Plug:
– Transmission installed in vehicle: Turn off the ignition.
cardiagn.com
Note
The connector on the Transmission Fluid Temperature Sensor 2

- G754- can be disconnected only when the ignition is turned off.
The transmission will switch to emergency mode if the ignition is
on. The counter for the increased temperature will count up and
a DTC memory entry will be stored in the Transmission Control
Module - J217- after 10 minutes.
– Disconnect the connector -2- from Transmission Fluid Tem‐

perature Sensor 2 - G754- and tie it up.
Note
Protect the connector -2- and the contacts on Transmission Fluid

Temperature Sensor 2 - G754- from transmission fluid. Clean the
connectors immediately if they come in contact with transmission
fluid (Manual Transmission Fluid). Transmission fluid can cause
contact problems in the connector contacts.
– Remove the Transmission Fluid Temperature Sensor 2 -

G754- -1-.
– Tighten the Transmission Fluid Temperature Sensor 2 - G754-
-1- and connect the connector -2-.
Transmission Fluid”, page 75 .
All Vehicles:
– Fill with transmission fluid (MTF). Referpermitted
to ⇒ unless
S tronic Trans‐
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
mission; Rep. Gr. 39 ; Transmission Fluid; Transmission
Fluid, Draining and Filling
2.3 Transmission Fluid Temperature Sen‐

sor 2 - G754- , Removing and Installing
The 7-speed DSG transmission 0B5 (S tronic) has an additional
Transmission Fluid Temperature Sensor 2 - G754- to monitor the

transmission fluid temperature of the wheel set on certain engine

versions.
♦ Component location: in place of the manual transmission fluid
(MTF) drain plug
Procedure
Caution

Without any or with too little manual transmission fluid inside
the transmission:
♦ do not start the engine and
♦ do not tow the vehicle
cardiagn.com
er. Refer to
page 61 .-
– Disconnect the connector -2- from Transmission Fluid Tem‐

perature Sensor 2 - G754- .
Note
Protect the connector -2- and the contacts on Transmission Fluid

Temperature Sensor 2 - G754- from transmission fluid. Clean the
connectors immediately if they come in contact with transmission
fluid (Manual Transmission Fluid). Transmission fluid can cause
contact problems in the connector contacts.
– Remove the Transmission Fluid Temperature
with respect Sensor
to the correctness 2 - in this document. Copyright by AUDI AG.
of information
G754- -1-.
• Tightening Specification: Transmission Fluid Temperature
Sensor 2 - G754- to transmission, 45 Nm
– Attach the wiring harness to the transmission -arrows-.
– Fill the transmission fluid (MTF). Refer to ⇒ S tronic Trans‐
Fluid, Draining and Filling .
– Clean the transmission and tunnel crossmember.
3 Seals
⇒ “3.1 Left Seal, Replacing”, page 80
⇒ “3.2 Right Seal, Replacing”, page 81
⇒ “3.3 Selector Shaft Seal, Replacing”, page 82
3.1 Left Seal, Replacing

♦ Seal Installer - Flange Shaft - T40164-
Procedure
page 61 .
cardiagn.com
SMN372500- under
Protected the transmission.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the right flange
with respect to theshaft. Refer
correctness to
⇒ “4.4 Right Flange Shaft, Removing and Installing”,
page 92 .
– Remove the bolts -arrows-.
– Carefully remove the front final drive cover; when doing this,
the transmission fluid will drain out.
Caution
Danger of causing damage to the differential.

♦ Slowly and carefully remove front final driver cover from
transmission housing. Otherwise differential can fall out of
transmission.
♦ A differential that has fallen out can no longer be installed.
If differential falls out, transmission must be replaced.
♦ Make sure the differential bearing inner race and adjust‐
ment shims do not fall out of the transmission housing and
front final drive cover.
♦ Bearing inner races and adjustments that have fallen out
cannot be allocated with workshop equipment.
– Carefully remove the differential -arrow- and lay it on a soft

support.
page 83 .

Caution
Danger of damaging the seating surface in the transmission

housing.
♦ Position the screwdriver.
– Pry out the seal from the back.
– Lightly coat the new seal on the outside with oil and install it
using the Seal Installer - Flange Shaft - T40164- .
• The open side of the seal faces the Thrust Piece for Final Drive
at Gearbox - T40164- .
– Install the shaft seal for the left flange shaft using the Seal
Installer - Flange Shaft - T40164- all the way; when doing this,
do not bend it.
cardiagn.com
– Install the differential.
– Install the front final drive cover with a new O-ring and tighten
the bolts. Refer to
⇒Protected
Fig. ““Tightening Specification and Sequence, Front Final
Drive
withCover”“ , page
respect to the 74 .of information in this document. Copyright by AUDI AG.
correctness

page 83 .
– Install the right flange shaft. Refer to
page 92 .
– Fill with transmission fluid (MTF). Refer to ⇒ S tronic Trans‐
3.2 Right Seal, Replacing

♦ Pry lever
Procedure
– Remove the right flange shaft. Refer to
page 92 .
3. Seals 81
– Pry out the flange shaft sealing ring -arrow-.

– Lightly coat the outer circumference of the new shaft seal with
oil.
– Drive in the right flange shaft seal using the Seal Installer -
Flange Shaft - T40163- until stop without tilting.
– Install the right flange shaft. Refer to
page 92 .
cardiagn.com
3.3 Selector Shaft Seal, Replacing
• The transmission is installed.
Description of the procedure. Refer to ⇒ S tronic Transmission;
Rep. Gr. 34 ; Selector Mechanism; Selector Shaft Seal, Replac‐
ing

4 Differential
⇒ “4.1 Left Flange Shaft, Removing and Installing”, page 83
⇒ “4.2 Left Flange Shaft Ball Bearing Pre-Tension, Checking and
Adjusting”, page 85
⇒ “4.3 Left Flange Shaft Ball Bearing Mounting Bracket, Remov‐
ing and Installing”, page 91
⇒ “4.4 Right Flange Shaft, Removing and Installing”, page 92
4.1 Left Flange Shaft, Removing and Instal‐

ling
Removing
cardiagn.com
page 61 .
– Tilt the transmission back on the engine/transmission holder
so the transmission fluid does not drain out.
– Remove the bolts -arrows- from the flange shaft mounting
bracket.
– Remove the left flange shaft -2- from the transmission in di‐
rection of -arrow A-.
Note
Ignore -1- and -arrow 3, B-.
– Remove the flywheel

4. Differential 83
Installing
⇒ “1.1 Overview - Final Drive”, page 73 .
– Always clean the left flange shaft, 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. Refer to
⇒ “3.1 Left Seal, Replacing”, page 80 .
– Clean the left flange shaft thoroughly.
The Following Work Must be Performed on the Listed Vehicle
cardiagn.com
Types Up to the Specified VIN:
Vehicle Model VIN Factory
Audi A4 MY 2008 Through Germany, Neckar‐
WAUZZZ8K9BN03 sulm
4383
Audi A4 MY 2008 Through Germany, Ingol‐
WAUZZZ8KXBA08 stadt
2742
Audi A5 Cabriolet Through Germany, Neckar‐
MY 2008 WAUVGAFH3BN00 sulm
9542
Audi A5 Coupe MY Through Germany, Ingol‐
2008 WAUZZZ8T9BA90 stadt
2081
Audi Q5 MY 2008 Through Germany, Ingol‐
WAUZZZ8R2BA06 stadt
1817
– Check the pre-tension on the ball bearing for the left flange
shaft based on the wear pattern on the bearing bracket
-arrow-. Refer to
⇒ “4.2 Left Flange Shaft Ball Bearing Pre-Tension, Checking
and Adjusting”, page 85 .

♦ Optimize the pre-tension on the ball bearing for the left flange
shaft if necessary. Refer to
⇒ “4.2.2 Pre-Tension on Ball Bearing, Optimizing, Left Flange
Shaft”, page 86 .
♦ Adjust the pre-tension on the ball bearing for the left flange
shaft if necessary. Refer to
⇒ “4.2.3 Pre-Tension on Ball Bearing, Adjusting, Left Flange
Shaft”, page 87 .

For all Vehicle Models

– Rotate the flywheel. Refer to -1- until the opening to the dif‐
ferential -arrow 3- is seen.
– Install the left flange shaft -2- into the transmission in direction
of -arrow B-. When doing this, insert the flange shaft centrally
into the shaft seal on the front differential -arrow 3-.
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ If the flange shaft is not centered, the flange shaft splines -2-
will damage the shaft seal between the final drive and the
♦ The shaft seal must be replaced if it is damaged.
♦ Ignore -arrow A-.

cardiagn.com
4.2 Left Flange Shaft Ball Bearing Pre-Ten‐

sion, Checking and Adjusting
⇒ “4.2.1 Left Flange Shaft Ball Bearing Pre-Tension, Checking”,
page 85
Shaft”, page 86
Shaft”, page 87
4.2.1 Left Flange Shaft Ball Bearing Pre-Ten‐

sion, Checking
Check the Ball Bearing Pre-Tension Using the Wear Pattern on
the Bearing Bracket -arrow-.
Note
♦ The pre-tension on the left flange shaft ball bearing must be

checked only on certain vehicles. Refer to the table for a list
of the vehicles. Refer to ⇒ page 84 .
♦ This is not necessary on vehicles built later because they have
been redesigned.
• The left flange shaft is removed. Refer to

⇒ “4.1 Left Flange Shaft, Removing and Installing”, page 83 .
4. Differential 85
Wear Pattern “A”

• Small indentations near the hole on the bearing bracket
-arrows-.
• No trace of wear or material erosion.
– Optimize the pre-tension on the ball bearing for the left flange
shaft. Refer to
Shaft”, page 86 .
Wear Pattern “B”
cardiagn.com
• Traces of wear, if necessary, with material erosion all around
the hole on the bearing bracket -arrow-.
– Adjust the pre-tension on the left flange shaft bearing. Refer
to
Shaft”, page 87 .
– Replace the bearing bracket, the ball bearing and the circlip.
Refer to
⇒ “4.3 Left Flange Shaft Ball Bearing Mounting Bracket, Re‐
moving and Installing”, page 91 .
4.2.2 Pre-Tension on Ball Bearing, Optimiz‐

ing, Left Flange Shaft
Note
♦ the pre-tension on the left flange shaft ball bearing must be

optimized only on certain vehicles. Refer to the table for a list
been redesigned.
Procedure

Conditions for optimizing:

• The bearing bracket does not show any traces of wear or ma‐
terial erosion.
• Small indentations near the hole on the bearing bracket
-arrows- are permissible.
• Bearing bracket with wear pattern “A”. Refer to ⇒ page 86 (the
cardiagn.com
bearing bracket does not shown any traces of wear or material
erosion).
• A shim is inserted into the bearing seat on the transmission to
optimize the pre-tension on the ball bearing.
– Insert a Shim - 0B4 409 227- -1- into the bearing seat on the
transmission before installing the flange shaft to improve the
pre-tension.
4.2.3 Pre-Tension on Ball Bearing, Adjusting,

Left Flange Shaft
Note
♦ the pre-tension on the left flange shaft ball bearing
permitted must be
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
optimized only on certain vehicles. Refer with
to the table
respect to the for a list of information in this document. Copyright by AUDI AG.
correctness
been redesigned.
4. Differential 87

• Bearing bracket with wear pattern “B”. Refer to ⇒ page 86
(traces of wear if necessary with material erosion all around
the hole).
• The bearing bracket and ball bearing must be replaced. Refer
to
moving and Installing”, page 91
Procedure
– Clean off any dirt and corrosion from the contact surface
-arrow- using 150 grain sand paper.
Note
It is not necessary to sand the contact surfaces all the way down
cardiagn.com
to bare metal. It is enough to just remove any dirt and corrosion.
– Clean the contact surface and bearing seat.
– Install the new left flange shaft ball bearing -arrow- into the
bearing seat.
Next procedure:
♦ By bearing oversize (the bearing sticks out slightly above the
contact surface). Refer to ⇒ page 89
♦ With bearing undersize (the bearing sits deeper than the con‐
tact surface). Refer to ⇒ page 90 .

Procedure If There Is Bearing Oversize

– Place Straight Edge - 500mm - VAS6075- straight across the
bearing and determine the distance to the contact surface on
the transmission housing on both sides with the feeler gauge.
– Write down the measured value.
– Place the straight edge 90° offset across the bearing and de‐
termine the distance to the contact surface on the transmission
housing on both sides with the feeler gauge.
Selecting the Shim(s):
Note
Use the smallest value take from the four values to select the shim
(s).
• Specified value, bearing oversize = 0.5 to 0.8 mm

Smallest bearing oversize (example = 0.1 mm)
cardiagn.com
+ Shim(s) thickness, (thickness = 0.3 mm)
= Bearing pre-load, (specified value = 0.5 to 0.8 mm)
Example:
1 shim:
0.1 mm + 0.3 mm = 0.4 mm, “bearing pre-load is too small”
2 Protected
shims:by copyright. Copying for private or commercial purposes, in part or in whole, is not
0.1 mm +to0.3
with respect mm + 0.3
the correctness mm = 0.7
of information in thismm, “bearing
document. Copyrightpre-load
by AUDI AG.is in
the specified range”
• Result: Insert two 0.3 mm shims to reach the bearing pre-load
= 0.7 mm within the 0.5 to 0.8 mm specified value.
4. Differential 89
Procedure If There Is Bearing Undersize
Note
The bearing undersize can only be determined in the described

procedure.
– Place Straight Edge - 500mm - VAS6075- straight across the

contact surface on the transmission housing and measure the
distance to the bearing on both sides with a feeler gauge.
– Place straight edge 90° offset across the contact surface on
the transmission housing and measure the distance to the
bearing on both sides with a feeler gauge.
Selecting the Shim(s):
Note
cardiagn.com
♦ Use the largest value take from the four values to select the
shim(s).
♦ Enter the measured bearing undersize as negative value (“–”)
into the calculation.
• Specified value, bearing oversize = 0.5 to 0.8 mm

– Larger determined bearing undersize (example -0.15 mm)
+ Shim(s) thickness, (thickness = 0.3 mm)
= Bearing pre-load (specified value = 0.5 to 0.8 mm)
Example:
1 shim:
–0.15 mm + 0.3 mm = 0.15 mm, “bearing pre-load is too small”
3 Shims:
–0.15 mm + 0.3 mm + 0.3 mm + 0.3 mm = 0.75 mm, “bearing
pre-load is in the specified range”
• Result: A 0.75 mm bearing pre-load within the specified value
of 0.5 to 0.8 mm is reached by installing three 0.3 mm shims.
Continuation for All with respect to the correctness of information in this document. Copyright by AUDI AG.
– Replace the bearing bracket, the ball bearing and the circlip.
Refer to
moving and Installing”, page 91 .
– Insert the determined number of shims -0B4 409 227- item
-1- into the bearing seat on the transmission before installing
the flange shaft.

4.3 Left Flange Shaft Ball Bearing Mounting

Bracket, Removing and Installing
♦ Press Piece - 42mm - VW516-
– Remove the locking ring -1- from the flange shaft.
cardiagn.com
– Remove the ball bearing -A- from the flange shaft
4. Differential 91
– Install the new bearing bracket -1-.

• Installed position: The printed side faces the drive axle flange.
– Install the new ball bearing -2-.
– Install the ball bearing -A-permitted
all theunless
wayauthorised
on withbythe bearing
AUDI AG. AUDI AG does not guarantee or accept any liability
cardiagn.com
bracket -B- installed.
– Install the circlip -1- in the flange shaft groove.
4.4 Right Flange Shaft, Removing and In‐

stalling
♦ Bearing/Bushing Installer - Multiple Use - VW295A-
♦ Slide Hammer Set - VW771-
♦ Lifting Eyebolt - 3368-
♦ M10 nut, quantity: 2

Removing
page 61 .
– Install the Lifting Eyebolt - 3368- into a threaded hole in the
right flange shaft.
– Position the Slide Hammer Set - VW771- with the -VW771/13-
on the Lifting Eyebolt - 3368- and remove the flange shaft.
Installing
cardiagn.com
Note
Replace the circlip on the right flange shaft.
– Clamp the flange shaft in a vise with jaw protectors. Remove

the old circlip from the groove in the flange shaft using the new
circlip -A-.
– Drive in the right flange shaft using the Bearing/Bushing In‐
staller - Multiple Use - VW295A- .
– Fill the transmission fluid (MTF). Refer to ⇒ S tronic Trans‐
4. Differential 93
5 Center Differential
⇒ “5.1 Overview - Self-Locking Center Differential”, page 94
⇒ “5.2 Self-Locking Center Differential, Removing and Installing”,
page 99
⇒ “5.3 Center Differential Housing, Servicing”, page 105
⇒ “5.4 Transmission Output Shaft Seal, Replacing”, page 111
5.1 Overview - Self-Locking Center Differ‐

ential
⇒ “5.1.1 Overview - Self-Locking Center Differential, Bolted Driv‐
eshaft”, page 94
⇒ “5.1.2 Overview - Self-Locking Center Differential, Mounted
Driveshaft”, page 96
5.1.1 Overview - Self-Locking Center Differ‐

ential, Bolted Driveshaft
cardiagn.com
Note
♦ Refer to ⇒ “1 Repair Information”, page 1 .

♦ Refer to
The Center Differential Housing Can Also be Removed and In‐

stalled With The Transmission Installed. Refer to
⇒ “5.2.1 Self-Locking Center Differential, Removing and Instal‐
ling, Bolted Driveshaft”, page 99 .

1 - Bolt
quence, Center Differ‐
ential Housing - Bolted
Driveshaft”“ , page 96
❑ Always replace
❑ Aluminum bolts
❑ Quantity 11
2 - Housing
❑ For the center differen‐
tial
❑ Refer to
⇒ “5.2.1 Self-Locking
Center Differential, Re‐
moving and Installing,
Bolted Driveshaft”, page
99
cardiagn.com
3 - Ball Bearing
❑ For the flange shaft
❑ Refer to
⇒ “5.3.1 Rear Flange
Shaft, Seal and Ball
Bearing, Removing and
Installing”, page 105
4 - Spacer Sleeve
ling. Refer to
⇒ “5.3.1 Rear Flange
Shaft, Seal and Ball
Bearing, Removing and
Installing”, page 105 .
5 - Gear Carrier
❑ Installed position: The tab must fit into the opening in the transmission intermediate housing
6 - Spacer Sleeve
7 - Shim
8 - Ball Bearing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For the center differential with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Center Differential
10 - Ball Bearing
❑ For the center differential
11 - Pressure Spring
12 - Shim
13 - Plate Spring
❑ Installed position: The side curved outward faces the shaft seal -17-
14 - Locking Ring
❑ For the flange shaft
⇒ “5.3.1 Rear Flange Shaft, Seal and Ball Bearing, Removing and Installing”, page 105 .
5. Center Differential 95
15 - Bolt
⇒ Fig. ““Tightening Specification and Sequence, Center Differential Housing - Bolted Driveshaft”“ , page
96
❑ Always replace
❑ Steel bolts
❑ Quantity: 2
16 - Balance Weight
❑ Installed depending on the version
17 - Shaft Seal
❑ Refer to ⇒ “5.3.1 Rear Flange Shaft,Protected
Seal and Ball Bearing, Removing and Installing”, page 105
18 - Rear Flange Shaft with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Without vibration damper

❑ Allocation. Refer to the Parts Catalog.
19 - Rear Flange Shaft
cardiagn.com
❑ With vibration damper
20 - Bolt
❑ 20 Nm +90°
❑ Always replace
Tightening Specification and Sequence, Center Differential Hous‐

ing - Bolted Driveshaft
– Tighten the bolts in eight steps as follows:
Step Bolts Tightening Specification/Addition‐
al Turn
1. Aluminum bolts -1- 8 Nm
2. Aluminum bolts -2- Install the bolt hand-tight.
3. Aluminum bolts -1- Loosen again and then install all
the way hand-tight
5. Steel bolts -4- Install the bolt hand-tight.
6. -1, 2, 3, 4- 10 Nm diagonally
7. Steel bolts -4- 15 Nm
8. -1, 2, 3, 4- 90° additional turn, diagonally
5.1.2 Overview - Self-Locking Center Differ‐

ential, Mounted Driveshaft
Note

♦ Refer to

The Center Differential Housing Can Also be Removed and In‐

stalled with the Transmission Installed. Refer to
ling, Bolted Driveshaft”, page 99 .
1 - Bolt
❑ 20 Nm +90°
❑ Always replace
2 - Bolt
quence, Center Differ‐
ential Housingpermitted
- Attach‐
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ed Driveshaft”“ with
, respect to the correctness of information in this document. Copyright by AUDI AG.
page 98
❑ Always replace
❑ Aluminum bolts
❑ Quantity 11
cardiagn.com
3 - Housing
❑ For the center differen‐
tial
❑ Refer to
⇒ “5.2 Self-Locking
Center Differential, Re‐
page 99
4 - Gear Carrier
❑ Installed position: The
tab must fit into the
opening in the transmis‐
sion intermediate hous‐
ing
5 - Center Differential
6 - Pressure Spring
7 - Assembly Sleeve
❑ Does not have to be in‐
stalled again
8 - Locking Ring
❑ For the transmission output shaft ball bearing with splines
⇒ “5.3.2 Transmission Output Shaft with Splines, Seal and Ball Bearing, Removing and Installing”, page
108 .
9 - Locking Ring
❑ For the transmission output shaft with splines
108 .
10 - Ball Bearing
❑ For the transmission output shaft with splines
❑ Refer to
108
11 - Bolt
⇒ Fig. ““Tightening Specification and Sequence, Center Differential Housing - Attached Driveshaft”“ ,
page 98
❑ Always replace
❑ Steel bolts
❑ Quantity: 2
12 - Balance Weight
❑ Installed depending on the version
13 - Shaft Seal
❑ Replace on vehicles with vibration damper. Refer to
108 .
❑ Replace on vehicles without vibration damper. Refer to
⇒ “5.4.1 Transmission Output Shaft Seal, Replacing, Transmission Output Shaft with Splines without
Vibration Damper”, page 111
14 - Dust Ring
❑ Replace after removing
cardiagn.com
❑ Depends on the version; for vehicles without a torsional vibration damper. Refer to the Parts Catalog.
15 - Transmission Output Shaft with Splines without Vibration Damper
108 .
16 - Transmission Output Shaft with Splines and Vibration Damper
❑ Removing and installing.Protected
Refer by tocopyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “5.3.2 Transmission Output Shaft
permitted unless with Splines,
authorised by AUDI Seal and
AG. AUDI AGBall Bearing,
does not guarantee Removing and Installing”, page
or accept any liability
108 . with respect to the correctness of information in this document. Copyright by AUDI AG.
Tightening Specification and Sequence, Center Differential Hous‐

ing - Attached Driveshaft
– Tighten the bolts in eight steps as follows:
Step Bolts Tightening Specification/Addition‐
al Turn
1. Aluminum bolts -1- 8 Nm
3. Aluminum bolts -1- Loosen again and then install all
the way hand-tight
5. Steel bolts -4- Install the bolt hand-tight.
6. -1, 2, 3, 4- 10 Nm diagonally
7. Steel bolts -4- 15 Nm
8. -1, 2, 3, 4- 90° additional turn, diagonally

5.2 Self-Locking Center Differential, Re‐

moving and Installing
ling, Bolted Driveshaft”, page 99
ling, Mounted Driveshaft”, page 102
5.2.1 Self-Locking Center Differential, Re‐

moving and Installing, Bolted Driveshaft
Removing with Transmission Installed
It is possible to remove the center differential housing with the
transmission still installed.
– Perform the vehicle-specific preliminary work. Refer to ⇒ S
tronic Transmission; Rep. Gr. 39 ; Center Differential .
cardiagn.com
Removing with the Transmission Removed
– Secure the transmission on the Engine And Transmission
page 61 .
Continuation for a Removed or Installed Transmission

– Remove the bolts -1 through 4- and carefully remove the cen‐
ter differential housing. The transmission fluid (MTF) will leak
out while doing this.
Protected by copyright.Caution
Copying for private or commercial purposes, in part or in whole, is not
Danger of damaging the center differential.
♦ Carefully and slowly pull center differential housing off of
transmission toward rear. Otherwise the center differential
can fall out of the transmission.
♦ A center differential that has fallen out may not be instal‐
led.
– Remove the pressure spring -3-, shim(s) -4- and plate spring
-5-.
– Pull the center differential -2- toward the rear.
If the gear carrier -1- remains in the center differential housing,

proceed as follows:
Caution
Danger of damaging the sealing surface on the center differ‐

ential housing.
♦ Use a hammer to hit the housing on several places.
– Hold the gear carrier -1- by one of the side ribs with pliers and
remove it in direction of -arrow A-.
– Using a Rubber Hammer, tap the housing on alternating sides

-arrows B-.
Installing
⇒ “5.1.1 Overview - Self-Locking Center Differential, Bolted
Driveshaft”, page 94 .
cardiagn.com
Note
Replace the bolts for the center differential housing.
– Clean both housing separating surfaces thoroughly. They

must be free of oil and grease.
– Apply a bead sealant -arrow 1- evenly and not too thick on the
housing surfaces; sealant. Refer to the Parts Catalog.
– Place a sealing ring round each bolt hole to prevent contact
corrosion -arrow 2-.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Coat the gear carrier with
surfaces
respect towith transmission
the correctness fluid
of information (MTF).
in this document. Copyright by AUDI AG.

– Make sure the spacer sleeve -2- and the shim -1- are mounted
on the output shaft.
– Coat both outer ring surfaces on the gear carrier slightly with
transmission fluid (MTF).
– Insert the gear carrier.
• Installed position: The tab on the gear carrier -arrow A- must
fit into the opening in the transmission intermediate housing
-arrow B-.
cardiagn.com
– Place the center differential -2- on the transmission -1-.
– Install the pressure spring -3- into the center differential.
– Attach the plate spring -5- and shim(s) -4- in the center differ‐
ential housing -6- with a little grease.
• Plate spring installation location: The side rounded on the out‐
side faces the flange shaft.

– Press the center differential housing centrally on until it makes

contact with the transmission intermediate housing and hold it
securely.
– Tighten the center differential housing bolts. Refer to
⇒ Fig. ““Tightening Specification and Sequence, Center Dif‐
ferential Housing - Bolted Driveshaft”“ , page 96 .
– Install the transmission. Refer to ⇒ S tronic Transmission;
Rep. Gr. 34 ; Transmission, Removing and Installing; Trans‐
mission, Installing .
Note
Check the vehicle data label or the designation on the rear final
drive itself to determine which one is installed in the vehicle. Then
select the correct rear final drive repair manual.
– Install the (attached) driveshaft. Refer
with respect to the to ⇒of information
correctness Rear Final in thisDrive
document. Copyright by AUDI AG.
0BC, 0BD, 0BE, 0BF; Rep. Gr. 39 ; Description and Operation
cardiagn.com
5.2.2 Self-Locking Center Differential, Re‐

moving and Installing, Mounted Drive‐
shaft
Removing with Transmission Installed
It is possible to remove the center differential housing with the
transmission still installed.
– Perform the vehicle-specific preliminary work. Refer to ⇒ S
tronic Transmission; Rep. Gr. 39 ; Center Differential
Removing with the Transmission Removed
page 61 .


– Remove the bolts -1 through 4- and carefully remove the cen‐
ter differential housing. The transmission fluid (MTF) will leak
out while doing this.
Caution
Danger of damaging the center differential.

♦ Carefully and slowly pull center differential housing off of
transmission toward rear. Otherwise the center differential
can fall out of the transmission.
♦ A center differential that has fallen out may not be instal‐
led.
– Remove the guide sleeve -4- and pressure spring -3-.

– Pull the center differential -2- toward the rear.
cardiagn.com
If the gear carrier -1- remains in the center differential housing,
proceed as follows:
Caution
Danger of damaging the sealing surface on the center differ‐

ential housing.
♦ Use a hammer to hit the housing carefully on several pla‐
ces.
Note
In this case the center differential is pulled
permitted off together
unless authorised by AUDIwith the AG does not guarantee or accept any liability
AG. AUDI
center differential housing. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Hold the gear carrier -1- by one of the side ribs with pliers and
remove it in direction of -arrow A-.
– Using a Rubber Hammer, tap the housing on alternating sides

-arrows B-.
Installing
⇒ “5.1 Overview - Self-Locking Center Differential”, page 94 .
Note
Replace the bolts for the center differential housing.
– Clean both housing separating surfaces thoroughly. They

must be free of oil and grease.

– Apply a bead sealant -arrow 1- evenly and not too thick on the
housing surfaces; sealant. Refer to the Parts Catalog.
– Place a sealing ring round each bolt hole to prevent contact
corrosion -arrow 2-.
– Coat the gear carrier surfaces with transmission fluid (MTF).
– Coat both outer ring surfaces on the gear carrier

withslightly with
respect to the correctness of information in this document. Copyright by AUDI AG.
cardiagn.com
transmission fluid (MTF).
– Insert the gear carrier.
• Installed position: The tab on the gear carrier -arrow A- must
fit into the opening in the transmission intermediate housing
-arrow B-.
– Place the center differential -2- on the transmission.
Note
The guide sleeve -4- is only necessary for production and must
not be reinstalled.
– Install the pressure spring -3- into the center differential.

– Press the center differential housing centrally on until it makes

contact with the transmission intermediate housing and hold it
securely.
– Tighten the center differential housing bolts. Refer to
⇒ Fig. ““Tightening Specification and Sequence, Center Dif‐
ferential Housing - Bolted Driveshaft”“ , page 96 .
mission, Installing
Note
– Install the (attached) driveshaft. Refer to ⇒ Rear Final Drive

cardiagn.com
5.3 Center Differential Housing, Servicing

⇒ “5.3.1 Rear Flange Shaft, Seal and Ball Bearing, Removing and
Installing”, page 105
⇒ “5.3.2 Transmission Output Shaft with Splines, Seal and Ball
Bearing, Removing and Installing”, page 108
5.3.1 Rear Flange Shaft, Seal and Ball Bear‐

ing, Removing and Installing
♦ Press Piece - Press
permitted Tube - by30-100-
unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Press Piece - Front Control Arm - 2040-
♦ Seal Installer - Cardan Flange - T40165-
♦ Plate - T40285- for vehicles with torsional vibration damper or
without vibration damper

Procedure
– Remove the center differential housing. Refer to
⇒ “5.2.1 Self-Locking Center Differential, Removing and In‐
stalling, Bolted Driveshaft”, page 99 .
– Remove the circlip -arrow-.
Transmission with Bolted Vibration Damper
– Remove the flange shaft by positioning the center differential

housing so the flange shaft does not touch the Press Plate -
VW401- and Press Plate - VW402- .
Transmission with Torsional Vibration Damper or without Vibra‐
tion Damper
cardiagn.com
– Remove the flange shaft by allowing the housing for the center
differential to rest on the Plate - T40285- .
All Transmissions
Note
Ignore item -2-.
– Pry out the shaft seal -1-.

– Remove the flange shaft ball bearing and spacer sleeve if

necessary.
– Installing the flange shaft ball bearing.

• The shoulder on the Press Piece - 60mm - VW415A-
Protected -arrow-
faces the Press Piece - Multiple Use - VW412- .
– The press in the spacer sleeve -item 4- ⇒ Item 4 (page 95)

using the Press Piece - 60mm - VW415A- .
cardiagn.com
– Lightly oil the outer circumference on the shaft seal and then
install it all the way using the Seal Installer - Cardan Flange -
T40165- .
– Install the flange shaft.

– Install the flange shaft into the center differential housing from
underneath.
– Position the housing and flange shaft on the Press Plate -
VW402- under the shop press.
– Press in the bearing inner race using the Press Piece - Press
Tube - 30-100- on the flange shaft.

– Install a new circlip -arrow- on the flange shaft.

– Install the center differential housing. Refer to
⇒ “5.2.1 Self-Locking Center Differential, Removing and In‐
stalling, Bolted Driveshaft”, page 99 .
5.3.2 Transmission Output Shaft with Splines,

Seal and Ball Bearing, Removing and
Installing
cardiagn.com
♦ Press Piece - Press Tube - 30-100-
♦ Press Piece - FrontProtected
Control by Arm - 2040-
copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Seal Installer - Outputwith
Shaft - toT40238-
respect the correctness of information in this document. Copyright by AUDI AG.

Procedure
– Remove the center differential housing. Refer to
ling”, page 99 .
– Remove the circlip -arrow A-.
– Remove the locking ring -arrow B- as well if the ball bearing is
also being removed.
Transmission Output Shaft With Splines without Vibration Damp‐

er:
– Pry off the dust ring -1-.
Note
The dust ring cannot be removed without destroying it.

– Position the center differential housing so that the transmis‐

sion output shaft with splines does not touch the thrust plates
Press Plate - VW401- and Press Plate - VW402- and remove
the transmission output shaft with splines.
Transmission Output Shaft With Splines and Vibration Damper:
– Position the center differential housing so that the vibration
damper does not touch the thrust plates Press Plate - VW401-
and Press Plate - VW402- and remove the transmission output
shaft with splines.
All:
– Pry out the shaft seal -1-.
Note
Ignore item -2-.
cardiagn.com
– Remove the transmission output shaft ball bearing with
splines, if necessary.
– Install the transmission output shaft ball bearing.

• The shoulder on the Press Piece - 60mm - VW415A- -arrow-
faces the Press Piece - Multiple Use - VW412- .

– Coat the seal on the outer circumference lightly with oil and
then install it all the way in using Seal Installer - Output Shaft
- T40238- .
– Install the transmission output shaft into the center differential

housing as follows:
– Attach the vibration damper (if equipped) to the center differ‐
ential housing. Tightening specification. Refer to
⇒ “5.1 Overview - Self-Locking Center Differential”, page 94 .
– Install the transmission output shaft with splines into the center
differential housing from underneath.
cardiagn.com
– Position the housing and transmission output shaft on the
Press Plate - VW402- under the shop press.
– Mount the Press Plate - 30-100- on the ball bearing inner race.
– Install the transmission output shaft.
– Mount the new locking ring -arrow A- for the transmission out‐
put shaft with splines and -arrow permitted
B- for unless
the ball bearing.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Transmission Output Shaft with Splines without Vibration Damp‐

er:
– Install a new dust ring -1-.
All:
– Install the center differential housing. Refer to
ling”, page 99 .

5.4 Transmission Output Shaft Seal, Re‐

placing
⇒ “5.4.1 Transmission Output Shaft Seal, Replacing, Transmis‐
sion Output Shaft with Splines without Vibration Damper”,
page 111
⇒ “5.4.2 Transmission Output Shaft Seal, Replacing, Transmis‐
sion Output Shaft with Splines with Vibration Damper”,
page 113
5.4.1 Transmission Output Shaft Seal, Re‐

placing, Transmission Output Shaft with
Splines without
permittedVibration
unless authorised Damper
by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Puller - Crankshaft/Power Steering Seal - T20143/1-
♦ Seal Installer - Output Shaft - T40238-
Procedure
cardiagn.com
Note

♦ Refer to
The Transmission Is Installed.

It is possible to replace the transmission output shaft seal with the
transmission installed.
Note
– Remove the (attached) driveshaft. Refer to ⇒ Rear Final Drive

0BC, 0BD, 0BE, 0BF; Rep. Gr. 39 ; Removal and Installation
Transmission Removed
– Secure the transmission to the Gearbox Support - T40173-
using a tension strap -1-.
or
page 61 .


– Pry off the dust ring -1-.
Note
The dust ring cannot be removed without destroying it.
– Shaft Seal, Transmission Output Shaft with Splines, Remov‐

ing
– Clean the running and sealing surface.
– Coat outer edge of seal with gear oil.
cardiagn.com
– Mount the Seal Installer - Output Shaft - T40238/1- item -1- on

the transmission output shaft with splines.
– Install the shaft seal -2-.
• Installed position: The open side of the seal faces the trans‐
mission housing.
– Install the shaft seal all the way around evenly using Seal In‐
staller - Output Shaft - T40238- . Do not bend the seal.

– Install a new dust ring -1-.

mission, Installing
Continuation for an Installed Transmission
Note
– Install the (attached) driveshaft. Refer to ⇒ Rear Final Drive

5.4.2 Transmission Output Shaft Seal, Re‐
cardiagn.com
placing, Transmission Output Shaft with
Splines with Vibration Damper
The transmission output shaft with splines on vehicles with a vi‐
bration damper must be removed in order to replace the trans‐
mission output shaft seal with splines.
Refer to
⇒ “5.3.2 Transmission Output Shaft with Splines, Seal and Ball
Bearing, Removing and Installing”, page 108 .

6 Special Tools

equipment required
cardiagn.com
♦ Seal Installer - Output Shaft - T40238-

cardiagn.com
6. Special Tools 115

♦ Puller - Crankshaft/Power Steering Seal - T20143/1-
cardiagn.com
♦ Seal Installer - Cardan Flange - T40165- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Plate - T40285- for vehicles with torsional vibration damper or

without vibration damper
♦ Bearing/Bushing Installer - Multiple Use - VW295A-
cardiagn.com
♦ Press Piece - 42mm - VW516-
♦ Slide Hammer Set - VW771-
6. Special Tools 117

♦ Lifting Eyebolt - 3368-
cardiagn.com

7 Revision History
DRUCK NUMBER: A005AI01121
Fac‐ Edit Job Fe Notes Quality
tory Edi‐ Type ed‐ Checke
Edi‐ tion ba d By
tion ck
12.2 12/0 Fac‐ N/ Eric P.

0018 6/20 tory A
18 Up‐
date
11.2 11/1 Cor‐ N/ Updated Revision History Eric P.
018 6/20 rec‐ A
18 tion
11.2 10/2 Fac‐ N/ Eric P.
018 9/20 tory A
18 Up‐
date
09.2 08/1 Lo‐ N/ Change Obergrup to “Drive‐ Tom
cardiagn.com
014 6/20 cal A train” Perry
16 Up‐
date
09.2 5/6/2 Link N/ Jim
014 015 Chec A Harder
king permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
09.2 3/24/ Fac‐ N/ Jim

014 2015 tory A Harder

Up‐
date
1/15/ Title N/ Jim
2015 Cha A Harder
nge
11/1 Link N/ This book refers to various Tom
8/20 Chec A models and has links refer‐ Perry
14 king ring to the Q5 book and oth‐
ers referring to the A6/A7
book
08/1 Fac‐ 10 Eric P.
3/20 tory 34
14 Up‐ 78
date 1
w/
Feed
back
7. Revision History 119

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 you or keep you from being fully alert.
•= Never run the engine with
unless
respectthe work
to the areaofisinformation
correctness well ventilated. Carbon
in this document. monoxide
Copyright by AUDI AG.(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.
•= Finger rings should be removed so that they cannot cause electrical 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
permitted unless authorised(A/C)
by AUDIsystem
AG. AUDI isAGfilled with
does not a chemical
guarantee refrigerant
or accept any liability that is hazardous. The A/C
system should
with respect becorrectness
to the serviced only by intrained
of information automotive
this document. service
Copyright by AUDI AG.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
Protected are highly
by copyright. Copyingflammable. Be extremely
for private or commercial purposes, incautious when
part or in whole, is notrepairing a tire that
may have been inflated using
with respect to thean aerosol
correctness tire inflator.
of information Keep sparks,
in this document. Copyrightopen
by AUDIflame
AG. 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

SM 22 Unlocked

Uploaded by

Copyright:

Available Formats

SM 22 Unlocked

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

SM 22 Unlocked

Uploaded by

Copyright:

Available Formats

What are the main components of the dual clutch transmission discussed in the document?

What are the main components of the dual clutch transmission discussed in the document?

What safety precautions should be taken when working with the air conditioning system?

What safety precautions should be taken when working with the air conditioning system?

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Audi AG, Ingolstadt D3E8045FFC4

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

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.3 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

00 – General, Technical Data

1.1 Guidelines for Clean Working Condi‐

1.2 General Repair Information

2 Rep. Gr.00 - General, Technical Data

1.3 Contact Corrosion

♦ Original replacement parts are recommended because they

1.1 Overview - Flywheel and Dual Clutch

4 Rep. Gr.30 - Clutch

❑ For the input shaft

Clutch Cover Tightening Specification and Sequence

1.2 Flywheel, Removing and Installing

– Turn the Puller - Clutch Module - T40176- upward.

To prevent the flywheel from tilting, counterhold it underneath as

Replace the shaft seal between the differential and transmission

– Clean the input shaft -arrow-.

6 Rep. Gr.30 - Clutch

– Remove the Puller - Clutch Module - T40176- from the fly‐

1.3 DSG Clutch, Removing

– Remove the bolts -1 through 5-.

– Turn the inside the Engine and Gearbox Jack - VAS6931- so

– Connect the Dual Clutch Lifting Device - T40123A- with the

– Remove the locking ring -arrow- with locking ring pliers.

8 Rep. Gr.30 - Clutch

1.4 Dual Clutch, Installing

Replace the O-ring and the circlip.

– Clean the sealing surface on the clutch cover.

– Check the hole -arrow- in the transmission for wear grooves.

– Install the dual clutch into the transmission housing. Using

10 Rep. Gr.30 - Clutch

♦ Do not let the O-ring get caught when installing.

– Tighten the clutch cover bolts -1 through 5- to the tightening

Special tools and workshop

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

12 Rep. Gr.30 - Clutch

♦ Puller - Clutch Module - T40176-

♦ Clutch Disc Shaft Spline Lubricant - G 000 100-

1.1 Overview - Mechatronic

1 - ATF Drain Plug

14 Rep. Gr.34 - Controls, Housing

16 Rep. Gr.34 - Controls, Housing

39 - Wiring Set for the Sensor Module

ATF Oil Pan, Tightening Specification and Sequence

Mechatronic, Tightening Specification and Sequence

1.2 Oil Pan, Removing and Installing

♦ General Repair Instructions. Refer to

The Transmission is Installed.

– Diagonally Loosen the screws -1 through 15-.

18 Rep. Gr.34 - Controls, Housing