Transmision-ZF6HP19

Service

Repair Manual

Audi Q7 2007 ➤

Automatic Transmission Edition 07.2006

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 - Technical Data 32 - Torque Converter 37 - Mechanism and Housing 38 - Gears, Control

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.

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 © 2016 Audi AG, Ingolstadt

D3E80022F58

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

Contents 00 - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 4 5 6 7 8

Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Information on 6-speed automatic transmission 0AT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code Letters, Transmission Allocations, Ratios and Equipment . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2 3 4 5 6 9 10

32 - Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 1.1 1.2 1.3 1.4 1.5

Torque converter, important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Shaft Seal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 11 11 12 13 13

37 - Mechanism and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 3.4 4 4.1 4.2 5 6 6.1 6.2 7 8 9 9.1 9.2 10 10.1 10.2

Electric and Electronic Components and Component Locations . . . . . . . . . . . . . . . . . . . . Shift Mechanism, Servicing, Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Mechanism, Performing Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Lever Knob, Servicing, Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Lever Transmission Range Position Display Unit Y26 , Removing and Installing ........................................................................ Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift Mechanism Function Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Mechanism Shift Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview . . by copyright. Shift Gate, Removing and Protected Installing . . . .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 Selector Lever Position “P” Locking Removing and Installing . . . . . .by. AUDI . . . AG. ....... with respectLever, to the correctness of information in this document.. Copyright Shift Lock Solenoid N110 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Park Selector Switch F305 , Removing and Installing . . . . . . . . . . . . . . . . . . Selector Lever Cable, Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Lever Cable, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Lever cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Shaft Lever, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, 6-Cylinder, Removing 3.6L FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, 6-Cylinder 3.6L FSI, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Level Inside Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Level, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF, Draining Or Filling after Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview . . ATF Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Pipes and ATF Cooler, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents

15 18 19 21 22 26 28 29 33 35 36 40 41 45 48 49 50 53 55 55 61 66 67 69 69 73 77 78 81

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Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

11 11.1 11.2

Shaft Seals, Replacing - Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Shaft Seal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 84 85

38 - Gears, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 1 1.1 1.2 1.3 2

Oil pan, oil strainer and Mechatronic, Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . ATF Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Screen, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechatronic, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

ii

Contents

88 88 90 92 96

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

00 –

Technical Data

1

Transmission Identification

(Edition 07.2006) The Audi Q7 has a “6-speed automatic transmission 0AT with AWD”. Allocation. Refer to ⇒ “4 Code Letters, Transmission Allocations, Ratios and Equip‐ ment ”, page 4 . Allocation of transmission code on transmission: Transmission code letters are located on the data plate under the transmission housing. Note

The transmission code letters are also included on the vehicle data labels.

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The following data are listen on the type plate: 1-

Transmission serial number

2-

Parts list number

3-

Transmission identification, here 6HP19

4-

Code, here GZV

Additional data depend on the manufacturing.

1. Transmission Identification

1

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

2

Information on 6-speed automatic transmission 0AT

Transmission design and function More information about the automatic transmission can be found in the training CD ⇒ Multimedia Training; Transmission Parts 1 to 3 . Transmission by copyright.drive Copyingis forequip‐ private or commercial purposes, in part or in whole, is not The 6-speed automatic transmissionProtected 0AT all-wheel permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ped with 6 hydraulically activated forward gears. When the lockwith respect to the correctness of information in this document. Copyright by AUDI AG. up clutch is closed, these forward gears become manually driven gears through bypassing the torque converter slip.

Torque Converter The torque converter is equipped with a slip controlled torque converter lockup clutch. Mechatronic The Mechatronic unit incorporates the hydraulic control, the Transmission Control Module - J217- , the Multifunction Trans‐ mission Range Switch - F125- and the sensors and actuators as a complete synchronized unit. The Mechatronic unit is installed in the transmission in the area of the oil pan. Transmission Control Module - J217The control module is a part of the Mechatronic unit in the trans‐ mission. Determining the driving situation and driving resistance depend‐ ent shift point occurs automatically. Advantages: ♦ It is shifted depending on consumption; ♦ Maximum engine output is always available; ♦ Individual adaptation of shift points in all driving situations; ♦ Gear shift points are infinitely variable. OBD Before beginning any service work on the automatic transmission, determine the cause of the damage using “Guided Fault Finding”. The “Guided Fault-finding” is performed using the Vehicle Diag‐ nosis, Testing and Information System - VAS 5051 A- . Shift Point Changes on Inclines and Declines An additional gear change map automatically selects the gear changes for gradients dependent upon accelerator pedal position and driving speed. ♦ The gear change map for extreme uphill stretches is matched to engine output ♦ The gear change map for extreme downhill stretches is match‐ ed to the braking effect of the engine. ♦ Direct gear selection by way of the Tiptronic function permits utilization of engine braking action with a specific gear engag‐ ed, for example, on a downhill gradient with a trailer.

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Rep. Gr.00 - Technical Data

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

3

Transmission Overview

1 - Automatic transmission 0AT AWD 2 - Transfer Case ❑ Removing and installing ⇒ Transfer case and fi‐ nal drive; Rep. Gr. 34 ❑ Transmission Carrier and Bracket, Removing and Installing. Refer to ⇒ Transfer Case and Fi‐ nal Drive; Rep. Gr. 34 . 3 - Rear Propshaft ❑ Removing and installing ⇒ Transfer case and fi‐ nal drive; Rep. Gr. 39 4 - Rear Final Drive ❑ Removing and installing ⇒ Transfer case and fi‐ nal drive; Rep. Gr. 39 5 - Front Propshaft ❑ Removing and installing ⇒ Transfer case and fi‐ nal drive; Rep. Gr. 39 6 - Front Final Drive ❑ Removing and installing ⇒ Transfer case and fi‐ nal drive; Rep. Gr. 39

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3. Transmission Overview

3

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

4

Code Letters, Transmission Allocations, Ratios and Equipment

Automatic Transmission Transmission

Torque Converter Mechatronic

Code letters Month of manufac‐ ture Code letters

Allocation

Type Engine

Gear Ratios

1. Gear 2. Gear 3. Gear 4. Gear 5. Gear 6. Gear Reverse gear Axle ratio

0AT.A JTU 06.06

from through

Z96 Allocation. Refer to ⇒ Electronic Parts Catalog (ETKA) . Audi Q7 from MY 07 6 cylinder 3.6L FSI engine 206kW 4,171 2,340 1,521 1,143 0,867 0,691 3,403 41 / 9 = 4,556

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4

Rep. Gr.00 - Technical Data

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

5

Capacities

Capacities

Automatic transmission 0AT

Original filling by the manufac‐ turer Change

Lubricant

8.55L + 0.4l for ATF cooling circuit If replacement is necessary: ⇒ Maintenance ; Booklet 406 Replace after repair, for exam‐ ple when removing the oil pan ATF ⇒ Electronic Parts Catalog (ETKA)

Caution

Only ATF available as a replacement part for automatic trans‐ mission 0AT may be used in the planetary gear. Refer to the ⇒ Electronic Parts Catalog (ETKA) . Using other fluids can cause malfunctions or transmission fail‐ ure. – ATF level, checking ⇒ “9 ATF Level Inside Transmission”, page 69 .

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5. Capacities

5

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

6

Repair Information

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission re‐ pairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs. A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Workshop Manual, are summarized here. They apply to this repair manual. WARNING

Before working with engine running, move the selector lever to “P” and set the parking brake. Contact Corrosion Contact corrosion can occur if incorrect connecting elements (bolts, nuts, washers, etc.), rivets, plugs, grommets, adhesive, etc., are used. For this reason, the manufacturer only uses compatible fasteners, coated with a special surface coating if necessary. Rubber, plastic and adhesives also consist of non-conductive material. These tested parts are also made available as replacement parts. Refer to the ⇒ Electronic Parts Catalog (ETKA) . If there are any doubts as to whether parts should be reused, just install new parts. Caution

♦ Accessories must be approved by AUDI AG! ♦ Warranty does not cover contact corrosion damage. Environmental and disposal regulations for oil Handle ATF, axle oil and other fluids with care. Dispose drained purposes, in part or in whole, is not Protected by copyright. Copying for privateof or commercial ATF properly. Always followpermitted the legal environmental andAUDI disposal unless authorised by AUDI AG. AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. regulations. Special Tools and Equipment Complete list of special tools used in this Repair Manual ⇒ "Spe‐ cial Tool" and "Workshop Equipment" binder Selector mechanism emergency release If the battery has been disconnected or is discharged and the ve‐ hicle must be towed or pushed, it will be necessary to push the shift mechanism emergency release to shift the selector lever from “P” to “N”. Refer to ⇒ “2.2 Selector Mechanism, Performing Emergency Release”, page 21 . Transmission ♦ Automatic Transmission Clean Working Conditions, refer to ⇒ “7 Transmission, Clean Working Conditions”, page 9 . ♦ Do not let the engine run or tow the vehicle when the oil pan is removed or when there is no ATF in the transmission.

6

Rep. Gr.00 - Technical Data

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 ♦ With the transmission removed, secure the torque converter so that it cannot fall out. ♦ Check installation dimension of torque converter before in‐ stalling transmission ⇒ , page 14 . ♦ When installing transmission, make sure that the alignment bushings are fitted correctly. ♦ When exchanging automatic transmission or components, all fluid levels should be checked and corrected, if necessary. Al‐ so, all transmission oil lines must be cleaned. Capacities and specifications, refer to ⇒ “5 Capacities”, page 5 . O-rings, shaft seals, sealing rings and seals ♦ Always replace o-rings, shaft seals, sealing rings and seals after removal. ♦ After removing gaskets, examine contact surface on housing/ shaft for burr resulting from removal or for other signs of dam‐ age. ♦ Before installing radial shaft seal, fill space between sealing lips -arrow- halfway with grease - G 052 128 A1- . ♦ The open side of the shaft seals point toward the fluid to be sealed in. ♦ Before installing, lightly lubricate shaft seal outer circumfer‐ ence and sealing lips with ATF or gear oil, depending on installation location. ♦ Coat o-rings with ATF before inserting to prevent crushing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not rings during installation. 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.

♦ Always only use approved ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.

♦ Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances). ♦ Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals. ♦ After installing, check the relevant fluid levels and fill if neces‐ sary. Capacities and specifications ⇒ “5 Capacities”, page 5 Bolts and Nuts ♦ Loosen the bolts opposite the tightening sequence. ♦ Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified. ♦ The tightening specifications stated apply to non-oiled nuts and bolts. ♦ Always replace self-locking nuts and bolts. ♦ Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Install the bolts with lock‐ ing fluid - AMV 185 101 A1- . ♦ Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

6. Repair Information

7

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Fasteners ♦ Do not overstretch the circlips. ♦ Always replace damaged or stretched circlips. ♦ The circlips must fit completely inside the groove. ♦ Replace the adapter sleeves. Installed position: slot is longi‐ tudinal to line of force. Bearings ♦ Install needle bearings with lettered side (thicker metal) racing the fitting tool. ♦ Insert bearing with axle oil or ATF, depending on 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. Tolerance variations make it possible to find the exact shim thickness required. ♦ Check for burrs and damage. Only install perfect shims. Mechatronic Caution

♦ Always discharge static by touching a grounded object, for example, vehicle ground, before touching or removing the Mechatronic unit. ♦ Connector terminals in connector must not be touched by hand under any circumstances because control module and therefore Mechatronic may be destroyed by static discharge. ♦ Replace the transmission if any of the shift elements are scorched. ♦ Allocate the Mechatronic to the transmission code. Refer to ⇒ Electronic Parts Catalog (ETKA) . Guided Fault Finding, OBD and Test Instruments Before performing repairs on the automatic transmission, the malfunction cause must be determined as exactly as possible via Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not the Vehicle Diagnostic, Testing and Information System - VAS permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 5051B- in the operating modes “Guided Fault Finding”, “Vehicle with respect to the correctness of information in this document. Copyright by AUDI AG. Self-Diagnosis” and “Test Instruments”.

8

Rep. Gr.00 - Technical Data

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

7

Transmission, Clean Working Condi‐ tions

– Follow repair instructions ⇒ “6 Repair Information”, page 6 . ♦ Always clean the connection locations and the area around them before loosening. ♦ Place removed parts on a clean surface and cover them. Use foil and paper. Use a lint-free cloth. ♦ Cover or plug unpacked components if repairs cannot be per‐ formed immediately. ♦ Only install clean components: Install replacement parts im‐ mediately after removing them from their packaging. ♦ Thoroughly clean the housing surfaces before assembling.

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7. Transmission, Clean Working Conditions

9

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

8

Towing Notes Caution

When towing, selector lever must be in “N” and vehicle must not to be towed for more than 50 km or at a speed in excess of 50 km/h as otherwise transmission can get damaged.

Note

“Tow-starting” the engine, e.g. when the battery is too low or the starter is not working, is not possible. If the battery has been disconnected or is discharged and the ve‐ hicle must be towed or pushed, it will be necessary to push the shift mechanism emergency release to shift thebyselector leverfor private or commercial purposes, in part or in whole, is not Protected copyright. Copying from “P” to “N”. Refer to 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. ⇒ “2.2 Selector Mechanism, Performing Emergency Release”, page 21 .

10

Rep. Gr.00 - Technical Data

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

32 –

Torque Converter

1

Torque converter, important informa‐ tion WARNING

Check installation dimension of torque converter before instal‐ ling transmission ⇒ , page 14 . If the torque converter is not inserted properly, the ATF pump will get damaged.

Note ♦ Automatic Transmission Clean Working Conditions, refer to

⇒ “7 Transmission, Clean Working Conditions”, page 9 .

♦ General Repair Instructions. Refer to

⇒ “6 Repair Information”, page 6 .

1.1

Torque Converter Identification

There are different torque converters. Use the code letters to identify the torque converter -arrow-. Protected by copyright. Copying for private or commercial purposes, Allocation torque converter/transmission, refer to in part or in whole, is not permitted unless authorised by AUDI AG. Allocations, AUDI AG does notRatios guaranteeand or accept any liability ⇒ “4 Code Letters, Transmission Equip‐ respect to the correctness of information in this document. Copyright by AUDI AG. ment ”, with page 4.

1.2

Torque Converter, Draining

Special tools and workshop equipment required ♦ Used oil collecting and extracting device - V.A.G 1782-

1. Torque converter, important information

11

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Procedure •

Torque converter removed

If the ATF becomes dirty due to shavings or during a major trans‐ mission overhaul, then the torque converter must be drained as follows: – Extract ATF from torque converter with Used Oil Collection and Extraction Tool - V.A.G 1782- .

1.3

Torque Converter Shaft Seal, Removing and Installing

Special tools and workshop equipment required ♦ Extractor lever - VW 681-

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♦ Thrust piece - T10137-

12

Rep. Gr.32 - Torque Converter

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Procedure •

Transmission removed.

– Remove the torque converter carefully. – Insert extractor lever - VW 681- directly behind the sealing lip of the sealing ring, so that the contact ring which is behind it is not damaged. – Remove torque converter shaft seal with Extractor Lever VW 681- . – Always replace shaft seal. – Coat outer circumference and sealing lips of new seal with ATF. Installed position: •

Open side of shaft seal faces transmission.

– Install the torque converter oil seal all the way using thrust piece - T10137- .

1.4

Torque Converter, Checking

– Check the hub on the torque converter for scoring -arrow-. The torque converter is welded and must be replaced if it is dam‐

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1.5

Torque Converter, Installing

Special tools and workshop equipment required ♦ Depth gauge Installing – Press torque converter hub through shaft seal as far as first stop. – Lightly press torque converter inwards and turn until slots on torque converter hub engage in drive lugs on ATF pump gear and torque converter slides in a noticeable distance.

1. Torque converter, important information

13

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Installation dimension ♦ When converter is inserted correctly, distance -a- between contact surfaces on threaded holes and on converter and tor‐ que converter bell housing contact surfaces is at least 22 mm. ♦ If torque converter is not completely inserted, this distance is only approximately 10 mm. WARNING

If the converter is not properly installed, the drive lugs on the converter and the ATF pump will be severely damaged when the transmission is attached to the engine. – Always use new screws to attach the torque converter to the drive plate. Refer to the ⇒ Electronic Parts Catalog (ETKA) . Torque converter to drive plate tightening specification, see trans‐ mission installation ⇒ “6 Transmission, Removing and Installing”, page 55 Note the following when installing the transmission. Caution

Risk of destroying transmission with incorrectly inserted torque converter. ♦ Before and during fastening the engine/transmission con‐ nection bolts, check that the torque converter can still be turned behind the drive plate. ♦ If torque converter cannot be rotated, the ATF pump drive plate and therefore the transmission can be destroyed when the connections are tightened to end torque. by copyright. Copying for private or commercial purposes, in part or in whole, is not –Protected Check the ATF level after installing the transmission and add permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability more ATF, necessary. Referin this to document. Copyright by AUDI AG. with respect to the if correctness of information ⇒ “9 ATF Level Inside Transmission”, page 69 .

14

Rep. Gr.32 - Torque Converter

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

37 –

Mechanism and Housing

1

Electric and Electronic Components and Component Locations

Diagnostic Connection Component location: diagnostic connector is located in passen‐ ger side footwell. The following listed components can be tested in “Guided Fault Finding” with the Vehicle Diagnostic, Testing and Information System - VAS 5051 A- .

Mechatronic The Mechatronic unit incorporates the hydraulic control, the trans‐ mission control module, the multifunction transmission range switch and the sensors and actuators as a complete synchronized unit. It contains the following components. ♦ Transmission Control Module - J217Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Multifunction Transmission Range Switch - F125-

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. ♦ Transmission Input Speed Sensor - G182-

♦ Transmission Output Speed Sensor - G195♦ Transmission Fluid Temperature Sensor - G93♦ Solenoid and pressure control valves Only the complete “Mechatronic” unit can be replaced. Note

OBD checks all the components named. Installed location: The mechatronic unit is bolted to the bottom of the transmission housing and is covered by the transmission fluid pan. – Mechatronic unit, Removing and Installing ⇒ “1.3 Mechatronic, Removing and Installing”, page 92 .

1. Electric and Electronic Components and Component Locations

15

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Selector Lever Transmission Range Position Display Unit - Y26Component location: the selector lever transmission range posi‐ tion display unit - Y26- next to the selector lever. The display shows “P, R, N, D, S”. – ⇒ “2.4 Selector Lever Transmission Range Position Display Unit Y26 , Removing and Installing”, page 26

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.

Selector Lever Sensor System Control Module - J587- with Tip‐ tronic Switch - F189Component location: the selector lever sensor system control module - J587- with the tiptronic switch - F189- is located on the selector mechanism under the shifter boot. Note ♦ The selector lever sensor system control module - J587- and

the tiptronic switch - F189- are a single component.

♦ Tiptronic Switch - F189- magnets are secured to cover. – ⇒ “2.5 Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , Removing and Installing”, page 28 Shift Lock Solenoid - N110Component location: the shift lock solenoid - N110- is on the se‐ lector mechanism. – ⇒ “3.3 Shift Lock Solenoid N110 , Removing and Installing”, page 41

16

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Transmission Range Display - Y6Installed location: integrated inside the instrument cluster Note

The transmission range display - Y6- can only be replaced to‐ gether wit the instrument cluster.

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.

1. Electric and Electronic Components and Component Locations

17

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

2

Shift Mechanism, Servicing, Assem‐ bly Overview WARNING

Before working with engine running, place selector lever in “P”position and engage parking brake. Overview: 1 - Selector Lever Cable ❑ Do not bend 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 ❑ ⇒ “4 Selector Lever Ca‐ with respect to the correctness of information in this document. Copyright by AUDI AG. ble, Assembly Over‐ view”, page 48 ❑ ⇒ “4.1 Selector Lever Cable, Removing and Installing”, page 49 ❑ ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 2 - Locking Plate ❑ Assembly instructions ⇒ “4 Selector Lever Ca‐ ble, Assembly Over‐ view”, page 48 3 - Selector Lever Cable Bolts ❑ Assembly instructions ⇒ “4 Selector Lever Ca‐ ble, Assembly Over‐ view”, page 48 4 - Clamp ❑ For securing the selec‐ tor lever handle to the selector lever ❑ Removing and Instal‐ ling. Refer to ⇒ “2.3 Selector Lever Knob, Servicing, As‐ sembly Overview”, page 22 . 5 - Selector Lever Boot ❑ Separate from the se‐ lector lever handle ⇒ “2.3 Selector Lever Knob, Servicing, Assembly Overview”, page 22 6 - Trim Ring ❑ Removing and Installing. Refer to ⇒ “2.3.2 Selector Lever Boot, Removing from Selector Lever Handle”, page 26 . 7 - Selector Lever Handle ❑ ⇒ “2.3 Selector Lever Knob, Servicing, Assembly Overview”, page 22 ❑ ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23

18

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 8 - Selector Lever Transmission Range Position Display Unit - Y26❑ Removing and Installing. Refer to ⇒ “2.4 Selector Lever Transmission Range Position Display Unit Y26 , Removing and Installing”, page 26 . 9 - Screw ❑ 1 Nm ❑ quantity: 4 10 - Selector Lever Sensor System Control Module - J587- with Tiptronic Switch - F189❑ Removing and Installing. Refer to ⇒ “2.5 Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , Removing and Installing”, page 28 . 11 - Shift Lock Solenoid - N110❑ Removing and Installing. Refer to ⇒ “3.3 Shift Lock Solenoid N110 , Removing and Installing”, page 41 . ❑ ⇒ “2.2 Selector Mechanism, Performing Emergency Release”, page 21 12 - Selector Mechanism Function Unit ❑ Check function: ⇒ “2.1 Selector Mechanism, Checking”, page 19 ❑ ⇒ “2.6 Shift Mechanism Function Unit, Removing and Installing”, page 29 ❑ ⇒ “3 Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview”, page 35 ❑ with Transmission Park Selector Switch - F305- installed, ⇒ “3.4 Transmission Park Selector Switch F305 , Removing and Installing”, page 45 13 - Screw ❑ 6.5 Nm ❑ quantity: 4 ❑ for securing the selector mechanism function unit to shift unit ❑ With additional threads on screw head for securing bracket to center console 14 - Screw ❑ 6.4 Nm ❑ quantity: 2 ❑ for securing center bracket to lower selector mechanism cover 15 - Screw ❑ 10 Nm ❑ quantity: 4 ❑ for securing selector mechanism shift unit to body 16 - Selector mechanism shift unit ❑ ⇒ “2.7 Selector Mechanism Shift Unit, Removing and Installing”, page 33 17 - Centering Bracket ❑ Must not be reinstalled in damaged or removed, is only necessary for factory production

2.1 Overview:

Selector Mechanism, Checking 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.

♦ ⇒ “2.1.1 Selector Mechanism Functionality Test”, page 20 ♦ ⇒ “2.1.2 Checking the Ignition Key Lock”, page 20

♦ ⇒ “2.1.3 Selector Lever Handle Locking Button, Checking”, page 21

2. Shift Mechanism, Servicing, Assembly Overview

19

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

2.1.1

Selector Mechanism Functionality Test

•

The starter does not work when the selector lever is in “S”, “D”, “R” or in the “tiptronic gate”.

•

If selector lever position “N” is selected at speeds greater than 5 km/h, the shift lock solenoid must not engage and block the selector lever. The selector lever can be moved into a another gear.

•

For speeds below 2 km/h (almost standstill) and shifting into selector lever position “N”, the shift lock solenoid must only engage after approximately 1 second. The selector lever can be move out of “N” only when the brake pedal is pressed.

Selector lever in “P” and the ignition turned on: – Do not press the brake pedal. •

The selector lever is locked and cannot be moved out of “P” while locking button on selector lever handle is pressed. The shift lock solenoid - N110- locks the selector lever.

– Press the brake pedal and hold it down. •

The shift lock solenoid - N110- unlocks the selector lever. It is possible to shift into a gear. Press the locking button in the selector lever handle and slowly move the selector lever out of “P” through “R, N, D, S”. While doing this, make sure the transmission range display - Y6- inside the instrument cluster matches the actual position of the selector lever.

The selector lever is in “N” and the ignition is turned on: – Do not press the brake pedal. •

After a brief moment: The selector lever is locked and cannot be moved out of “N” even though the locking button in the se‐ lector lever handle is pressed. The shift lock solenoid - N110locks the selector lever.

– Press the brake pedal. •

The shift lock solenoid - N110- unlocks the selector lever. It is possible to shift into “D”.

Selector lever in “D” and the ignition is on: – Move the selector lever into the “tiptronic gate”. •

The “D” in the selector lever transmission range position dis‐ play unit - Y26- must turn off and the “+” and “–” must turn on.

•

The transmission range display - Y6- inside the instrument cluster must change from “PRNDS” to “654321” when the se‐ lector lever is moved into the “tiptronic gate”.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not If the specified values are not obtained:

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. – ⇒ “2.1.3 Selector Lever Handle Locking Button, Checking”, page 21

– Adjust the selector lever cable. Refer to ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 . – Check ignition key removal lock. Refer to ⇒ “2.1.2 Checking the Ignition Key Lock”, page 20 .

2.1.2

Checking the Ignition Key Lock

– To reach “ignition on”, turn the key to right. – Press the brake pedal and hold it down.

20

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 •

It must be possible to move the selector lever out of “P” without “getting stuck” when the locking button in the selector lever handle is pressed.

– Turn off the ignition. •

It should not be possible to remove the ignition key when the selector lever is in any position other than “P”.

– Move the selector lever into “P”. – Remove ignition key. •

It should be possible to remove the key only when the selector lever is in “P”.

•

It is not possible to move the selector lever out of “P” when both the locking button and the brake pedal are pressed.

If ignition key removal lock does not function as described, check Access/Start Authorization Switch - E415- using Vehicle Diag‐ nostic, Testing and Information System - VAS 5051- in “Guided Fault Finding” function.

2.1.3 •

Selector Lever Handle Locking Button, Checking

The ignition is switched on.

Locking button on selector lever handle must be pressed for the following shifts. If it is not pressed, the selector lever cannot be shifted into the specified position. ♦ Move the selector lever from “P” into “R” and press the brake pedal at the same time. ♦ “D” into “S” ♦ “N” into “R”; stationary, press the brake pedal after waiting longer ♦ “R” into “P” If the specified values are not obtained: – Check whether selector lever handle is installed correctly ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 – Adjust the selector lever cable. Refer to ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 .

2.2

Selector Mechanism, Performing Emer‐ gency Release Note

♦ It is not possible to move the selector lever out of “P” if the

battery is disconnected or if it is discharged.

♦ The shift lock solenoid - N110- will cancel out the lock when

the emergency release is activated.

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.

2. Shift Mechanism, Servicing, Assembly Overview

21

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Vehicles with ashtray: – Remove front ashtray insert. – Pry off the cap inside the ashtray housing -arrow-. Vehicles without ashtray: – Remove storage compartment in front of selector mechanism ⇒ Body Interior; Rep. Gr. 68 All:

– Push the emergency release lever -arrow-, for example, with a screwdriver, and at the same time move the selector lever out of “P”.

Note

The screwdriver will be guided through the funnel -1- to the emer‐ gency release lever.

2.3

Selector Lever Knob, Servicing, Assem‐ bly Overview

Overview:

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.

22

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 1 - Clamp ❑ For securing the selec‐ tor lever handle to the selector lever ❑ Removing and Instal‐ ling. Refer to ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 . 2 - Trim Ring ❑ Removing and Instal‐ ling. Refer to ⇒ “2.3.2 Selector Lever Boot, Removing from Selector Lever Handle”, page 26 . 3 - Selector Lever Handle ❑ ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 4 - Selector Lever Boot ❑ ⇒ “2.3.2 Selector Lever Boot, Removing from Selector Lever Handle”, page 26 5 - Selector Lever Transmis‐ sion Range Position Display Unit - Y26❑ Must not be removed to remove selector lever handle. ❑ ⇒ “2.4 Selector Lever Transmission Range Position Display Unit Y26 , Removing and In‐ stalling”, page 26

2.3.1

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Selector Lever Handle, Removing and Installing

Special tools and workshop equipment required ♦ Hose clamp pliers - V.A.G 1275-

2. Shift Mechanism, Servicing, Assembly Overview

23

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Removing – Move the selector lever into “N”. Note

Both the selector lever handle and the selector lever boot are re‐ moved. – Remove the frame for the selector lever boot -1- -arrows-.

– Secure the locking button in its pulled-out position with a cable tie -arrow-, as illustrated.

– Fold the selector lever boot -1- upward and lever handle -2-.

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 to the correctness of information in this document. Copyright by AUDI AG. overwith therespect selector

– Open the clamp -arrow- and remove both the selector lever handle and the selector lever boot without touching the locking button.

24

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Installing Note ♦ In order to install the selector lever handle, the locking button

must be pulled out all the way and secured either with a cable tie -arrow- or with the assembly tool supplied with a new han‐ dle.

♦ If the lock button was not secured, do not pull it out from the

handle using mechanical aids. Position the compressed air gun under the handle and press the locking button out with compressed air.

– Install the shifter lever handle completely on the shifter lever. The lock button faces toward the driver. •

The handle must lock into the selector lever ring groove.

– Remove cable tie or assembly aid, lock button mechanism engages in vertical groove on selector lever. – If necessary, press lock button back into selector lever handle. – Clamp the handle -2- to the selector lever, using a new clamp -arrow-. Use hose clamp pliers - V.A.G 1275- . – Install the selector lever boot frame -1- in the center console.

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.

2. Shift Mechanism, Servicing, Assembly Overview

25

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

2.3.2

Selector Lever Boot, Removing from Selector Lever Handle

Removing – Remove the handle from the selector lever. Refer to ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 . – Bind together the spring tabs -1- on the selector lever handle using a cable tie -3- as illustrated. – Slide the sleeve for the selector lever boot -2- over the tabs -arrow-. – Remove the cable tie and remove the both the sleeve and se‐ lector lever boot from the selector lever. Installing Install in reverse order of removal. Note the following: Selector lever boot installed position •

The longer side of the selector lever boot frame faces toward the driver side (toward the selector lever transmission range position display unit - Y26- ).

– Install the handle on the selector lever. Refer to ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 .

2.4

Selector Lever Transmission Range Po‐ sition Display Unit - Y26- , Removing and Installing

Overview:

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26

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 5 - Selector Lever Transmis‐ sion Range Position Display Unit - Y26-

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Removing – Move the selector lever into “N”. – Remove the frame for the selector lever boot -1- -arrows-. – Fold up the selector lever boot.

2. Shift Mechanism, Servicing, Assembly Overview

27

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Release the spring -2- and remove the selector lever trans‐ mission range position display unit - Y26- -1- -arrow-. – Disconnect the connector. Installing Install in reverse order of removal.

2.5

Selector Lever Sensor System Control Module - J587- with Tiptronic Switch F189- , Removing and Installing 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 Note with respect to the correctness of information in this document. Copyright by AUDI AG.

The selector lever sensor system control module - J587- and the tiptronic switch - F189- are a single component. Removing – Remove the handle from the selector lever. Refer to ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 . – Remove the selector lever transmission range position display unit - Y26- . Refer to ⇒ “2.4 Selector Lever Transmission Range Position Display Unit Y26 , Removing and Installing”, page 26 . – Remove the frame with the multimedia system control head E380- -1-. Refer to ⇒ Body Interior; Rep. Gr. 68 .

– Disconnect the connector -1-. – Remove the bolts -arrows- and remove the selector lever sen‐ sor system control module - J587- together with the tiptronic switch - F189- . Installing Install in reverse order of removal. Note the following: Tightening specifications: ⇒ “2 Shift Mechanism, Servicing, Assembly Overview”, page 18

28

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Position the selector lever sensor system control module J587- and tiptronic switch - F189- on the selector mechanism and tighten the screws -arrows- to the tightening specification. – Connect the connector -1- to the selector lever sensor system control module - J587- with tiptronic switch - F189- . – Remove the frame with the multimedia system control head E380- -1-. Refer to ⇒ Body Interior; Rep. Gr. 68 . – Install the handle on the selector lever. Refer to ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 . – Install the selector lever transmission range position display unit - Y26- . Refer to ⇒ “2.4 Selector Lever Transmission Range Position Display Unit Y26 , Removing and Installing”, page 26 .

2.6

Shift Mechanism Function Unit, Remov‐ ing and Installing

Special tools and workshop equipment required ♦ Socket wrench - T40031-

Removing – Remove the handle from the selector lever. Refer to ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 . – Remove the frame with the multimedia system control head E380- -1-. Refer to ⇒ Body Interior; Rep. Gr. 68 .

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.

2. Shift Mechanism, Servicing, Assembly Overview

29

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Disconnect the connector -1-. – Remove the noise insulation -2- from the shift housing. – Remove the front ashtray or front storage compartment. Refer to ⇒ Body Interior; Rep. Gr. 68 .

– Remove the bolts -arrows- and -1- from the center console bracket.

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– Disconnect the connector -1-. – Remove the four bolts -arrows-.

– Remove the four bolts -arrows-. Note

The center console bracket is not shown in the illustration. – Remove center console bracket by tilting selector mechanism function unit.

30

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Press and hold the parking lock button -C-. – Pull the selector rod -B- up and move the selector lever -arrow- into “S”. Note ♦ Ignore -A-. ♦ Selector mechanism is shown from the front in the illustration. – Lift the selector mechanism function unit. Note

Do not bend or kink the selector lever cable.

– Remove the clamping screw -1- through the opening at the top of the selector mechanism -arrow- using the socket - T40031- .

– Remove the locking plate -2- from the selector lever cable -1-. – Remove selector mechanism function unit upward.

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.

2. Shift Mechanism, Servicing, Assembly Overview

31

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Installing Install in reverse order of removal. Note the following: Tightening specifications: ⇒ “2 Shift Mechanism, Servicing, Assembly Overview”, page 18 Note ♦ Do not bend or kink the selector lever cable. ♦ Coat the bearings and the sliding surfaces with polycarbamide

grease - G 052 142 A2- .

•

Selector lever in “S”.

– Slide selector lever cable into selector mechanism function unit. – Insert the end of the selector lever cable -2- into the shift gate joint -3-. – Install the clamping screw -1- through the opening at the top of the selector mechanism -arrow- using the socket - T40031- . – Secure the selector lever cable -1- with the new locking plate -2-. •

Installation position: Angled end of retaining clamp points to‐ ward rear.

– Insert the two retaining hooks -A- in selector mechanism shift unit. – Position selector mechanism function unit on shift unit. Note

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Do not bend or kink the selector lever cable. – Insert center console bracket by tilting function unit at the same time. – Install the bolts -arrows-.

32

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Connect the connector -1-. – Install the center console bracket. Refer to ⇒ Body Interior; Rep. Gr. 68 .

– Install the noise insulation -2- in the shift housing. – Connect the connector -1- to the selector lever sensor system control module - J587- with the tiptronic switch - F189- . – Install front ashtray/front compartment ⇒ Body Interior; Rep. Gr. 68 . – Install installation frame with Multimedia Control Head - E380⇒ Rep. Gr. 68 . – Install the handle on the selector lever. Refer to ⇒ “2.3.1 Selector Lever Handle, Removing and Installing”, page 23 . – Adjust the selector lever cable. Refer to ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 . – Check the selector mechanism. Refer to ⇒ “2.1 Selector Mechanism, Checking”, page 19 .

2.7

Selector Mechanism Shift Unit, Remov‐ ing and Installing

Removing – Shifter Mechanism Function Unit, Removing ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ ling”, page 29 . – Press boot -arrow- forward out of selector mechanism shift unit.

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– Remove the hooks -1- and -2-. – Remove the bolts -arrows-.

2. Shift Mechanism, Servicing, Assembly Overview

33

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Pull selector mechanism shift unit -1- back slightly and remove screws -arrows- on center bracket -2-. – Remove selector mechanism shift unit upward. – Remove center bracket upward. It may not be installed again. Note

The center bracket is only needed for factory production. Installing Install in reverse order of removal. Note the following: Tightening specifications: ⇒ “2 Shift Mechanism, Servicing, Assembly Overview”, page 18 – Insert selector mechanism shift unit from above into opening. •

Ensure seal is seated correctly on selector mechanism shift unit. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Insert selector lever cable -3- through hole in selector mech‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability anism shift unit. with respect to the correctness of information in this document. Copyright by AUDI AG. – Tighten the bolts -arrows-. – Install the hooks -1- and -2-.

– Carefully insert boot -arrow- on selector lever cable all around in selector mechanism shift unit. – Install shift mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ ling”, page 29 .

34

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

3

Shift Mechanism Function Unit, Disassembling and Assembling - As‐ sembly Overview Note

Coat the bearings and the sliding surfaces with polycarbamide grease - G 052 142 A2- . 1 - Function Unit Housing 2 - Selector lever position “P” locking lever ❑ ⇒ “3.2 Selector Lever Position P Locking Lev‐ er, Removing and In‐ stalling”, page 40 3 - Bushings ❑ secures selector lever position “P” locking lev‐ er 4 - Axial Bearing ❑ For the shift gate 5 - Bearing Shell ❑ For the shift gate ❑ Clipped to the function unit housing

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6 - Locking Plate ❑ For the axial bearing ❑ Always replace 7 - Shift Bearing ❑ For the shift gate 8 - Bearings ❑ For the shift bearing 9 - Shift Gate ❑ ⇒ “3.1 Shift Gate, Re‐ moving and Installing”, page 36 10 - Shift Lock Solenoid N110❑ ⇒ “3.3 Shift Lock Sole‐ noid N110 , Removing and Installing”, page 41 11 - Transmission Park Selector Switch - F305❑ ⇒ “3.4 Transmission Park Selector Switch F305 , Removing and Installing”, page 45 12 - Emergency Release Lever Guide ❑ is clipped into function unit housing 13 - Stop Buffer

3. Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview

35

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

3.1

Shift Gate, Removing and Installing

Removing: – Remove selector mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ ling”, page 29 . •

Selector lever in “S”.

– Remove the guide -1- for the emergency release lever in -direction of arrow-.

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– Disengage electrical line at selector mechanism -arrow A-.

– Pry off both bearing shells -1- with a screwdriver. – Remove the locking plate -2-.

36

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Pry out both lower bearings -1- with a screwdriver.

– Pull the shift gate -1- down slightly.

– If necessary, press emergency release lever -arrow- down so that shift gate can be removed.

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3. Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview

37

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Pry out retaining pins -A- with a screwdriver. – Remove micro-switch -B-. Note

Two micro-switches make up the transmission park selector switch - F305- . Micro-switch -B- is one of the two. The two microswitches create the signal that the electronic ignition key removal lock needs to release the key only in selector lever position P. – Disengage electrical wiring from tab -arrow C- and remove micro-switch from shift mechanism. – Remove the shift gate -1- downward.

Installing Install in reverse order of removal. Note the following: Note

Coat the bearings and the sliding surfaces with polycarbamide grease - G 052 142 A2- . – Make sure the stop buffer fits correctly -1-. Note

The stop buffer -1- is installed on the opposite side in right-hand drive vehicles. – Install the shift gate -1- from underneath. •

Shift gate selector lever in “S” (as illustrated).

– Install the micro-switch -B- into the shift gate and secure it with the retaining pin -A-. Note

Micro-switch must lie flush on all sides. – Attach the electric wire to the tab -arrow C-. – Push both axial bearings -2- onto the shift gate -1-. – Position both shift bearings -3- on the shift gate.

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.

38

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Slide the shift gate into the function unit housing. If necessary, push the emergency release lever -arrow- down to make it possible to install the shift gate.

– Push the lower bearings -1- in on both sides. •

Bearings -1- must engage in the shift bearing bushings -arrow- -A-.

– Press the new locking plate -2- onto rear axial bearing. •

Installed position: the angled end of securing plate faces to‐ ward shift gate.

– Install both bearing shells -1-.

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.

3. Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview

39

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Secure the electric wire -arrows A- to the selector mechanism as illustrated. – Make sure the micro-switch is installed correctly and is secure -B-. Note

Ignition key removal lock does not function correctly if microswitch is not inserted correctly or properly secured.

– Install the guide -1- for the emergency release lever opposite the -direction of arrow-. – Install shift mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ ling”, page 29 . 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.

3.2

Selector Lever Position “P” Locking Lev‐ er, Removing and Installing Note

Coat the bearings and the sliding surfaces with polycarbamide grease - G 052 142 A2- .

40

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Removing: – Remove shift gate ⇒ “3.1 Shift Gate, Removing and Installing”, page 36 – Pry out both the left and right bearing bushings -2- with a screwdriver. – Remove selector lever position “P” locking lever. Installing Install in reverse order of removal. Note the following: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Insert the locking lever and bothofleft and right withsecure respect to it thewith correctness information in this document. Copyright by AUDI AG. bearing bushings -2-.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Make sure the locking lever is working correctly. •

The emergency release lever -arrow- must move easily and can be moved up and down. Note

♦ If will be difficult to move emergency release lever -arrow- if

the bushings are installed incorrectly.

♦ If emergency release lever is difficult to move, ignition key re‐

moval lock does not work.

– Install shift gate ⇒ “3.1 Shift Gate, Removing and Installing”, page 36

3.3

Shift Lock Solenoid - N110- , Removing and Installing

Removing – Remove the frame with the multimedia system control head E380- -1-. Refer to ⇒ Body Interior; Rep. Gr. 68 .

3. Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview

41

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Disconnect the connector -1-. – Remove the noise insulation -2- from the shift housing. – Remove the front ashtray or front storage compartment. Refer to ⇒ Body Interior; Rep. Gr. 68 .

– Remove the bolts -arrows- and -1- from the center console bracket.

– Disconnect the connector -1-. – Remove the four bolts -arrows-.

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.

– Remove the four bolts -arrows-. Note

The center console bracket is not shown in the illustration. – Remove center console bracket by tilting selector mechanism function unit.

42

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Press and hold the parking lock button -C-. – Place selector lever in position “S”.

– Disconnect the connector -1- from the shift lock solenoid Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not N110- . 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.

Note ♦ When removing magnets, lift them forward slightly so that ball

head -2- disengages from the operating lever -1-.

♦ Shown with selector mechanism removed to provide a better

illustration.

– Open the catches -arrow A- and remove the shift lock solenoid - N110- forward -arrow B-.

3. Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview

43

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Installing •

Selector lever in “S”.

– Unclip the guide for the emergency release lever in -direction of arrow-.

– Pull the emergency release lever -arrow- upward.

Note

The operating lever -1- for the shift lock solenoid - N110- moves into its installed position when the emergency release lever is pulled up. 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

– At the same time, position lockofsolenoid N110intoCopyright by AUDI AG. with respect the to theshift correctness information in- this document. the guide at an angle. – Push the shift lock solenoid - N110- into the guide until it clicks. •

The ball head -2- on the shift lock solenoid - N110- must fit into the operating lever on the selector mechanism.

– Connect the connector -1-.

44

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Perform a functionality test on the shift lock solenoid - N110- . – Connect the connector -1 -.

– Connect the connector -1 -. – Before completing the assembling, check the function of the shift lock solenoid - N110- with the selector lever in “P” and “N” ⇒ “2.1.1 Selector Mechanism Functionality Test”, page 20 . Further installation is done in reverse order of removal, similar to installation of selector mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Installing”, page 29 .

3.4

Transmission Park Selector Switch F305- , Removing and Installing

Transmission Park Selector Switch - F305- consists of two microswitches. The twoProtected micro-switches create the signal that the elec‐ by copyright. Copying for private or commercial purposes, in part or in whole, is not tronic ignition key permitted removal lock needs release keynotonly in or accept any liability unless authorised by to AUDI AG. AUDI the AG does guarantee selector lever position P. to the correctness of information in this document. Copyright by AUDI AG. with respect The first micro-switch is closed when the shift lock solenoid N110- is not active when the selector lever is in “P” (brake pedal not pressed) and also the selector lever manual release below the ashtray is not actuated. The second micro-switch is closed when the button on selector lever handle is not actuated in selector lever position “P”. Following points must be observed before replacing Transmis‐ sion Park Selector Switch - F305- : 1-

Both micro-switches are switched electrically in sequence, that is, both switches must be closed for ignition key to be removed. Micro-switches can be checked using Vehicle Di‐ agnosis, Testing and Information System - VAS 5051A- in Guided Fault Finding. After performing tests on vehicle sys‐ tem, you must select test program “F305 - Gear selector position P switch” via function/component selection (drive/ automatic transmission/01-On Board Diagnostic (OBD) ca‐ pable systems/02 - Transmission Electronics/Electrical components).

2-

An electrical test on the micro-switch is also possible. If a continuity test is performed with a multimeter, note that in this case, there is a resistance value of approximately 470 Ohm when both switches are closed.

Removing – Remove selector mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ ling”, page 29 .

3. Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview

45

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Remove shift gate ⇒ “3.1 Shift Gate, Removing and Installing”, page 36 – Pry out the retaining pin -A- in -direction of arrow- with a screwdriver. – Remove the first micro-switch -B-. – Disengage electrical wiring from tab -arrow C- and remove micro-switch from shift mechanism.

– Disconnect the connector -D- from the shift lock solenoid N110- . – Disconnect the connector -E- upward. – Push the tab -C- in direction of -arrow 1-. – Remove the second micro-switch -B- in direction of -arrow 2-. – Disengage electrical line at selector mechanism -arrow A-.

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.

46

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Installing Install in reverse order of removal. Note the following: Note

Coat the bearings and the sliding surfaces with polycarbamide grease - G 052 142 A2- . – Guide micro-switch on longer electrical line into opening under parking lock button in selector mechanism. – Install the shift gate -1- from underneath. •

Shift gate selector lever in “S” (as illustrated).

– Install the micro-switch -B- into the shift gate and secure it with the retaining pin -A-. Note

Micro-switch must lie flush on all sides. – Attach the electric wire to the tab -arrow C-. Note ♦ Retaining screws -A- secure the micro-switch -B- inside the

shift gate.

♦ Ignition key removal lock does not function correctly if micro-

switch is not inserted correctly or properly secured.

– Secure the electric wire -arrows A- to the selector mechanism as illustrated. – Install the micro-switch -B-. Note

Ignition key removal lock does not function correctly if microswitch is not inserted correctly or properly secured. – Connect the connector -D- to the shift lock solenoid - N110- . – Install the connector -E- from the top. – Install shift gate ⇒ “3.1 Shift Gate, Removing and Installing”, page 36 – Install shift mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ Protected by copyright. ling”, page 29 . 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.

3. Shift Mechanism Function Unit, Disassembling and Assembling - Assembly Overview

47

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

4

Selector Lever Cable, Assembly Overview

1 - Selector Lever Cable ❑ Do not bend ❑ ⇒ “4.1 Selector Lever Cable, Removing and Installing”, page 49 ❑ in case of damaged rub‐ ber boot, selector lever cable must be replaced ❑ Ball socket and ball head must be free of oil and grease ❑ check whether selector lever cable rubber boot is engaged in selector mechanism shift unit and is sealed properly ❑ ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 2 - Clip ❑ for the selector lever ca‐ ble on the selector mechanism function unit ❑ Always replace 3 - Screw ❑ 13 Nm ❑ For adjusting the selec‐ tor lever cable 4 - Selector Lever Cable Bolts ❑ The plastic retaining spring on adjustment slide must lock the pins so that they cannot fall out. 5 - Adjustment Slide 6 - Selector shaft lever ❑ Ball socket and ball head must be free of oil and grease ❑ ⇒ “5 Selector Shaft Lever, Removing and Installing”, page 53 7 - Bracket ❑ For selector lever cable 8 - Screw ❑ 10 Nm ❑ Attaching bracket to transmission Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 9 - Clip permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ for selector lever cable to bracket with respect to the correctness of information in this document. Copyright by AUDI AG. ❑ Always replace

10 - Screw ❑ 10 Nm ❑ Attaching bracket to transmission

48

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

4.1

Selector Lever Cable, Removing and In‐ stalling

Special tools and workshop equipment required ♦ Pry lever - 80-200-

Removing Note

Before removing selector lever cable, secure a cable on selector lever cable so that it can be threaded easily when installing. – Remove selector mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ ling”, page 29 . – Press boot -arrow- forward out of selector mechanism shift unit. – Remove screws and remove rear noise insulation -2-.

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.

4. Selector Lever Cable, Assembly Overview

49

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Remove the ball head -2- on the selector lever cable from the selector shaft lever using the pry lever - 80-200- . – Remove the clips -1- and then remove the selector lever cable from transmission. Note

Do not bend or kink the selector lever cable.

Installing Install in reverse order of removal. Note the following: Tightening specifications: ⇒ “4 Selector Lever Cable, Assembly Overview”, page 48 – Secure selector lever cable to cable that was guided in during removal. – Guide the selector lever cable with boot -2- into the selector mechanism shift unit -1-. Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Selector shaft lever must not be bend when pressing permitted unless authorised by AUDI AG. selector AUDI AG does not guarantee or accept any liability lever cable on, counterhold with if necessary. respect to the correctness of information in this document. Copyright by AUDI AG.

– Carefully remove the selector lever cable -2- from the selector shaft lever. – Secure selector lever cable sleeve to bracket using a new clip -1-.

– Carefully insert boot -arrow- all around in selector mechanism shift unit. – Install shift mechanism function unit ⇒ “2.6 Shift Mechanism Function Unit, Removing and Instal‐ ling”, page 29 . – Adjust selector lever cable. Refer to ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 Tightening Specification Component

Nm

Heat shield to transmission

4.2

Selector Lever cable, Adjusting

Special tools and workshop equipment required

50

9

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 ♦ Socket wrench - T40031-

Procedure – Remove the frame for the selector lever boot -1- -arrows-.

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.

4. Selector Lever Cable, Assembly Overview

51

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Place selector lever in position “S”. Note ♦ The clamping screw is only accessible when the selector lever

is in “S”.

♦ Loosen the clamping screw approximately 1 turn but do not

remove it.

– Loosen selector lever cable clamping screw approximately 1 turn using Socket - T40031- . – Carefully move the selector lever forwards and backwards slightly without shifting a different selector position. Protectedto by copyright. Copying for privatelever 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.

Note

This loosens the selector lever cable. – Switch ignition on. The two following conditions must be fulfilled: •

The “S” in the “PRNDS” display in the transmission range dis‐ play - Y6- must be lit.

•

The “S” inside the selector lever transmission range position display unit - Y26- must be illuminated.

Conditions are not fulfilled: – Tighten the clamping screw -arrow- for the selector lever cable in this position using the socket - T40031- . – Connect Vehicle Diagnostic, Testing and Information System - VAS 5051- read out DTC memory, correct malfunctions in Guided Fault Finding if necessary. – Then perform selector lever cable adjustment again ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 Conditions are fulfilled: Note

Do not move the selector lever forward or backward while tight‐ ening the clamping screw otherwise the adjustment will be incor‐ rect. – Tighten the bolt -arrow- on the selector lever cable using the socket - T40031- . Rest of installation is performed in reverse order of removal. Tightening specification ⇒ “4 Selector Lever Cable, Assembly Overview”, page 48 – Check the selector mechanism. Refer to ⇒ “2.1 Selector Mechanism, Checking”, page 19 .

52

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

5

Selector Shaft Lever, Removing and Installing

Special tools and workshop equipment required ♦ Pry lever - 80-200-

Removing: – Remove screws and remove rear noise insulation -2-.

– Remove the ball head -2- on the selector lever cable from the selector shaft lever using the pry lever - 80-200- .

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.

5. Selector Shaft Lever, Removing and Installing

53

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Remove the spring pin -1- on the selector shaft lever -2-arrow- until it is possible to remove the lever from the shaft. Installing Install in reverse order of removal. Note the following: – Install the spring pin on the selector shaft lever while it is still removed. – Slide selector shaft lever onto selector shaft, align it and then install the spring pin. Note

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.

Selector shaft lever must not be bend when pressing selector lever cable on, counterhold if necessary. – Carefully install the selector lever cable -2- to the selector shaft lever without bending the lever.

54

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

6

Transmission, Removing and Instal‐ ling

♦ ⇒ “6.1 Transmission, 6-Cylinder, Removing 3.6L FSI engine ”, page 55 ♦ ⇒ “6.2 Transmission, 6-Cylinder 3.6L FSI, Installing”, page 61

6.1

Protected by copyright. Copying for private commercial purposes, in part or in whole, is not Transmission, 6-Cylinder, Removing 3.6L FSIorengine 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.

Special tools and workshop equipment required ♦ Engine support bridge 10-222A♦ Spindle - 10-222 A/10♦ Shackle - 10-222A/12♦ Engine Support Adapter 10-222A/22♦ Engine/transmission jack V.A.G 1383/A♦ Engine Support Basic Set T40091-

6. Transmission, Removing and Installing

55

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 ♦ Thrust bearing from Assembly Tool - 3301-

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.

♦ Engine Support Supplement Set - T40093-

♦ Step ladder - VAS 5085-

♦ Pry lever - 80-200-

56

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

Note ♦ Automatic Transmission Clean Working Conditions, refer to

⇒ “7 Transmission, Clean Working Conditions”, page 9 .

♦ General Repair Instructions. Refer to

⇒ “6 Repair Information”, page 6 .

Procedure – Install engine support bridge. Refer to Transfer Case, Auto‐ matic Transmission, Removing ⇒ Transfer case and final drive; Rep. Gr. 39 ; Transfer case, vehicles with 6-cylinder 3.6L FSI engine, Removing and Installing . – Activate the vehicle lift mode if the vehicle has air suspen‐ sion.⇒ Rep. Gr. 43 – Lift the vehicle ⇒ Maintenance ; Booklet 406 . – Remove the bolts and remove front -1- and rear -2- noise in‐ sulation. 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.

– Wrap a suitable wood block -1- with dimension -a- with an elastic layer (e.g. rubber). •

-a- = 40 mm

– Place wooden block between ATF oil pan and subframe. Note

This procedure is necessary so that ATF oil pan does not lie di‐ rectly on subframe when assembly is lowered. Caution

Risk of damage Follow the procedure for removing and installing the transfer case exactly. – Remove transfer case ⇒ Transfer case and final drive; Rep. Gr. 39 ; Transfer case, Removing and Installing - vehicles with 6-cyl. 3.6L FSI engine .

6. Transmission, Removing and Installing

57

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Remove the ball head -2- on the selector lever cable from the selector shaft lever using the pry lever - 80-200- . – Remove the clips -1- and then remove the selector lever cable from transmission. Note

Do not bend or kink the selector lever cable.

Caution

Risk of destroying transmission control module - J217- (Me‐ chatronic) with static discharge. ♦ Do not touch contacts in transmission connector with hands. – To discharge static, touch vehicle ground with hand (without glove). – Disconnect the connector on transmission by rotating screw connections counter-clockwise -arrow-. – Remove the ATF pipe -1- from transmission.

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.

58

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Vehicles with 4-zone climate control: – Remove rear coolant pipe bolts -1 and 2-. Note

Ignore -arrows-. All: Note

Place a cloth under separation point to collect to escaping ATF. – Remove the bolt -3- and then remove the ATF pipes from the transmission. – Seal off the ATF pipes and transmission with suitable plugs. – Remove the starter ⇒ Electrical Equipment; Rep. Gr. 27 ; Starter, Removing and Installing . – To loosen torque converter bolts, counterhold crankshaft at vibration damper bolt. – In opening for removed starter, remove 3 torque converter bolts while rotating crankshaft 1/3 rotation further in direction of engine rotation.

– Install Transmission Support - 3282- on Engine/Transmission Jack - V.A.G 1383 A- . – Place Adjustment Plate - 3282/49- on Transmission Support 3282- as shown in illustration. – Align the arms of the transmission support to correspond with the holes in the adjustment plate .

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 – Install support elements as shown on adjustment plate. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Roll the engine/transmission jack - V.A.G 1383 A- with trans‐ mission support - 3282- under the transmission. Note

The arrow symbol on the adjustment plate points in the direction of travel. – Align the adjustment plate so that it is parallel to the transmis‐ sion. – Fasten mount on threaded hole at rear of transmission with a bolt -arrow- and secure.

6. Transmission, Removing and Installing

59

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Position side mounts at left and right in oil pan notch as shown in illustration. – Raise the transmission slightly.

– Remove the wooden block -1-.

– Remove the lower bolts -arrows- from the engine to transmis‐ sion connection.

– Remove remaining bolts from engine to transmission connec‐ tion.

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.

60

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Press transmission off engine, thereby removing the torque converter from drive plate with a pry bar -arrow-. – Lower the transmission using engine/transmission jack V.A.G 1383 A- .

6.2

Transmission, 6-Cylinder 3.6L FSI, In‐ stalling

Procedure Note ♦ Automatic Transmission Clean Working Conditions, refer to

⇒ “7 Transmission, Clean Working Conditions”, page 9 .

♦ General Repair Instructions. Refer to

⇒ “6 Repair Information”, page 6 .

♦ When installing, bring all cable ties back to same positions. Tightening specifications: ⇒ page 64 – Check the installed dimension -a- of the torque converter. Re‐ fer to ⇒ “1.5 Torque Converter, Installing”, page 13 . Caution 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.

If the converter is not properly installed, the drive lugs on the converter and the ATF pump will be severely damaged when the transmission is attached to the engine.

– Make sure alignment sleeves -A- for centering engine/trans‐ mission are installed in engine. Install if necessary.

6. Transmission, Removing and Installing

61

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Before putting engine and transmission together, rotate en‐ gine torque converter and drive plate so that holes or threaded holes are at the same height as opening on removed starter -arrow-. – Make sure that no wires become pinched when connecting the transmission and engine. Note the following when installing the transmission. Caution

Risk of destroying transmission with incorrectly inserted torque converter. ♦ Before and during fastening the engine/transmission con‐ nection bolts, check that the torque converter can still be turned behind the drive plate. ♦ If torque converter cannot be rotated, the ATF pump drive plate and therefore the transmission can be destroyed when the connections are tightened to end torque. – Attach the transmission to engine. – Use new bolts for attaching the drive plate to the torque con‐ verter. Refer to the ⇒ Electronic Parts Catalog . – First install new torque converter bolts in the opening for re‐ moved starter and tighten by hand by turning crankshaft 1/3 turn in direction of engine rotation. – Then tighten torque conveter bolts in opening in removed starter to the tightening specification. To do this, rotate crank‐ shaft 1/3 rotation each in direction of engine rotation. Further installation in reverse order, paying attention to the fol‐ lowing: – Install the starter ⇒ Rep. Gr. 27 . – Install the transfer case. Refer to ⇒ Transfer Case and Final drive; Rep. Gr. 39 . – Install the ATF pipes ⇒ “10 ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview ”, page 77

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.

62

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

Caution

Risk of destroying transmission control module - J217- (Me‐ chatronic) with static discharge. ♦ Do not touch contacts in transmission connector with hands. – To discharge static, touch vehicle ground with hand (without glove). – Connect the connector to the transmission and lock screw connections by rotating clockwise -opposite direction of arrow-. Caution

Selector shaft lever must not be bend when pressing selector lever cable on, counterhold if necessary.

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.

6. Transmission, Removing and Installing

63

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Carefully remove the selector lever cable -2- from the selector shaft lever. – Secure the selector lever cable sleeve to the bracket with a new clip -1-. – Selector Lever Cable, Adjusting. Refer to ⇒ “4.2 Selector Lever cable, Adjusting”, page 50 – Install the exhaust system so that it is free of tension ⇒ Rep. Gr. 26 . – Observe measures after connecting the battery ⇒ Rep. Gr. 27 . Caution

Do not use a charging unit as a starting aid. Vehicle control modules could be damaged. – After installing an exchanged transmission after Copying repairing Protected byor copyright. 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 transmission with respect to the correctness ⇒ “10.2 ATF Pipes and ATF Cooler, Cleaning”, page 81 of information in this document. Copyright by AUDI AG. – Check the ATF level and add, if necessary. Refer to ⇒ “9 ATF Level Inside Transmission”, page 69 . – On vehicles with air suspension, activate vehicle lifting mode ⇒ Rep. Gr. 43 . Tightening specifications: Note ♦ The tightening specifications apply only to lightly greased,

oiled, phosphated or blackened nuts and bolts.

♦ Additional lubricant such as engine or transmission oil may be

used, but do not use graphite lubricant.

♦ Do not use any ungreased parts. ♦ Tightening specification tolerance: ± 15 %. Mounting transmission to engine Item

Screw

Nm

1, 8, 9, 10 2

M10x50 M12 x 70 M12 x 60

45 80 80

M12 x 140

80

3 1), 4, 5 6 2), 7 A •

1)

double bolt.

•

2)

Connection with nut.

64

Alignment sleeve for centering

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Drive plate to torque converter Component

Nm

Drive plate to torque converter

85 1)

•

1)

Replace the bolts.

Component Bolts/nuts

Nm M6 M8 M10 M12

9 20 40 65

except for the following: Selector lever cable heat shield to transmission 8 Front catalytic converter strap to transmission 23

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.

6. Transmission, Removing and Installing

65

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

7

Transmission, Transporting

Special tools and workshop equipment required ♦ Attachment and holding rig - 3457-

♦ Support bridge - 30-211 A-

Procedure

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– Secure torque converter in transmission against falling out with bracket - 30-211 A- . The Transmission Support - 3282- can be used when transporting the automatic transmission and for setting up the Attachment and Holding Rig - 3457- . Note ♦ Bolt on Attachment and Holding Rig - 3457- should only be

installed by hand in transmission.

♦ If screw is installed with pliers, transmission housing can be

damaged.

– Attach attachment and holding rig - 3457- to mounts on trans‐ mission housing and secure.

66

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

8

Transmission, Securing to Assembly Stand

Special tools and workshop equipment required ♦ Attachment and holding rig - 3457♦ Holding fixture - VW 313♦ Retaining plate - VW 309♦ Shop crane - V.A.G 1202 Aor shop crane - VAS 6100-

♦ Support bridge - 30-211 A-

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•

Transmission is removed.

8. Transmission, Securing to Assembly Stand

67

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Secure torque converter in transmission against falling out with bracket - 30-211 A- .

– Attach attachment and holding rig - 3457- to mounts on trans‐ mission housing and secure. Note ♦ Bolt on Attachment and Holding Rig - 3457- should only be

installed by hand in transmission.

♦ If screw is installed with pliers, transmission housing can be

damaged.

– Attach transporting device to Holding Plate - VW 309- and in‐ sert this in holding fixture - VW 313- with help of shop crane. WARNING

Center of gravity of transmission is outside center of rotation at holding fixture. To prevent back swing, a second technician must hold transmission housing when rotating the transmis‐ sion on the transmission support.

Note

If the filled transmission is turned upside down with the oil pan facing upward, the vents for transmission housing and final drive must be closed off.

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68

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

9

ATF Level Inside Transmission

Overview: ♦ ⇒ “9.1 ATF Level, Checking and Filling”, page 69 ♦ ⇒ “9.2 ATF, Draining Or Filling after Repair”, page 73

9.1

ATF Level, Checking and Filling

Special tools and workshop equipment required ♦ Used oil collecting and extracting device - V.A.G 1782-

♦ ATF filling system - V.A.G 1924Protected 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.

♦ Vehicle diagnosis, testing and information system - VAS 5051-

Procedure Note

ATF inspection plug must be replaced after removal.

9. ATF Level Inside Transmission

69

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

WARNING

Wear protective eyewear. Test Conditions •

The transmission must not be in the emergency running

•

The vehicle must be horizontal.

•

Selector lever in “P” and engine at idle.

•

The A/C and the heater are off.

•

Vehicle Diagnosis, Testing and Information System VAS 5051- connected, “Vehicle Self-Diagnosis and vehicle system”and vehicle system “02 - Transmission electronics” selected.

•

At the start of the testing, the ATF temperature must not be higher than 30 °C; let the transmission cool down. Note

♦ ATF temperature appears in the display of Vehicle Diagnosis,

Testing and Information System - VAS 5051- .

♦ The ATF level will vary depending on the temperature of the

ATF.

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.

Performing ATF level check when the ATF temperature is too low causes overfilling.

♦ Performing ATF level check when the ATF temperature is too

high causes underfilling.

♦ Only use the ATF available as a replacement part for the plan‐

etary gear in automatic transmission 0AT. Other oils could cause malfunctions or damage to the transmission. ATF spec‐ ification for corresponding engines ⇒ “5 Capacities”, page 5 . Caution

♦ Do not start the engine or tow the vehicle if there is no ATF in the transmission. ♦ Too little or too much ATF will impair the transmission. ♦ Perform this check twice if the ATF circuit to the cooler was opened during a repair. Important: The ATF must be at least 80 °C after the first check. Perform a road test with tester. Check the ATF level after it has cooled down as described.

70

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

Note ♦ ATF cooling circuit can only be bled if ATF temperature is

above 75 °C and the thermostat to ATF cooler opens.

♦ If ATF pipes from ATF thermostat to ATF cooler were opened,

e.g. to clean or replace cooler, the “ventilation road test” must be performed.

♦ Location of ATF thermostat and cooler

⇒ “10 ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview ”, page 77

Check the ATF temperature. Display on -VAS 5051- : – In the selection -1-, tap the diagnostic function “011 - Meas‐ ured values” or “08 - Read measured values block”.

Display on -VAS 5051- :

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1 - Enter display group – In the button field “2” -6-, enter “Display group 006” and press the Q button.

Display on -VAS 5051- : – Read the ATF temperature in the display field -1-. ATF, Checking Level and Correcting Note ♦ The ATF level is checked at the ATF check hole. ♦ The ATF level is correct if a small amount of fluid drips out of

the check hole (this is normal as the fluid expands as it heats up) at an ATF temperature between 35 ° and 45 °C (for hot countries 50 °C).

– Drive the vehicle onto a 4-column hoist or over a service pit so that it is absolutely level.

9. ATF Level Inside Transmission

71

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Fill the reservoir of the ATF Filler Tool - V.A.G 1924- with ATF for automatic transmission 0AT; ATF specification ⇒ “5 Capacities”, page 5 . – Secure ATF Filler Tool - V.A.G 1924- reservoir as high as possible on vehicle. – Remove screws and remove rear noise insulation -2-.Start the engine and let it idle. – With engine idling depress the brake pedal and shift the se‐ lector lever through all the selector lever positions leaving the selector lever at least 10 seconds in each position. – Place old oil collecting and extracting device - V.A.G 1782beneath transmission. Test temperature 35 °C to 45 °C

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– When the ATF reaches 35 ?, remove the ATF check plug -arrow- and drain off any excess ATF if necessary. Note

The ATF inspection plug must be screwed in again before the ATF reaches a temperature of 45 °C (for hot countries 50 °C).

•

If ATF leaks from ATF check hole before temperature has reached 40 °C, ATF level -arrow- is OK.

•

If no ATF drips out of the ATF check hole before 40 °C is reached, then the ATF level -arrow- is not OK. Fill is necessary ⇒ page 73 .

72

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 If ATF is OK: – Replace ATF inspection plug. – Tighten new ATF inspection plug -arrow- tightening specifica‐ tion ⇒ “1 Oil pan, oil strainer and Mechatronic, Assembly Over‐ view”, page 88 . The ATF level test is completed. – Turn off the engine.

Fill ATF – Guide filler hook of ATF filler tool - V.A.G 1924- from below into ATF inspection opening -arrow-, do not push cap up and in while doing so. – Add ATF using ATF Filler Tool - V.A.G 1924- until ATF drips from the check hole.

– Replace ATF inspection plug. – Tighten new ATF inspection plug -arrow- tightening specifica‐ tion ⇒ “1 Oil pan, oil strainer and Mechatronic, Assembly Over‐ view”, page 88 . The ATF level test is completed. – Turn off the engine.

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9.2

ATF, Draining Or Filling after Repair

Special tools and workshop equipment required

9. ATF Level Inside Transmission

73

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 ♦ Used oil collecting and extracting device - V.A.G 1782-

♦ ATF filling system - V.A.G 1924-

♦ Vehicle diagnosis, testing and information system - VAS 5051-

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♦ Protective eyewear Procedure •

The engine is off. Note

Drain plug and ATF inspection plug must be replaced after re‐ moving. – Drive the vehicle onto a 4-column hoist or over a service pit so that it is absolutely level.

74

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Fill the reservoir of the ATF Filler Tool - V.A.G 1924- with ATF for automatic transmission 0AT; ATF specification ⇒ “5 Capacities”, page 5 . – Secure ATF Filler Tool - V.A.G 1924- reservoir as high as possible on vehicle.

– Remove bolts and remove rear noise insulation -2-. WARNING

Wear protective eyewear. – Place old oil collecting and extracting device - V.A.G 1782beneath transmission.

– Remove the drain plug -arrow A-. – Drain the ATF. Note ♦ Ignore items -1 through 13-. ♦ Follow all applicable disposal regulations. ♦ Do not start the engine or tow the vehicle if there is no ATF in

the transmission.

– Replace the drain plug. – Tighten the drain plug, tightening specification ⇒ “1 Oil pan, oil strainer and Mechatronic, Assembly Over‐ view”, page 88 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Fill the transmission withpermitted ATF. 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.

9. ATF Level Inside Transmission

75

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Remove the ATF check plug -arrow-.

– Guide filler hook of ATF filler tool - V.A.G 1924- from below into ATF inspection opening -arrow-, do not push cap up and in while doing so. – Add ATF using ATF Filler Tool - V.A.G 1924- until ATF drips from the check hole. – Move the selector lever into “P”. – Start the engine, wait 20 seconds and then turn it off. – Add ATF using ATF Filler Tool - V.A.G 1924- until ATF drips from the check hole. – Start the engine. – Continue to add ATF using the ATF filler tool - V.A.G 1924until ATF starts to come out again from the check hole. – Tighten the old ATF inspection plug. – With engine idling depress the brake pedal and shift the se‐ lector lever through all the selector lever positions leaving the selector lever at least 10 seconds in each position. – Move the selector lever into “N”. – Increase the RPM to 2000 and hold it there for at least 60 sec‐ onds. – Move the selector lever into “P”. – ATF Level, Checking and Filling. Refer to ⇒ “9.1 ATF Level, Checking and Filling”, page 69 . Note

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Follow the instructions and test requirements for “checking the ATF level”.

76

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

10

ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, As‐ sembly Overview

1 - ATF thermostat ❑ Opening temperature approximately 75°C 2 - ATF Pipe 3 - O-Ring ❑ Always replace 4 - Union nut ❑ 20 Nm ❑ Insert the pipe all the way by hand before tightening 5 - ATF Cooler ❑ ⇒ “10.1 ATF Cooler, Re‐ moving and Installing”, page 78 6 - Clamp 7 - ATF Pipe 8 - Screw ❑ 5 Nm 9 - Clamps 10 - Bracket ❑ Installed together with starter 11 - Screw ❑ 25 Nm 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 ❑ before tightening, insert with respect to the correctness of information in this document. Copyright by AUDI AG. ATF pipes by hand into transmission as far as stop 12 - O-Ring ❑ Always replace 13 - Screw ❑ 5 Nm 14 - Bracket 15 - Screw ❑ 10 Nm ❑ before tightening, insert ATF pipes by hand into thermostat as far as stop 16 - O-Ring ❑ Always replace

10. ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview

77

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

10.1

ATF Cooler, Removing and Installing

ATF cooler overview 1 - Radiator 2 - Clamps 3 - Condenser 4 - ATF Cooler 5 - Power Steering Cooler 6 - Lock Carrier

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.

Special tools and workshop equipment required ♦ Used oil collecting and extracting device - V.A.G 1782-

♦ Protective eyewear Removing – Remove the bolts and remove front -1- and rear -2- noise in‐ sulation. WARNING

Wear protective eyewear.

– Remove both union nuts -4- at top of ATF cooler.

78

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

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.

– Press off clips -2- and -3-. Note

Ignore bolt -1-, does not need to be removed to remove ATF cooler. – Seal ATF pipes and ATF cooler -4- with clean plugs. – Remove ATF cooler -4-.

Installing

10. ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview

79

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

Install in by reverse Pay attention Protected copyright.order Copyingof for removal. private or commercial purposes, in to partthe or in following: whole, is not Tightening with respectspecifications: to the correctness of information in this document. Copyright by AUDI AG. ⇒ “10 ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview ”, page 77

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Replace o-ring -3- and coat with ATF. – Remove plugs, completely insert ATF pipes -2- in ATF cooler -5-. – Tighten union nuts -4- while counterholding at ATF cooler. – ATF Level, Checking and Filling. Refer to ⇒ “9.1 ATF Level, Checking and Filling”, page 69 . – Test ATF pipe connections for leaks and check. Note ♦ Because ATF pipes from ATF thermostat to ATF cooler were

opened, a “ventilation road test” must be performed after ATF check. Afterward, an ATF check must be performed again, see ⇒ “9.1 ATF Level, Checking and Filling”, page 69

♦ ATF cooling circuit can only be bled if ATF temperature is

above 75 °C and the thermostat to ATF cooler opens.

80

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

10.2

ATF Pipes and ATF Cooler, Cleaning

Special tools and workshop equipment required ♦ Used oil collecting and extracting device - V.A.G 1782-

♦ Protective eyewear Before installing a replacement transmission, always clean out the ATF cooler and ATF pipes using compressed air (maximum 10 bar). WARNING

Wear protective eyewear. – Clean the following connections thoroughly: ATF pipe/trans‐ mission, ATF pipe/thermostat and ATF pipe/ATF cooler. Place the used oil collecting and extracting device - V.A.G 1782underneath. 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 – Remove the bolt -1- and the ATF pipes from the ATF thermo‐ with respect to the correctness of information in this document. Copyright by AUDI AG. stat -2-.

– Remove front ATF pipes to ATF cooler at ATF thermostat -2-. For this, counterhold at ATF thermostat. – Remove and empty ATF cooler, flush with ATF if there is heavy contamination, replace if necessary ⇒ “10.1 ATF Cooler, Removing and Installing”, page 78 .

10. ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview

81

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Remove the bolt -3- and then remove the ATF pipes from the transmission. – Attach a hose to one transmission/thermostat ATF pipe and secure it with a hose clamp. Hang the other end of the hose in a suitable container. – Clear the ATF pipe with compressed air. – Connect the hose to the other ATF pipe and repeat the pro‐ cedure. – Installing the ATF cooler, refer to ⇒ “10.1 ATF Cooler, Removing and Installing”, page 78 . – Install the ATF pipes ⇒ “10 ATF pipes, ATF Thermostat and ATF Cooler, 6-Cylinder 3.6L FSI, Assembly Overview ”, page 77 Note

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♦ Because ATF pipes from ATF thermostat to ATF cooler were

opened, a “ventilation road test” must be performed after ATF check. Afterward, an ATF check must be performed again, see ⇒ “9.1 ATF Level, Checking and Filling”, page 69

♦ ATF cooling circuit can only be bled if ATF temperature is

above 75 °C and the thermostat to ATF cooler opens.

82

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

11

Shaft Seals, Replacing - Assembly Overview

1 - Transmission 2 - Output shaft seal ❑ ⇒ “11.1 Input Shaft Seal, Replacing”, page 84 3 - Selector shaft lever ❑ ⇒ “5 Selector Shaft Lev‐ er, Removing and In‐ stalling”, page 53 4 - Spring pin

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5 - Selector shaft seal ❑ ⇒ “11.2 Selector Shaft Seal, Removing and In‐ stalling”, page 85 6 - Torque converter shaft seal ❑ ⇒ “1.3 Torque Converter Shaft Seal, Removing and Installing”, page 12 7 - Torque Converter ❑ ⇒ “1 Torque converter, important information”, page 11 ❑ Torque converter to drive plate tightening specification, see trans‐ mission installation ⇒ “6 Transmission, Re‐ moving and Installing”, page 55

11. Shaft Seals, Replacing - Assembly Overview

83

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

11.1

Input Shaft Seal, Replacing

Special tools and workshop equipment required ♦ Puller - T10055♦ Engine Support Adapter T10055/2♦ Sleeve - T10180♦ Thrust piece - T10186♦ Sheet metal screw

Removing – Remove transfer case ⇒ Transfer case and final drive; Rep. Gr. 39 .

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84

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

Note ♦ For the next step, install sheet metal screw so that it jams be‐

tween seal and metal ring.

♦ Be careful not to install the screw too deep otherwise the bear‐

ing underneath will get damaged.

– Install sheet metal screw in shaft seal -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove seal with Puller - T10055- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Installing

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Lubricate outer circumference and space between sealing lips with ATF. ♦ Installation position: the open side of the seal faces the trans‐ mission. – Carefully guide shaft seal over output shaft to transmission and lightly press in with hand. – Drive in shaft seal as far as stop with Thrust Piece - T40134- . Do not tilt shaft seal when doing so. – Install transfer case ⇒ Transfer case and final drive; Rep. Gr. 39 . – Check the ATF level and add, if necessary. Refer to ⇒ “9 ATF Level Inside Transmission”, page 69 .

11.2

Selector Shaft Seal, Removing and In‐ stalling

Special tools and workshop equipment required ♦ Pry lever - 80 - 200-

♦ Thrust piece - T10135-

11. Shaft Seals, Replacing - Assembly Overview

85

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Removing – Remove screws and remove rear noise insulation -2-.

– Remove the ball head -2- on the selector lever cable from the selector shaft lever using the pry lever - 80-200- .

– Remove the spring pin -1- on the selector shaft lever -2-arrow- until it is possible to remove the lever from the shaft.

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86

Rep. Gr.37 - Mechanism and Housing

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

Caution

Do not damage or scratch selector shaft running surface. – Pierce through shaft seal with a small screwdriver or scriber and pull out. Installing Install in reverse order of removal. Note the following: – Lubricate outer circumference and space between sealing lips with ATF. ♦ Installation position: the open side of the seal faces the trans‐ mission. – Press new shaft seal onto selector shaft. – Press on new shaft seal as far as the stop using Thrust Piece - T10135- and assembly lever -A- or plastic hammer without twisting seal. – Install the spring pin on the selector shaft lever while it is still removed. – Slide selector shaft lever onto selector shaft, align it and then install the spring pin.

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11. Shaft Seals, Replacing - Assembly Overview

87

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

38 –

Gears, Control

1

Oil pan, oil strainer and Mechatronic, Assembly Overview

1 - Screw ❑ 12 Nm ❑ tighten diagonally ❑ Securing oil pan to transmission 2 - ATF Drain Plug ❑ 12 Nm ❑ Always replace the bolt. 3 - ATF inspection and filler plug ❑ 80 Nm ❑ Always replace the bolt.

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4 - Oil Pan ❑ ⇒ “1.1 ATF Pan, Re‐ moving and Installing”, page 88 5 - Cover cap ❑ inserted in oil pan open‐ ing 6 - Magnet ❑ ensure full surface con‐ tact ❑ clean before installation 7 - Oil pan seal ❑ Always replace 8 - ATF Strainer ❑ ⇒ “1.2 Oil Screen, Re‐ moving and Installing”, page 90 9 - Screw ❑ 8 Nm ❑ Note different lengths ❑ Following removal and installation instructions ⇒ “1.3 Mechatronic, Removing and Installing”, page 92 10 - Mechatronic ❑ ⇒ “1.3 Mechatronic, Removing and Installing”, page 92 11 - Seal 12 -

1.1

ATF Pan, Removing and Installing

Special tools and workshop equipment required

88

Rep. Gr.38 - Gears, Control

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 ♦ Used oil collecting and extracting device - V.A.G 1782-

♦ Torque wrench - V.A.G 1331Protected 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.

Removing Note ♦ General Repair Instructions. Refer to

⇒ “6 Repair Information”, page 6 .

♦ Automatic Transmission Clean Working Conditions, refer to

⇒ “7 Transmission, Clean Working Conditions”, page 9 .

– Remove bolts and remove rear noise insulation -2-.

1. Oil pan, oil strainer and Mechatronic, Assembly Overview

89

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Place the used oil collection and extraction device - V.A.G 1782- under the transmission. WARNING

Wear protective eyewear. – Remove the drain plug -arrow A-. – Drain the ATF. – Loosen oil pan bolts in -13 to 1- sequence and remove oil pan. Installing Install in reverse order of removal. Note the following: Tightening specifications. Refer to ⇒ “1 Oil pan, oil strainer and Mechatronic, Assembly Overview”, page 88 . – Clean all magnets in oil pan recesses. Note ♦ Make sure that the magnets are in full contact with the oil pan. ♦ Replace the seal. ♦ Replace the drain plug. – Clean the sealing surface from all sealant residue. •

The sealing surfaces must be dry and free of grease.

– Install the oil pan with new seal. – Tighten the oil pan bolts in stages and in sequence -1 to 13-. – Install the new drain plug. – Fill the ATF and check the level after installing. Refer to ⇒ “9.2 ATF, Draining Or Filling after Repair”, page 73 .

1.2

Oil Screen, Removing and Installing

Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1410-

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90

Rep. Gr.38 - Gears, Control

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Removing Note ♦ General Repair Instructions. Refer to

⇒ “6 Repair Information”, page 6 .

♦ Automatic Transmission Clean Working Conditions, refer to

⇒ “7 Transmission, Clean Working Conditions”, page 9 .

– Remove the ATF pan. Refer to ⇒ “1.1 ATF Pan, Removing and Installing”, page 88 . – Carefully remove the oil screen -A-. Installing Install in reverse order of removal. Note the following: Note

Replace the oil strainer only if it is damaged.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not If oil strainer is being replaced, then not the following: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– If present, carefully remove oil strainer seal -A- from transmis‐ sion using a screwdriver.

with respect to the correctness of information in this document. Copyright by AUDI AG.

Note ♦ Do not damage sealing surface. ♦ The seal is shown with the Mechatronic removed to provide a

better illustration.

♦ The new oil strainer comes with the seal installed.

1. Oil pan, oil strainer and Mechatronic, Assembly Overview

91

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Continuation for new and old oil strainer: – Install the oil strainer intake tube -A- all the way into the open‐ ing in the transmission. Note

A new oil strainer with attached seal is installed in the transmis‐ sion. – Install the ATF pan. Refer to ⇒ “1.1 ATF Pan, Removing and Installing”, page 88 . – Fill the ATF and check the level after installing. Refer to ⇒ “9.2 ATF, Draining Or Filling after Repair”, page 73 .

1.3

Mechatronic, Removing and Installing Note

♦ Always replace the Mechatronic unit if it is dirty or defective. ♦ General Repair Instructions. Refer to

⇒ “6 Repair Information”, page 6 .

♦ Automatic Transmission Clean Working Conditions, refer to

⇒ “7 Transmission, Clean Working Conditions”, page 9 .

Removing Caution

Complete the steps for disconnecting the battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 . – Turn off the ignition and disconnect the battery ground cable. – Remove the ATF pan. Refer to ⇒ “1.1 ATF Pan, Removing and Installing”, page 88 . – Remove the ATF strainer. Refer to ⇒ “1.2 Oil Screen, Removing and Installing”, page 90 .

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92

Rep. Gr.38 - Gears, Control

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Turn the screw counter-clockwise and disconnect the connec‐ tor -arrow-. Caution

♦ Always discharge static by touching a grounded object, for example, vehicle ground, before touching or removing the Mechatronic unit. ♦ Connector terminals in connector must not be touched by hand under any circumstances because control module and therefore Mechatronic may be destroyed by static discharge. – To discharge static, touch vehicle ground with hand (without Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not glove).

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.

– Press the tab -arrow 1- and remove locking lever -arrow 2-. – Remove the connector housing -arrow 3-.

– Remove the Mechatronic bolts in the following sequence: -10 to 1-. Note ♦ Only bolts marked with -10 to 1- may be loosened. ♦ If other bolts are loosened, this may affect the function of the

Mechatronic unit or it may come apart.

– Remove the Mechatronic from the transmission.

1. Oil pan, oil strainer and Mechatronic, Assembly Overview

93

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 Installing Install in reverse order of removal. Note the following: Tightening specifications. Refer to ⇒ “1 Oil pan, oil strainer and Mechatronic, Assembly Overview”, page 88 . – Make sure the seal -B- is installed correctly and is secure. •

If Mechatronic is replaced, then is it necessary to reaplce the seal -B- as well.

– Set Mechatronic unit in place without using force, and at the same time insert stud on the selector lever -arrow- into the groove on the selector slide -A-; if necessary, move selector slide back or forth.

– Tighten the bolts -1- and -2- on the Mechatronic to 2 Nm. – Tighten the bolts to tightening specification in the following sequence: -1 to 10-.

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.

94

Rep. Gr.38 - Gears, Control

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006 – Replace the connector housing -A-. – Lightly coat the o-rings -1- and seals -2- on the new connector housing -A- with ATF. – Press the connector housing -A- all the way into the transmis‐ sion -arrow 1-. Rotate it slightly if necessary. – Install the locking lever into the transmission -arrow 2-. Make sure it engages. Note ♦ The seal connector is then secured against falling out with a

clip.

♦ If locking lever does not engage, lightly press or rotate con‐

nector housing.

– Install the ATF strainer. Refer to ⇒ “1.2 Oil Screen, Removing and Installing”, page 90 . 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 – Install the ATF pan. Refer to with respect to the88 correctness of information in this document. Copyright by AUDI AG. ⇒ “1.1 ATF Pan, Removing and Installing”, page .

– Fill the ATF and check the level after installing. Refer to ⇒ “9.2 ATF, Draining Or Filling after Repair”, page 73 . – Complete the steps required after connecting the battery. Re‐ fer to ⇒ Electrical Equipment; Rep. Gr. 27 .

1. Oil pan, oil strainer and Mechatronic, Assembly Overview

95

Audi Q7 2007 ➤ Automatic Transmission - Edition 07.2006

2

Revision History

DRUCK NUMBER: A005Q701721 Fac‐ Edit Job Im Fe Notes tory Edi‐ Type pa ed Edi‐ tion ct ba tion ck

Quality Check ed By

07.2 08/1 Lo‐ Lo Change Obergrup to 006 6/20 cal w “Drivetrain” 16 Up‐ date 07.2 12/1 Feed 10 006 2/20 back 65 14 89 8

Tom Perry Jim Harder

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96

Rep. Gr.38 - Gears, Control

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 for the latest information.

•=

Any time the battery has been disconnected anor automatic Protected by copyright. Copying for private or commercial purposes, on in part in whole, is not transmission vehicle, it will be permitted unless authorised by AUDI AG. AUDI AG does notControl guaranteeModule or accept any liability basic settings using the VAG necessary to reestablish Transmission (TCM) with respect to the correctness of information in this document. Copyright by AUDI AG.

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 unless the work area is well ventilated. Carbon monoxide (CO) kills.

•=

Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear goggles, gloves and other protective clothing whenever the job requires working with harmful substances.

•=

Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result.

=Page

1 of 3

© 2002 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 1.0

Cautions & Warnings •=

Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

•=

Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

•=

Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

•=

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 all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to the work and use only replacement parts meeting Audi specifications. Makeshift tools, parts and procedures will not make good repairs.

•=

Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously.

•=

Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque listed.

•=

Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.

•=

Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that govern the disposal of wastes.

•=

The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not system should be serviced only byauthorised trainedbyautomotive technicians using permitted unless AUDI AG. AUDIservice AG does not guarantee or accept anyapproved liability with respect to the correctness of information in this safety document.precautions, Copyright by AUDIand AG. familiar with refrigerant recovery/recycling equipment, trained in related 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

© 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 •=

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.

•=

Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair.

•=

When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

I have read and I understand these Cautions and Warnings. 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.

=Page

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© 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