Audi A8 2003 Multitronic 01j Front Wheel Drive Workshop Manual Edition 112007

Service
Workshop Manual
Audi A8 2003 ➤
multitronic 01J, front-wheel drive
Edition 11.2007
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
13 - Crankshaft group
37 - Controls, housing
38 - Gears, control
39 - Final drive - differential
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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.
Audi A8 2003 ➤
multitronic 01J, front-wheel drive - Edition 11.2007
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Notes on CVT gearbox type “multitronic 01J (front-wheel drive)” . . . . . . . . . . . . . . . . . . . . 2
3 Code letters, gearbox allocation, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Notes on towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.3 Rules for cleanliness when working on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Damper unit, for description refer to: Engine, mechanics; Repair group 13 . . . . . . . . . . . . 10
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 ...................................................................... 11
2 Checking ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Servicing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Exploded view - selector mechanism cover, selector lever handle . . . . . . . . . . . . . . . . . . 16
4.2 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Removing and installing selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Removing and installing tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6 Operating manual release for selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.7 Removing and installing manual release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.8 Removing and installing shift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.9 Selector lever cable - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.10 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.11 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Removing gearbox - vehicles with 3.0 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Installing gearbox - vehicles with 3.0 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Removing gearbox - vehicles with 3.2 ltr. FSI engine and 2.8 ltr. FSI engine . . . . . . . . . . 49
5.4 Installing gearbox on vehicles with 3.2 ltr. FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Transporting the automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8 Removing and installing gearbox mounting and gearbox support . . . . . . . . . . . . . . . . . . . . 60
8.1 Removing and installing gearbox mounting and gearbox support (left-side) . . . . . . . . . . . . 60
8.2 Removing and installing gearbox mounting and gearbox support (right-side) . . . . . . . . . . 62
9 Checking ATF level and changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2 Changing ATF or filling up after performing repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10 Servicing ATF cooling system on vehicles with 3.0 ltr. MPI engine . . . . . . . . . . . . . . . . . . 74
10.1 Removing and installing ATF pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.2 Cleaning ATF pipes and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.3 Removing and installing additional ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.4 Removing and installing additional ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.5 Removing and installing bracket for additional ATF filter and additional ATF cooler . . . . . . 81
Contents i
Audi A8 2003 ➤
11 Servicing ATF cooling system on vehicles with 3.2 ltr. FSI engine and 2.8 ltr. FSI engine
........................................................................ 82
11.1 Removing and installing ATF pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
11.2 Cleaning ATF pipes and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.3 Removing and installing additional ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.4 Removing and installing additional ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.5 Removing and installing bracket for additional ATF filter and additional ATF cooler . . . . . . 88
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Removing and installing end cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Removing and installing automatic gearbox control unit J217 . . . . . . . . . . . . . . . . . . . . . . 95
1.3 Cleaning selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.4 Removing and installing hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.5 Removing and installing input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1 Checking gear oil in front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2 Servicing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.1 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.2 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.3 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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2.4 Renewing oil seal and grooved ball bearing for flange shaft (right-side) . . . . . . . . . . . . . . 103
2.5 Removing and installing cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
ii Contents
Audi A8 2003 ➤
00 – Technical data
1 Gearbox identification
The continuously variable automatic gearbox “multitronic 01J,
front-wheel drive” is installed in the Audi A8 2003 ▸ in combination
with various engine types. Allocation
⇒ “3 Code letters, gearbox allocation, ratios, equipment ”,
page 3 .
Location of code letters on gearbox
Gearbox code letters and gearbox serial number are stamped
onto the bottom of the gearbox case -arrow-.
Example: FRC 03 07 01
Code letters Day Month Year (2001)
of manufacture
Note
The code letters for the gearbox are also given on the vehicle data
stickers.
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1. Gearbox identification 1
Audi A8 2003 ➤
2 Notes on CVT gearbox type “multi‐

tronic 01J (front-wheel drive)”
Detailed information on the basic principle of this gearbox ⇒ Self-
study programme No. 228 ; CVT gearbox multitronic 01J .
Note
The multitronic 01J is also referred to as “Continuously Variable

Transmission”, in short “CVT”.
Guided Fault Finding

Before commencing any repair work, always perform the “Guided
Fault Finding procedure” using vehicle diagnostic, testing and in‐
formation system -VAS 5051 A- .
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2 Rep. Gr.00 - Technical data

Audi A8 2003 ➤
3 Code letters, gearbox allocation, ra‐

tios, equipment
Front-wheel drive
multitronic 01J.G 01J.B 01J.B
Gearbox Code letters GVN GXU HCQ
Manufac‐ from 06.03 05.04 07.03
tured to 05.05 05.04
Allocation Model Audi A8 2003 ▸ Audi A8 2003 ▸ Audi A8 2003 ▸
Engine 3.0 ltr. MPI 5V - 3.0 ltr. MPI 5V - 3.0 ltr. MPI 5V -
160 kW 162 kW 162 kW
Input stage 51 : 46 1.109 51 : 46 1.109 51 : 46 1.109
Final drive 41 : 8 5.125 43 : 9 4.778 43 : 9 4.778
multitronic 01J.M 01J.B 01J.B

Gearbox Code letters HJA HRZ HVA
Manufac‐ from 05.05 03.05 05.05
tured to 05.05
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Engine 3.2 ltr. 4V FSI 3.0 ltr. MPI 5V - 3.0 ltr. MPI 5V -
-191 kW 162 kW 162 kW
Input stage 49 : 48 1.021 51 : 46 1.109 51 : 46 1.109
Final drive 43 : 9 4.778 43 : 9 4.778 43 : 9 4.778
multitronic 01J.M 01J.M 01J.M

Gearbox Code letters JLN JSP KEN
Manufac‐ from 11.05 05.06 05.08
tured to
Engine 3.2 ltr. 4V FSI 3.2 ltr. 4V FSI 3.2 ltr. 4V FSI
-191 kW -191 kW -191 kW
Input stage 49 : 48 1.021 49 : 48 1.021 49 : 48 1.021
Final drive 43 : 9 4.778 43 : 9 4.778 43 : 9 4.778
multitronic 01J.M 01J.C 01J.B

Gearbox Code letters KEP KFT KRH
Manufac‐ from 05.08 05.08 05.08
tured to
Engine 3.2 ltr. 4V FSI 2.8 ltr. 4V FSI - 2.8 ltr. 4V FSI -
-191 kW 154 kW 154 kW
Input stage 49 : 48 1.021 53 : 45 1.178 51 : 46 1.109
Final drive 43 : 9 4.778 43 : 9 4.778 43 : 9 4.778
multitronic 01J.C 01J.B 01J.M

Gearbox Code letters KRV KRW KTE
3. Code letters, gearbox allocation, ratios, equipment 3

Audi A8 2003 ➤
multitronic 01J.C 01J.B 01J.M

Manufac‐ from 09.07 11.07 09.07
tured to
Engine 2.8 ltr. 4V FSI - 2.8 ltr. 4V FSI - 3.2 ltr. 4V FSI
154 kW 154 kW -191 kW
Input stage 53 : 45 1.178 51 : 46 1.109 49 : 48 1.021
Final drive 43 : 9 4.778 43 : 9 4.778 43 : 9 4.778
multitronic 01J.M
Gearbox Code letters KTF
Manufac‐ from 09.07
tured to
Allocation Model Audi A8 2003 ▸
Engine 3.2 ltr. 4V FSI
-191 kW
Input stage 49 : 48 1.021
Final drive 43 : 9 4.778
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Audi A8 2003 ➤
4 Capacities
ATF section in gearbox
Capacities Gearbox multitronic
Initial filling approx. 7.5 ltr. 01J
Changing 4.5 … 5.0 ltr.
Change interval for ATF⇒
Maintenance tables
Lubricant ATF for CVT gearbox
ATF for CVT gearbox is available as a replacement part ⇒ Elec‐
tronic parts catalogue
Caution
The ATF required for the multitronic 01J gearbox is different to

the ATF used for fixed-ratio automatic gearboxes. Only the
ATF available as a replacement part for the CVT gearbox may
be used in the gearbox.
Checking ATF level and changing ATF ⇒ page 65

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Front final drive

Capacities Front final drive multitronic
Initial filling approx. 1.3 ltr. 01J
Changing No change intervals
Lifetime filling
No change required un‐
less repair work has been
performed (max. 1.3 ltr.)
Lubricant Gear oil for multitronic
Gear oil for multitronic is available as a replacement part ⇒ Elec‐
tronic parts catalogue
Caution
The gear oil required for the multitronic 01J gearbox is different
from the oil used in fixed-ratio automatic gearboxes. Only the
gear oil available as a replacement part for the multitronic 01J
may be used in the front final drive.
Checking oil level in front final drive ⇒ page 97 .
4. Capacities 5
Audi A8 2003 ➤
5 Notes on towing
Caution
When the vehicle is towed, the selector lever must be set to

position “N” and the vehicle must not be towed for a distance
of more than 50 km or at a speed in excess of 50 km/h, as the
gearbox would otherwise be seriously damaged.
Note
It is not possible to start the engine by means of tow-starting, for

instance in the case of insufficient battery charge or if the starter
is not working.
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Audi A8 2003 ➤
6 Repair instructions
6.1 Contact corrosion!

General information:
Contact corrosion can occur if non-approved fasteners such as
bolts, nuts, washers etc. are used on the vehicle.
For this reason, only fasteners with a special surface coating are
fitted. These parts can be identified by their greenish colour.
Rubber, plastic and adhesives also consist of non-conductive
materials.
If you are not sure whether used parts can be re-installed, always
fit new parts.
The following applies in particular to gearboxes:
♦ The housing of the multitronic gearbox 01J is made of a mag‐
nesium alloy.
♦ Bolts and other components which have direct contact with the
gearbox have a surface coating which is compatible with the
magnesium gearbox housing.
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♦ On gearboxes built of magnesium, the bolts must always be

renewed on the following bolted connections: gearbox cover
to gearbox housing, final drive cover to gearbox housing and
engine to gearbox.
♦ If the incorrect components are used (bolts, nuts, washers
etc.), this will cause contact corrosion. The gearbox housing
will be damaged.
♦ The gearbox housing, gearbox cover and cover for final drive
must also all be of the same material.
♦ If you are not sure whether used parts can be re-installed, al‐
ways fit new parts.
Caution
♦ We recommend using only Audi Genuine Parts.

♦ Accessories must be approved by AUDI AG.
♦ Damage resulting from contact corrosion is not covered
by the warranty.
6.2 General repair instructions
WARNING
Prior to performing work with engine running, move selector

lever to position “P” and operate parking brake button to apply
the electronic parking brake.
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. The usual basic safety
precautions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
6. Repair instructions 7
Audi A8 2003 ➤
places in the Workshop Manual - are summarised here. They ap‐

ply to the work described in this Manual.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ "Special tools, Workshop equipment"
Gearbox
♦ Observe rules for cleanliness when working on gearbox
⇒ page 9 .
♦ The engine must not be run and the vehicle must not be towed
with the end cover removed or without ATF in the gearbox.
♦ Only install clean components: do not remove replacement
parts from packaging until just before installation.
♦ After installing, the following fluid levels must be checked and
topped up if necessary: ATF in planetary gearbox
⇒ page 65 and gear oil in front final drive ⇒ page 97 . Ca‐
pacities and specifications ⇒ page 5
O-rings, oil seals, gaskets
♦ Always install new O-rings, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
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or for other signs of damage.

♦ Thoroughly clean housing joint surfaces before assembling.
♦ Lightly lubricate the outer circumference and sealing lip of
seals with ATF before installing.
♦ Lightly lubricate O-rings with ATF before installation to prevent
them getting crushed during assembly.
♦ Use only ATF for parts running in ATF. Other lubricants will
cause malfunction of the gearbox hydraulics.
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ When installing a new oil seal, position the seal in the housing
so that the sealing lip does not contact the shaft in the same
place as the old seal (make use of insertion depth tolerances).
♦ After installing, the following fluid levels must be checked and
topped up if necessary: ATF in planetary gearbox
⇒ page 65 and gear oil in front final drive ⇒ page 97 . Ca‐
pacities and specifications ⇒ page 5
Nuts, bolts
♦ Loosen bolts in reverse sequence to the specified tightening
sequence.
♦ Bolts and nuts used to secure covers and housings must be
tightened in steps according to the specified tightening se‐
quence and method.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then install bolts with locking fluid; for
locking fluid refer to ⇒ Electronic parts catalogue .

Audi A8 2003 ➤
♦ Threaded holes which take self-locking bolts or bolts coated

with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
Locking elements
♦ Do not over-stretch circlips.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
Bearings
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
♦ Lubricate bearings with gear oil or ATF, depending on fitting
location.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er and use new bearings from a single manufacturer.
Shims
♦ Use a micrometer to measure the shims at several points.
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Tolerance variations make it possible to obtain the exact shim

thickness required.
♦ Check for burrs and damage. Install only shims which are in
perfect condition.
Guided Fault Finding
Before commencing any repair work, always perform the “Guided
Fault Finding procedure” using vehicle diagnostic, testing and in‐
formation system -VAS 5051 A- .
6.3 Rules for cleanliness when working on

the gearbox
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use sheeting and paper. Use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components: do not remove replacement
parts from packaging until just before installation.
6. Repair instructions 9
Audi A8 2003 ➤
13 – Crankshaft group
1 Damper unit, for description refer to:
Engine, mechanics; Repair group 13
See the corresponding Workshop Manual ⇒ Rep. Gr. 13 for a
description of how to remove and install the damper unit.
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10 Rep. Gr.13 - Crankshaft group

Audi A8 2003 ➤
37 – Controls, housing
1 Electrical/electronic components and fit‐
ting locations
1. Diagnostic connector
♦ Fitting location: diagnostic connector -arrow- is located below
knee padding on left side of steering wheel.
2. Selector lever lock solenoid -N110-

♦ Fitting location: The selector lever lock solenoid -N110- is a
fixed component of the selector mechanism -arrow- and can
only be renewed together with the shift unit.
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3. Control unit for automatic gearbox -J217-

♦ Fitting location: The multitronic gearbox control unit -J217- is
fitted to the rear end of the gearbox, directly onto the hydraulic
control unit.
The components listed below are integrated in the automatic
gearbox control unit -J217- :
A - Gearbox output speed sender -G195- and gearbox output
speed sender 2 -G196-
B - Gearbox oil temperature sender -G93-
C - Multi-function switch -F125-
D - Gearbox input speed sender -G182-
E - Automatic gearbox hydraulic pressure sender 1 -G193-
F - Automatic gearbox hydraulic pressure sender 2 -G194-
Note
♦ The automatic gearbox control unit -J217- is monitored via

self-diagnosis.
♦ Removing and installing automatic gearbox control unit -J217-
⇒ Servicing multitronic 01J and 0AN; Rep. Gr. 38 .
1. 11
Audi A8 2003 ➤
4. Hydraulic control unit

♦ Fitting location: The hydraulic control unit is bolted to rear end
of gearbox. The multitronic gearbox control unit -J217- is fitted
directly onto the hydraulic control unit.
A - Connector for automatic gearbox pressure control valve 1 -
N215-
B - Connector for automatic gearbox pressure control valve 2 -
N216-
C - Connector for solenoid valve 1 -N88-
Note
Removing and installing hydraulic control unit ⇒ Servicing

multitronic 01J and 0AN; Rep. Gr. 38 .
The following valves are integrated into the hydraulic control unit
(not shown in illustration):
♦ Automatic gearbox pressure control valve 1 -N215- (clutch
solenoid valve)
♦ Automatic gearbox pressure control valve 2 -N216- (solenoid
valve for transmission ratio)
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♦ Solenoid valve 1 -N88- (clutch cooling/safety shut-off).

♦ Clutch cooling valve
♦ Minimum-pressure valve
♦ Pressure limiting valve
♦ Clutch control valve
♦ Control-pressure valve
Note
♦ The valves are checked by self-diagnosis

♦ Description and function of the individual valves ⇒ Self-study
programme No. 228 ; CVT gearbox multitronic 01J .
5. tiptronic switch -F189-

♦ Fitting location: The tiptronic switch -F189- is integrated in the
printed circuit of the symbol panel, which is located in the se‐
lector mechanism cover.
Note
♦ If malfunctions occur in the tiptronic switch -F189- , first check

that the magnet on the transverse slide of the sliding cover is
secured properly. If necessary, renew sliding cover. The prin‐
ted circuit must only be renewed after the wiring has been
checked.
♦ Removing and installing tiptronic switch -F189- ⇒ page 18 .
12 Rep. Gr.37 - Controls, housing

Audi A8 2003 ➤
6. Kick-down switch -F8-

♦ Fitting location: The kick-down switch -F8- is bolted onto the
floor under the pedals.
Note
♦ The kick-down -F8- switch is tested via Self-diagnosis.

♦ Removing and installing kick-down switch -F8- ⇒ Fuel supply
system, petrol engines; Rep. Gr. 20 .
7. Selector lever position display -Y6-

♦ Fitting location: The selector lever position display -Y6- is in‐
tegrated in the instrument cluster.
Note
♦ If all the characters in the display light up together, this indi‐

cates a simple fault.
♦ A flashing display indicates a critical fault.
ProCarManuals.com
♦ A blank display indicates defective wiring or a defective se‐

lector lever position display -Y6- .
♦ If the selector lever position indicator -Y6- is defective, renew
the instrument cluster ⇒ Electrical system; Rep. Gr. 90 .
1. 13
Audi A8 2003 ➤
2 Checking ignition key removal lock
WARNING

– Turn the ignition key slightly clockwise to the “ignition on” po‐
sition.
– Press and hold brake pedal.
• When interlock button in selector lever handle is pressed, it
should be possible to move selector lever out of position “P”
without “catching”.
– Switch off ignition.
• It should not be possible to remove the ignition key when the
selector lever is in any position other than “P”.
– Shift selector lever to position “P”.
– Remove ignition key.
ProCarManuals.com
• It should only be possible to remove ignition key in selector

lever position “P”.
• Selector lever can then not be shifted out of “P” position with
interlock button pressed and brake pedal depressed.
If the ignition key removal lock does not function as described:
– Check entry and start authorisation control unit -J518- in func‐
tion “Guided fault finding” ⇒ Vehicle diagnosis, testing and
information system VAS 5051.

Audi A8 2003 ➤
3 Checking selector mechanism
WARNING

♦ It should not be possible to operate the starter while the se‐

lector lever is in position “S”, “D”, “R” or in the “tiptronic gate”.
♦ When travelling at speeds above 5 km/h and shifting into se‐
lector lever position “N”, the solenoid for the selector lever lock
must not engage and block the selector lever. The selector
lever can be shifted into a driving gear.
♦ When travelling at speeds below 5 km/h (almost stationary)
and shifting into selector lever position “N”, the solenoid for the
selector lever lock should only engage after about 1 second.
Selector lever cannot be shifted out of “N” position until brake
pedal is depressed.
Selector lever in “P” position and ignition switched on:
– Do not depress brake pedal.
ProCarManuals.com
• Selector lever is locked and cannot be shifted out of “P”posi‐

tion. Solenoid for selector lever lock blocks selector lever.
– Press and hold brake pedal.
• Solenoid for selector lever lock releases selector lever. It is
possible to shift into a driving gear. Shift selector lever slowly
from “P” position through “R, N, D and S” and check whether
the display in the instrument cluster shows the correct selector
lever position in each case.
Selector lever in “N” position and ignition switched on:
– Do not depress brake pedal.
• After a short waiting time: Selector lever is locked and cannot
be shifted out of “N”position. Solenoid for selector lever lock
blocks selector lever.
– Depress brake pedal.
• Solenoid for selector lever lock releases selector lever. It is
possible to shift into a driving gear.
Selector lever in position “D”, ignition and lights switched on:
– Shift selector lever into “tiptronic gate”.
• The illuminated “D” symbol in the selector lever position dis‐
play should go out and the “+” and “-” symbols should light up.
• The selector lever position indicator in the instrument cluster
should switch from “PRNDS” to “7654321” when the selector
lever is shifted into the “tiptronic gate”.
– Adjust selector lever cable ⇒ page 33 .
– Checking ignition key removal lock ⇒ page 14 .
3. Checking selector mechanism 15

Audi A8 2003 ➤
4 Servicing selector mechanism
WARNING

4.1 Exploded view - selector mechanism cover, selector lever handle
1 - Guide for sliding cover

❑ To separate the two
halves, lever out the re‐
taining tabs, see "Re‐
moving tiptronic switch -
F189- " ⇒ page 18 .
2 - Sliding cover
❑ With integrated magnet
for tiptronic switch -
F189- on transverse
slide.
ProCarManuals.com
❑ Removing and installing

⇒ “4.4 Removing and in‐
stalling tiptronic switch
F189 ”, page 18
3 - Frame with printed circuit
❑ With printed circuit; can
only be renewed as
complete unit
❑ With integrated tiptronic
switch -F189-
❑ With symbol illumination
switches
❑ If malfunctions occur in
the switches, first check
that the appropriate
magnet on the sliding
cover
⇒ Item 2 (page 16) is se‐
cured properly. If neces‐
sary, renew sliding cov‐
er.
❑ The printed circuit can
be checked via “Guided
Fault Finding”
⇒ page 18
❑ Before renewing printed circuit when fault memory indicates fault code “18161”, first check adjustment
of selector lever cable ⇒ page 33
4 - Selector lever handle
❑ Removing and installing ⇒ page 17
❑ Different versions (according to model) ⇒ Electronic parts catalogue
5 - Sleeve for selector lever
❑ Removing and installing ⇒ “4.2 Removing and installing selector lever handle”, page 17

Audi A8 2003 ➤
6 - Cover plate
❑ Includes symbol insert
❑ Removing and installing ⇒ “4.4 Removing and installing tiptronic switch F189 ”, page 18
7 - Magnet for symbol illumination switch
8 - Magnet for tiptronic recognition switch
4.2 Removing and installing selector lever

handle
Removing
– Shift selector lever to position “D”.
– Turn sleeve -1- in clockwise direction until you feel it engage.
Push sleeve downwards in this position.
– Pull off handle -2- from selector lever.
Installing
Installation is carried out in reverse sequence; note the following:
– Fit sleeve -1- onto selector lever.
ProCarManuals.com
– Press handle -2- onto selector lever as far as it will go.

• Installation position: Button points to driver.
– Keep turning sleeve in both directions and simultaneously
push it upwards until lugs on sleeve engage in slits on handle.
– Turn sleeve in anti-clockwise direction until you feel it engage.
4.3 Removing and installing selector mech‐

anism cover
Removing
– Remove selector lever handle ⇒ page 17 .
– Take out insert -1- for front ashtray by pressing button
-arrow-.
– Unscrew bolt -arrow - and remove housing for front ashtray.

– Unplug electrical connector.
4. Servicing selector mechanism 17

Audi A8 2003 ➤
– Lift off centre console switch panel -arrows-.

– Unplug electrical connectors.
– Release locking hooks -1- on both sides of selector mecha‐

nism -arrow- and lift up cover -3-.
– Unplug electrical connector -2- and remove cover.
Installing
– Install selector lever handle ⇒ page 17 .
ProCarManuals.com
4.4 Removing and installing tiptronic switch

-F189-
Note
♦ The tiptronic switch -F189- is a fixed component of the printed

circuit.
♦ The magnet for the tiptronic switch -F189- is attached to the
sliding cover.
Removing
– Remove selector lever handle ⇒ page 17 .
– Remove selector mechanism cover ⇒ page 17 .
– Press together middle section of frame -arrows- and simulta‐
neously pull off the cover plate.

Audi A8 2003 ➤
– Carefully lever out retaining tabs -arrows A- and -arrows B-

(retaining tabs are concealed).
– Detach guide and sliding cover together with tiptronic switch -
F189- from frame.
Note
♦ Printed circuit -1- can only be renewed together with frame.

♦ Magnet for tiptronic switch -F189- can only be renewed to‐
gether with sliding cover.
♦ Guide must be renewed if retaining tabs are damaged.
Installing
– Install selector mechanism cover ⇒ page 17 .
4.5 Exploded view - selector mechanism
1 - Rubber sleeve for selector

lever cable
ProCarManuals.com
❑ Check that rubber

sleeve for selector lever
cable is correctly attach‐
ed and make sure it
seals it off properly
2 - Locking plate
❑ For securing selector
lever cable to shift unit
❑ Installation position: an‐
gled end points upwards
3 - Selector lever cable
❑ Do not bend or kink
❑ Selector lever cable
must be renewed if rub‐
ber sleeve is damaged
⇒ page 28
❑ Before installing, lightly
lubricate ball socket with
polycarbamide grease -
G 052 142 A2- .
❑ When installing, make
sure that rubber sleeve
on gearbox end is not
twisted
❑ Adjusting ⇒ page 33
4 - Bracket
❑ With rocker mechanism
for manual release
❑ Different versions (ac‐
cording to model) ⇒
Electronic parts cata‐
logue

Audi A8 2003 ➤
5 - 8 Nm
6 - 3.5 Nm
7 - Operating cable for manual release
8 - Electrical connector
❑ For selector lever lock solenoid -N110- and switch for gear selector position P -F305-
9 - Shift unit
❑ With selector lever lock solenoid -N110- and switch for gear selector position P -F305-
❑ Can only be renewed as a complete unit
10 - 8 Nm
11 - Cover for shift unit
❑ With glued-on gasket
12 - Noise insulation
13 - Securing clip
❑ For securing noise insulation to selector mechanism
ProCarManuals.com
❑ Renew
14 - 1.5 Nm
4.6 Operating manual release for selector

mechanism
Note
♦ If the battery is disconnected or discharged, the selector lever

cannot be shifted from position “P”.
♦ When you operate the manual release mechanism the selec‐
tor lever lock solenoid -N110- will release the lock without
current supply.
Procedure
-arrow-.

Audi A8 2003 ➤
Note
Should there be a trim cap on the rocker mechanism for manual

release, it will have to be levered off with a screwdriver.
– Use a screwdriver or similar to press on the rocker mechanism

for manual release -A- and simultaneously shift the selector
lever out of position “P” -arrow-.
ProCarManuals.com
4.7 Removing and installing manual release

mechanism
Removing
• Shift unit removed.
– Unscrew bolts -1- and remove manual release mechanism.
Installing
– To assemble manual release mechanism, insert slide -3- with
lugs -arrows A- into recesses -arrows B- on cover -2-.
– Clip end of Bowden cable -4- into slide and support bracket
into cover.
– Secure assembled manual release mechanism to shift unit.
• Flat edge -arrow C- points towards connecting wires.
4.8 Removing and installing shift unit

Removing
– If applicable, activate jacking mode when raising the vehicle
⇒ Running gear, front-wheel drive and four-wheel drive; Rep.
Gr. 43 ; Adaptive air suspension .
– Raise vehicle or drive onto inspection pit.

Audi A8 2003 ➤
– On vehicles fitted with auxiliary heater, remove screws

-arrows- securing exhaust pipe of auxiliary/ additional heater
to noise insulation.
– Release quick-release fasteners -1- and -2- and detach noise

insulation panels.
ProCarManuals.com
– Remove front cross member -arrows-.
– Loosen clamps -1- and -2-.

Audi A8 2003 ➤
Note
The flexible pipe connection (de-coupling element) on the front

exhaust pipe must not be bent more than 10° - otherwise it can
be damaged.
– Unscrew nuts -arrows- on brackets for front exhaust pipes (left

and right).
– Tie up left and right exhaust system onto body.

ProCarManuals.com
– Unscrew bolts -arrows- and remove tunnel cross member.
– Remove heat shield for selector mechanism -arrows-.

Audi A8 2003 ➤
– Remove bolt -1-.

– Lever off lock washers -2- and remove noise insulation.

– Turn sleeve -1- in clockwise direction until you feel it engage.
Push sleeve downwards in this position.
– Now pull off handle -2- from selector lever.
ProCarManuals.com

-arrow-.


Audi A8 2003 ➤

– Release locking hooks -1- on both sides of selector mecha‐

nism -arrow- and lift up cover -3-.
– Unplug electrical connector -2- and remove cover.
– Unplug electrical connector for selector lever lock solenoid -
N110- and switch for gear selector position P -F305- .
ProCarManuals.com
– Lever Bowden cable for manual release mechanism -1- out of

bracket -2-.
– Remove bolts -4-.
– Carefully pull shift unit upwards slightly...

Audi A8 2003 ➤
– .... while simultaneously guiding manual release mechanism

-A- and selector lever cable -B- out of cover for shift unit.
Note
If necessary, unclip rubber sleeve of selector lever cable from

cover for shift unit.
– Loosen clamping bolt -arrow- of selector lever cable with sock‐

et (Torx 25).
– Pull out locking plate -C- for selector lever cable towards the
front.
– Pull shift unit out forwards, while simultaneously pulling out
selector lever cable.
Note
Do not bend or kink the selector lever cable.
Installing
ProCarManuals.com
• Selector lever and selector shaft lever in position “D”.

– Insert selector lever cable -B- into hole for clamping bolt
-arrow-.
– Fit locking plate -C- securing selector lever cable to shift unit.
• Installation position: angled end of locking plate points up‐
wards.
– Check if rubber sleeve for selector lever cable is correctly
hooked into cover of shift unit and make sure it seals it off
properly.
– Carefully guide shift unit into cover for shift unit, making sure
manual release mechanism stays in position and is not dam‐
aged.
• The Bowden cable must be routed beneath the mounting
bracket (right-side) -D-.

Audi A8 2003 ➤
Note
♦ Nuts -3- for lateral adjustment and/or bolts -4- for vertical ad‐
justment have to be loosened in order to align selector mech‐
anism with centre console switch panel.
♦ -Item 1- and -item 2- can be disregarded.
– Install front ashtray in centre console switch panel ⇒ General

body repairs, interior; Rep. Gr. 68 .
– Check selector mechanism ⇒ page 15 .
– Deactivate jacking mode ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. Gr. 43 ; Adaptive air suspension .
Tightening torques
Component Nm
Cover for shift unit to body 8
Shift unit to cover for shift unit 3.5
Front cross member to body 23
4.9 Selector lever cable - exploded view of components

ProCarManuals.com
1 - Selector shaft lever

❑ With damper
2 - Locking plate
❑ For selector lever cable
3 - Selector lever cable
❑ Do not bend or kink
❑ Before installing, lightly
lubricate ball socket with
polycarbamide grease -
G 052 142 A2- .
⇒ page 28
❑ Adjusting ⇒ page 33
❑ Selector lever cable
must be renewed if rub‐
ber sleeve is damaged
❑ When installing, make
sure that rubber sleeve
on gearbox end is not
twisted
4 - Locking plate
5 - Rubber sleeve for selector
lever cable
❑ Check if rubber sleeve
for selector lever cable
is correctly hooked into
cover of shift unit and
make sure it seals it off
properly.

Audi A8 2003 ➤
6 - 23 Nm
7 - Support bracket
8 - 9 Nm
4.10 Removing and installing selector lever

cable
Special tools and workshop equipment required
♦ Removal lever -80-200-
ProCarManuals.com
Removing
-arrow-.
– Unscrew bolt -arrow- and remove housing for front ashtray.


Audi A8 2003 ➤

– Loosen clamping bolt -1- for selector lever cable by approx. 1

turn.
– Lever off retaining clip -2- with a screwdriver.
– Raise vehicle.
ProCarManuals.com


Audi A8 2003 ➤

insulation panels.

ProCarManuals.com

and right).
Note

be damaged.

Audi A8 2003 ➤
– Tie left and right front exhaust pipes up onto body -arrows-.

ProCarManuals.com
– Remove heat shield for selector mechanism -arrows-.
– If fitted, unscrew bolt -1-.

– Lever off lock washers -2-.
– Pull noise insulation downwards slightly.

Audi A8 2003 ➤
Note
Do not bend or kink the selector lever cable.
– Remove rubber sleeve -2- from selector mechanism.

– Remove retaining clip for selector lever cable (already re‐
leased in an earlier step).
– Detach selector lever cable -1- downwards out of shift unit.
– Apply lifting column of engine and gearbox jack -V.A.G 1383

A- to gearbox from below (place a block of wood -1- between
lifting column and gearbox).
– Use engine and gearbox jack to lift gearbox up slightly.
ProCarManuals.com
– First remove bolts -2- and -3- and then subframe securing
bolts -1- and -4-.
– Using engine and gearbox jack -V.A.G 1383 A- , lower gearbox
far enough to be able to access selector lever cable at selector
shaft lever at top of gearbox.

Audi A8 2003 ➤
– Remove bolts -3- at support bracket for selector lever cable.

– Use removal lever -80-200- to prise ball head -1- on selector
lever cable off selector shaft lever -arrow-.
Note
-Item 2- can be disregarded.
Installing
Note
♦ Do not bend or kink the selector lever cable.

♦ Before installing, lightly lubricate ball socket on selector lever
cable with polycarbamide grease -G 052 142 A2- .
– Push selector shaft lever into position “D”.
Note
ProCarManuals.com
In order to securely set position “D” on selector shaft lever move

the selector shaft lever on gearbox forwards as far as it will go,
into position “P”. Then shift it three positions to the back (opposite
to direction of travel).
– Install subframe ⇒ Running gear, front-wheel drive and four-

wheel drive; Rep. Gr. 40 .
– Install exhaust system and perform stress-free alignment ⇒
Rep. Gr. 26 .
Tightening torques
Component Nm
Support bracket to gearbox 23
Tunnel cross member to body 40
4.11 Adjusting selector lever cable


Audi A8 2003 ➤
♦ Torque wrench -V.A.G 1331-
Procedure
• The “D” symbol must be lit up in the selector lever position
indicator in the instrument cluster.
-arrow-.
ProCarManuals.com
– Unscrew bolt -arrow- and remove housing for front ashtray.


• Cover on selector mechanism must remain installed for dura‐
tion of adjustment process.
• Selector lever in position “D”.

Audi A8 2003 ➤
– Loosen clamping bolt for selector lever cable by approx. 1 turn.
Note
♦ Clamping bolt can only be accessed with selector lever in po‐

sition “D”.
♦ Loosen clamping bolt approx. 1 turn – do not remove.
Caution
• After loosening clamping bolt, selector lever must remain

in position “D” for total duration of adjustment process.
– Carefully move selector lever slightly forwards and backwards,

without shifting lever into a different selector lever position.
The selector lever cable is then relieved of stress.
– Check that selector lever is set accurately in position “D”. To
do so, push selector lever slightly towards driver's seat and
check selector lever position indicator in instrument cluster.
ProCarManuals.com
Caution
• When tightening the clamping bolt, the selector lever must

not be pulled forwards or backwards, as otherwise the
setting will not be accurate.
– Tighten clamping bolt for selector lever cable in this position

(tightening torque: 13 Nm).
Assembly is performed in reverse sequence.

Audi A8 2003 ➤
5 Removing and installing gearbox

♦ ⇒ “5.1 Removing gearbox - vehicles with 3.0 ltr. MPI engine”,
page 36
♦ ⇒ “5.2 Installing gearbox - vehicles with 3.0 ltr. MPI engine”,
page 47
♦ ⇒ “5.3 Removing gearbox - vehicles with 3.2 ltr. FSI engine
and 2.8 ltr. FSI engine”, page 49
♦ ⇒ “5.4 Installing gearbox on vehicles with 3.2 ltr. FSI engine”,
page 55
5.1 Removing gearbox - vehicles with 3.0 ltr. MPI engine
Special tools and workshop

equipment required
♦ Support bracket -10-222 A-
♦ Adapters -10-222 A/21-
♦ Gearbox support -T10337-
ProCarManuals.com
♦ Engine and gearbox jack -

V.A.G 1383 A-
• Lock carrier and torque reaction support installed.
Note
All cable ties which are released or cut open during removal must
be fitted in the same position when installing.

Audi A8 2003 ➤

Caution
Follow steps required when disconnecting battery ⇒ Rep. Gr.

27 .
Note
The ignition key must be left in the ignition lock when disconnect‐
ing the battery so that the front wheels can be turned after the
battery has been disconnected.
– Disconnect battery ⇒ Rep. Gr. 27 .

– Pull off rear engine cover panel -arrows-.
ProCarManuals.com
– Pull off front engine cover -arrows-.
– Remove cover for suspension turret (right-side); to do so, de‐

tach spreader clips -1- and unscrew nut -2-.
– Pull cover out of retainers -arrows-.
5. Removing and installing gearbox 37

Audi A8 2003 ➤
– Detach air intake hose -1- from air-mass meter -G70- .

– Remove bolts -arrows- from solenoid valve mounting plate
-3-.
– Pull hose -4- off air duct -2-.
– Unscrew bolt -arrow- and detach air duct -2- from throttle valve
module -J338- .
– If fitted, detach hose -1- from air duct.
Note
For illustration purposes, the air duct is shown from rear, with en‐
gine removed.
ProCarManuals.com
– Detach vacuum hose -arrow- to brake servo at bulkhead.
– Remove electrical connectors -1- and -2- from retainer and

unplug.
– Guide electrical wires to Lambda probes downwards.

Audi A8 2003 ➤
– Unscrew bracket for electrical connectors (left-side) from bulk‐

head and remove electrical connectors from bracket.
– Unplug electrical connectors -2-, -3- and -4- and move elec‐
trical wiring clear.
– Guide electrical wires to Lambda probes downwards.
– Unscrew nut -2- (access from above), connecting left front ex‐
haust pipe with exhaust manifold.
Note
For illustration purposes here shown from rear, with engine re‐
moved.
ProCarManuals.com
– Unscrew nut -2- (access from above), connecting right front

exhaust pipe with exhaust manifold.
Note
For illustration purposes here shown from rear, with engine re‐
moved.
– Remove bolts -5- and -6- (access from above) from engine/
gearbox flange.

Audi A8 2003 ➤
– Pull rubber seal -1- off plenum chamber covers.

– Detach plenum chamber covers -2- and -3-.
– Unscrew rear securing bolts -3- for body brace.

– Secure support bracket -10-222 A- with adapters -10-222 A/
21- and adapter -10-222 A/3- to suspension turrets.
• The adapters -10-222 A/3- point to front.
• Adapters are marked for left and right side of vehicle.
• Centre resting point -2- for adapters is positioned on front bolts
for body brace.
• The adapters -10-222 A/21- are secured with rear securing
bolts -3- for body brace.
ProCarManuals.com
• Knurled screw -1- must be tightened far enough to allow sup‐

port plate to rest on suspension turret.
– Hook spindles of support bracket -10-222 A- into front engine

mounting eyes and adapters -10-222 A/3- .
– Lightly pre-tension spindles of support bracket.
– Remove both front wheels.
Note
Secure brake discs with wheel bolts.


Audi A8 2003 ➤

insulation panels.
– Unscrew bolts -1- and remove bracket for noise insulation.

– Unscrew bolts -2- and remove cross member.
ProCarManuals.com
– Unbolt heat shields -1- for drive shafts (left and right).
– Unbolt drive shafts (left and right) from gearbox flanges.
– Unscrew bolts -1- and -2- on bracket for exhaust system (left-
side) and remove bracket.

Audi A8 2003 ➤
– Unscrew bolts -1- and -2- on bracket for exhaust system (right-

ProCarManuals.com
Note
To stabilise exhaust system, the clamps must first remain in their

installation position; the front exhaust pipes remain inserted in
clamps.
Note

be damaged.

and right).
– Remove bracket for exhaust system from gearbox.

Audi A8 2003 ➤
– Position engine and gearbox jack -V.A.G 1383 A- with gearbox

support -T10337- underneath gearbox, as shown in illustra‐
tion, and support gearbox.
– Slightly lift gearbox with engine and gearbox jack -V.A.G 1383
A- .
– Unplug electrical connector -1- at gearbox mounting (left-

side).
– Unscrew bolts -arrows- and remove gearbox mounting (left-
side).
ProCarManuals.com
– Unscrew gearbox support (left-side) -arrows-.
– Unplug electrical connector -1- at gearbox mounting (right-

side).
– Unscrew bolts -arrows- and remove gearbox mounting (right-
side).

Audi A8 2003 ➤
– Unscrew gearbox support (right-side) -arrows-.

– Lower gearbox slightly.
– Move Lambda probe wires clear.

– Unscrew nuts -1- and -3- (accessible from below) connecting
front exhaust pipe to exhaust manifold on left side.
Note
For illustration purposes here shown with engine removed.
– Remove front exhaust pipe with catalytic converter.

ProCarManuals.com
– Move Lambda probe wires clear.

– Unscrew nuts -1- and -3- (accessible from below) connecting
front exhaust pipe to exhaust manifold on right side.
Note
For illustration purposes here shown with engine removed.
– Remove front exhaust pipe with catalytic converter.

Audi A8 2003 ➤
– Unscrew bolts -1- and -2- and remove heat shield (left-side)
from gearbox.
– Unbolt bracket for ATF pipe (right-side) on bottom section of

sump -arrow-.
ProCarManuals.com
Note
Rules for cleanliness when working on the automatic gearbox

⇒ page 9 .
– Place a cloth below the connection to catch escaping ATF.

– Unscrew bolt -arrow- and detach ATF pipes from gearbox.
– Tie ATF pipes to one side.
– Remove bolt -arrow- and detach bracket for wiring harness

from top section of sump.

Audi A8 2003 ➤
– Remove bolts -1 ... 4- and -7 ... 11- from engine/gearbox

flange.
Note
Only slacken bolt -Item 8- and leave it in position (finger-tight).
– Lower gearbox again slowly.
– Release electrical connector -1- and detach from gearbox.

– Move wiring harness to engine clear -arrows-.
Note
For illustration purposes here shown with gearbox removed.

ProCarManuals.com

support -T40173- underneath gearbox and secure with ten‐
sioning strap -1- as shown in illustration.
– Use engine and gearbox jack -V.A.G 1383 A- to lift gearbox
up slightly.
– Remove the last engine/gearbox securing bolt.
– Pull gearbox off dowel sleeves and use engine and gearbox
jack -V.A.G 1383 A- to carefully lower gearbox far enough to
be able to access selector lever cable.
– Use removal lever -80-200- to prise ball head on selector lever

cable off selector shaft lever -arrow-.
– Pull off retaining clip -2- and detach selector lever cable from
gearbox.
Note
– Lower gearbox out of vehicle slowly.

– When lowering gearbox make sure there is sufficient clear‐
ance for drive shaft flanges.

Audi A8 2003 ➤
5.2 Installing gearbox - vehicles with 3.0 ltr.

MPI engine
Note
♦ Before fitting a replacement gearbox, always clean the ATF

pipes and ATF cooler ⇒ page 75 and renew the additional
ATF filter ⇒ page 76 .
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew oil seals, gaskets, O-rings and bolts which are tight‐
ened by turning through a specified angle.
♦ Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .
♦ All cable ties which are released or cut open during removal
must be fitted in the same position when installing.
– Clean gearbox input shaft splines and damper unit splines on

flywheel. Remove corrosion and apply only a very thin coat of
grease for clutch plate splines -G 000 100- to the splines. It is
ProCarManuals.com
important to remove excess grease.

– Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block; install if necessary.
– Before installing gearbox, tie electrical wiring off to one side
so that it cannot be trapped between the engine and the gear‐
box.
– Lift gearbox high enough to be able to install selector lever
cable.
Note

– Raise gearbox carefully and move to installation position using

gearbox support -T40173- .
– Bolt gearbox onto engine.
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine or gearbox oil may be
used, but do not use graphite lubricant.
♦ Do not use parts which have been degreased.
♦ Tolerance for tightening torques ±15%.
– Raise the gearbox slightly at the rear to install the lower bolts
for securing gearbox to engine.

Audi A8 2003 ➤
Tightening torques for securing gearbox to engine (illustration

shows gearbox flange)
Item Bolt 1 Nm
1, 10, 11 M10x45 45
2 M10x80 65 2)
3 M12x100 65
4, 8 M12x67 65
5, 6 M12x75 65
7 M10x90 45
9 M10x57 45
A Dowel sleeves for centralising
• 1) Renew bolts for securing gearbox to engine.
• 2) Bolt strength rating 10.9
– Install ATF pipes with new O-rings ⇒ page 74 .

– Install front exhaust pipes and align exhaust system so it is
free of stress ⇒ Engine, mechanics; Rep. Gr. 26
– Install gearbox supports and gearbox mountings
⇒ page 60 .
ProCarManuals.com
– Bolt drive shafts to flange shafts ⇒ Running gear, front-wheel

drive and four-wheel drive; Rep. Gr. 40 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Check oil level in front final drive ⇒ page 97 .
– Follow steps required after connecting battery ⇒ Electrical
system; Rep. Gr. 27 .
– After gearbox has been installed, check and top up ATF level
⇒ page 65 .
Tightening torques
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Except for the following:
Heat shield (left-side) to gearbox 23
Heat shield for drive shaft to gearbox 23
Cross member to subframe 56 1)
Air duct to throttle valve module -J338- 10
Body brace to suspension turret 45
• 1) Renew nuts.

Audi A8 2003 ➤
5.3 Removing gearbox - vehicles with 3.2 ltr. FSI engine and 2.8 ltr. FSI engine

equipment required
♦ Support bracket -10-222 A-
♦ Adapters -10-222 A/21-
♦ Engine and gearbox jack -
V.A.G 1383 A-
ProCarManuals.com
• Lock carrier and torque reaction support installed.
Note
All cable ties which are released or cut open during removal must
be fitted in the same position when installing.

Caution
Follow steps required when disconnecting battery ⇒ Rep. Gr.

27 .

Audi A8 2003 ➤
Note
The ignition key must be left in the ignition lock when disconnect‐
ing the battery so that the front wheels can be turned after the
battery has been disconnected.
– Disconnect battery ⇒ Rep. Gr. 27 .

– Remove front exhaust pipes (left and right) ⇒ Rep. Gr. 26 .
– Pull off front engine cover -arrows-.
– Pull off rear engine cover panel -arrows-.

ProCarManuals.com
– Detach vacuum hose -arrow- (leading to brake servo) at bulk‐

head.

Audi A8 2003 ➤
– Remove bolts -3 ... 6- (access from above) from engine/gear‐

box flange.
– Pull rubber seal -1- off plenum chamber cover.

– Detach plenum chamber covers -2- and -3-.
ProCarManuals.com
– Unscrew rear securing bolts -3- for body brace.

– Secure support bracket -10-222 A- with adapters -10-222 A/
21- and adapter -10-222 A/3- to suspension turrets.
• The adapters -10-222 A/3- point to front.
• Adapters are marked for left and right side of vehicle.
• Centre resting point -2- for adapters is positioned on front bolts
for body brace.
• The adapters -10-222 A/21- are secured with rear securing
bolts -3- for body brace.
• Knurled screw -1- must be tightened far enough to allow sup‐
port plate to rest on suspension turret.
– Move electrical wires clear at engine lifting eye.

– Hook spindles of support bracket -10-222 A- into front engine
mounting eyes and adapters -10-222 A/3- .
– Lightly pre-tension spindles of support bracket.
– Remove both front wheels.
Note
Secure brake discs with wheel bolts.

Audi A8 2003 ➤
– Remove bolts -1- and detach noise insulation bracket.

– Remove bolts -2- and detach cross member.
ProCarManuals.com
– Unbolt heat shields -1- for drive shafts (left and right).
– Unbolt drive shafts (left and right) from gearbox flange shafts.

A- .

Audi A8 2003 ➤

side).
side).

ProCarManuals.com

side).
side).


Audi A8 2003 ➤
– Unbolt bracket for ATF pipe (right-side) on bottom section of

sump -arrow-.
Note
Observe rules for cleanliness when working on automatic gear‐

box ⇒ page 9 .
– Place a cloth below the connection to catch escaping ATF.

– Unscrew bolt -arrow- and detach ATF pipes from gearbox.
– Tie ATF pipes to one side.
ProCarManuals.com
– Remove bolts -1-, -2- and -8 ... 10- on engine/gearbox flange.
Note
Only slacken bolt -Item 7- and leave it in position (finger-tight).
– Lower gearbox again slowly.
– Release electrical connector -1- and detach from gearbox.

– Move wiring harness to engine clear -arrows-.
Note
For illustration purposes here shown with gearbox removed.

Audi A8 2003 ➤

support -T40173- underneath gearbox and secure with ten‐
sioning strap -1- as shown in illustration.
A- .
– Remove the last engine/gearbox securing bolt.
– Pull gearbox off dowel sleeves and use engine and gearbox
jack -V.A.G 1383 A- to carefully lower gearbox far enough to
be able to access selector lever cable.
– Use removal lever -80-200- to prise ball head on selector lever

cable off selector shaft lever -arrow-.
– Pull off retaining clip -2- and detach selector lever cable from
gearbox.
ProCarManuals.com
Note
– Lower gearbox out of vehicle slowly.

– When lowering gearbox make sure there is sufficient clear‐
ance for drive shaft flanges.
5.4 Installing gearbox on vehicles with 3.2

ltr. FSI engine
Note
♦ Before fitting a replacement gearbox, always clean the ATF

pipes and ATF cooler ⇒ page 75 and renew the additional
ATF filter ⇒ page 83 .
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew oil seals, gaskets, O-rings and bolts which are tight‐
ened by turning through a specified angle.
♦ Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .
♦ All cable ties which are released or cut open during removal
must be fitted in the same position when installing.
– Clean gearbox input shaft splines and damper unit splines on

flywheel. Remove corrosion and apply only a very thin coat of
grease for clutch plate splines -G 000 100- to the splines. It is
important to remove excess grease.

Audi A8 2003 ➤
– Check that dowel sleeves for centralising engine/gearbox are

in the cylinder block; install if necessary.
– Before installing gearbox, tie electrical wiring off to one side
so that it cannot be trapped between the engine and the gear‐
box.
– Lift gearbox high enough to be able to install selector lever
cable.
Note

– Raise gearbox carefully and move to installation position using

gearbox support -T40173- .
– Bolt gearbox onto engine.
Note
♦ Tightening torques apply only to lightly greased, oiled,

ProCarManuals.com
phosphated or black-finished nuts and bolts.

♦ Additional lubricant such as engine or gearbox oil may be
used, but do not use graphite lubricant.
♦ Do not use parts which have been degreased.
♦ Tolerance for tightening torques ±15%.
– Raise the gearbox slightly at the rear to install the lower bolts
for securing gearbox to engine.

Audi A8 2003 ➤
Tightening torques for securing gearbox to engine (illustration

shows gearbox flange)
Item Bolt 1 Nm
1, 7 M10x115 65 2)
2 M12x130 65
3, 4, 5, 6 M12x110 65
8, 9, 10 M10x80 45
A Dowel sleeves for centralising
• 1) Renew bolts for securing gearbox to engine.
• 2) Bolt strength rating 10.9
– Install ATF pipes with new O-rings ⇒ page 82 .

– Install front exhaust pipes and perform stress-free alignment
⇒ Rep. Gr. 26.
– Install gearbox supports and gearbox mountings
⇒ page 60 .
– Install drive shafts ⇒ Running gear, front-wheel drive and four-
ProCarManuals.com
– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.
– Check oil level in front final drive ⇒ page 97 .
– Follow steps required after connecting battery ⇒ Electrical
system; Rep. Gr. 27 .
– Check ATF level ⇒ page 65 .
Tightening torques
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Except for the following:
Heat shield (left-side) to gearbox 23
Cross member to subframe 56 1)
Body brace to suspension turret 45
• 1) Renew nuts.

Audi A8 2003 ➤
6 Securing gearbox to assembly stand

Description of work sequence ⇒ Servicing multitronic 01J and
0AN; Rep. Gr. 38
ProCarManuals.com

Audi A8 2003 ➤
7 Transporting the automatic gearbox

♦ Lifting aid -T40013-
Procedure
The lifting aid -T40013- can be used to transport the gearbox and
also when setting up the gearbox on gearbox support -3282- .
– Attach lifting aid -T40013- to upper web of gearbox housing
and secure in place.
ProCarManuals.com
7. Transporting the automatic gearbox 59

Audi A8 2003 ➤
8 Removing and installing gearbox

mounting and gearbox support
♦ ⇒ “8.1 Removing and installing gearbox mounting and gear‐
box support (left-side)”, page 60
♦ ⇒ “8.2 Removing and installing gearbox mounting and gear‐
box support (right-side)”, page 62
8.1 Removing and installing gearbox

mounting and gearbox support (left-
side)
♦ Engine and gearbox jack -V.A.G 1383 A-
ProCarManuals.com
Removing

insulation panels.

Audi A8 2003 ➤

ProCarManuals.com

side).
side).

Installing
– Install bracket for front exhaust pipes ⇒ Rep. Gr. 26. .
8. Removing and installing gearbox mounting and gearbox support 61

Audi A8 2003 ➤
Tightening torques for gearbox mounting (left-side)

1- 23 Nm
2- Subframe
3- Gearbox mounting (left-side)
4- 40 Nm
5- 40 Nm
6- 40 Nm
7- Washer
8- 40 Nm
9- Gearbox support (left-side):
8.2 Removing and installing gearbox

mounting and gearbox support (right-
side)
ProCarManuals.com

Removing

Audi A8 2003 ➤

insulation panels.
– Unscrew bolts -1- and -2- on bracket for exhaust system (right-
ProCarManuals.com


side).
side).
8. Removing and installing gearbox mounting and gearbox support 63

Audi A8 2003 ➤

Installing
– Install bracket for front exhaust pipes ⇒ Rep. Gr. 26. .
Tightening torques for gearbox mountings (right-side)

1- 23 Nm
2- Subframe
3- Gearbox mounting (right-side)
4- Gearbox support (right-side)
5- Washer
6- 40 Nm
ProCarManuals.com
7- 40 Nm
8- 40 Nm

Audi A8 2003 ➤
9 Checking ATF level and changing

ATF
♦ Vehicle diagnostic, testing and information system -VAS 5051
A-
♦ ATF charging device for CVT gearboxes -VAS 5162-

ProCarManuals.com
♦ Used oil collection and extraction unit -V.A.G 1782-
♦ Safety goggles
• When the engine is running, the exhaust system must always
be connected to the exhaust gas extractor.
9.1 Checking ATF level
Caution
The ATF required for the CVT multitronic 01J gearbox is dif‐
ferent from the fluid used in fixed-ratio automatic gearboxes.
Only the ATF available as a replacement part for the CVT
gearbox may be used in the planetary gearbox. ATF specifi‐
cation ⇒ page 5 .
9. Checking ATF level and changing ATF 65

Audi A8 2003 ➤
Note
♦ The illustration on the reservoir of the ATF charging device for

CVT gearboxes -VAS 5162- displays a warning in the top left
corner to use ONLY the ATF specially formulated for CVT
gearboxes.
♦ The illustration also shows the steps to follow when filling up;
these are also described below.
Caution
♦ The engine must not be started if only a little or no ATF

remains in gearbox after repair work or after excessive
ATF leakage.
♦ In this case you need to fill the gearbox first with 4.5 … 5
litres of ATF.
Test conditions
• Gearbox must not be in emergency running (backup) mode.
• Vehicle must be level (horizontal).
ProCarManuals.com
• Vehicle diagnostic, testing and information system -VAS 5051

A- connected; vehicle self-diagnosis and vehicle system “02 -
Gearbox electronics” selected.
• Engine idling.
• The air-conditioner and heating system must be switched off.
• The ATF temperature at the beginning of the test must not be
higher than 30°C. If necessary, first allow the gearbox to cool
down.
Note
♦ The ATF level will vary according to the ATF temperature.

♦ If the ATF level is checked when the ATF temperature is too
low, this will result in overfilling.
♦ If the level is checked when the ATF temperature is too high,
this will result in underfilling.
♦ Both overfilling and underfilling will impair the function of the
gearbox.
♦ The ATF temperature is taken from the reading on the vehicle
diagnostic, testing and information system -VAS 5051 A- .
ATF temperature reading

Audi A8 2003 ➤
Display on -VAS 5051 A- :

– From list -1-, select diagnostic function “08 - Read measured
value block”.

1 - Enter display group (max. input value = 255).
– Use keypad -2- to enter “10” for “Display group number 10”
and confirm by touching Q key.
ProCarManuals.com

– Reading for ATF temperature is shown in display zone -3-.
Checking ATF level
– With the brake pedal depressed, shift through all selector lever
positions (P, R, N, D) and hold in each position for approx. 2
sec. at idling speed.


Audi A8 2003 ➤
– Unfasten quick-release catches -2- and detach rear noise in‐

sulation. Do not remove front noise insulation.
– Place used oil collection and extraction unit -V.A.G 1782- be‐
low gearbox.
WARNING
Wear safety goggles.
– When the ATF has reached a temperature of 35°C, unscrew

ATF inspection plug -B-.
ProCarManuals.com
Note
When the plug is opened, approx. 5 cl of ATF will always run out
of the inner oil level tube.
The ATF level is correct if a small amount of fluid comes out at

the ATF inspection plug when ATF temperature is between 35°C
and 45°C, or 50°C in hot climates (the fluid level rises due to ex‐
pansion as it warms up).
– Renew ATF inspection plug.
• Tightening torque: 30 Nm
Note
The ATF inspection plug must be screwed in again at the latest

when ATF reaches a temperature of 45°C (or 50°C in hot cli‐
mates).
If no ATF fluid has drained out of the inspection plug when tem‐
perature reaches 40 °C, top up ATF.
Filling up ATF
• Engine keeps running at idle speed.

Audi A8 2003 ➤
– Attach filled reservoir of ATF charging device for CVT gear‐

boxes -VAS 5162- at the highest possible point on the vehicle.
♦ ATF specification ⇒ page 5
Note
The stopcock on ATF charging device for CVT gearboxes -VAS

5162- must be closed.
– Screw connecting piece on stopcock of ATF charging device

for CVT gearboxes -VAS 5162- into threaded hole for ATF in‐
spection plug -B-.
ProCarManuals.com
– Turn stopcock in direction of filling hose -lower arrow-.

ATF flows into gearbox.
– Hold a suitable container under drain pipe of ATF charging
device for CVT gearboxes -VAS 5162- .

Audi A8 2003 ➤
– Check ATF level by turning stopcock in direction of drain pipe

-lower arrow-.
Fluid level is correct if only a small quantity of ATF comes out of
drain pipe before ATF reaches a temperature of 45 °C.
Note
Approx. 5 cl of ATF will always run out of internal fluid level pipe.
– If no additional ATF emerges, turn stopcock back in direction

of filler hose and allow some more ATF to flow into gearbox;
check ATF level repeatedly.
– Once correct ATF level has been reached unscrew stopcock.
Note
A few drops of ATF will escape after unscrewing stopcock.
– Renew ATF inspection plug.
– Close inspection plug -B- before ATF temperature exceeds 45

°C (50 °C in countries with hot climate).
ProCarManuals.com
• Tightening torque: 30 Nm
Note
If ATF temperature exceeds 45 °C too much fluid will escape as

it expands when heated. In this case the quantity of fluid in the
gearbox is NOT sufficient!
– Exit from function “08 - Read measured value block” by touch‐

ing < key.
– Press “06 - End output”.
– Switch off ignition and unplug diagnostic connector.
9.2 Changing ATF or filling up after perform‐

ing repairs
♦ ATF charging device for CVT gearboxes -VAS 5162-

Audi A8 2003 ➤
♦ Socket -3357-

ProCarManuals.com
♦ Safety goggles
Caution
Do not run engine or tow vehicle when there is no ATF in the

gearbox.
Note
♦ Please observe requirements for disposal.

♦ Before fitting a new gearbox, always blow through the ATF
cooler and ATF pipes with compressed air (not more than
10 bar) and renew the additional ATF filter: vehicles with 3.0
ltr. MPI engine ⇒ page 76 ; vehicles with 3.2 ltr. FSI engine
⇒ page 83 .

Audi A8 2003 ➤
Procedure
– Attach filled reservoir of ATF charging device for CVT gear‐
boxes -VAS 5162- at the highest possible point on the vehicle.
♦ ATF specification ⇒ page 5
Note
The stopcock on ATF charging device for CVT gearboxes -VAS

5162- must be closed.


ProCarManuals.com
– Unfasten quick-release catches -2- and detach rear noise in‐

sulation. Do not remove front noise insulation.
low gearbox.

Audi A8 2003 ➤
– Unscrew ATF drain plug -A- with multi-point bit -3357- and
drain off ATF.
– Tighten ATF drain plug to 24 Nm.
– Unscrew ATF inspection plug -B-.
– Screw connecting piece on stopcock of ATF charging device
for CVT gearboxes -VAS 5162- into threaded hole for ATF in‐
spection plug -B-.
– Turn stopcock in direction of filling hose -lower arrow-. ATF

flows into gearbox.
– Fill gearbox with at least 4.5 to 5 ltr. of fresh ATF.
– Move selector lever to position “P”, start engine and allow to
run at idling speed.
Vehicles from model year 2005:
– Shift selector lever to position “P”.
– Start engine.
ProCarManuals.com
– Rev engine briefly to 2500 rpm.
Caution
The engine must be revved to 2500 rpm to vent air from the
ATF pump after performing repairs on the gearbox.
All models:
– Check and top up ATF level ⇒ page 65 .
Note
Observe all notes and test requirements for “Checking ATF level”.

Audi A8 2003 ➤
10 Servicing ATF cooling system on ve‐

hicles with 3.0 ltr. MPI engine
10.1 Removing and installing ATF pipes
Note
♦ General repair instructions ⇒ page 7 .

♦ Rules for cleanliness when working on the automatic gearbox
⇒ page 9 .
♦ To install, first press ATF pipes onto gearbox or cooler by hand
until they engage, then bolt on.
♦ Check ATF level after renewing ATF pipes ⇒ page 65 .
ProCarManuals.com

Audi A8 2003 ➤
1 - Bolt, 9 Nm
2 - Bracket for ATF pipes
3 - ATF pipe
❑ Return pipe from addi‐
tional ATF filter
❑ Tighten union nut to 29
Nm
4 - O-ring
❑ Renew
❑ Lubricate with ATF
when fitting
5 - ATF pipe
❑ Supply pipe to addition‐
al ATF cooler
6 - Bolt, 5 Nm
❑ For securing ATF pipe
to additional ATF cooler
7 - ATF pipe
❑ Supply pipe from gear‐
box to additional ATF
ProCarManuals.com
cooler
8 - ATF pipe
tional ATF filter to gear‐
box
9 - Bolt, 21 Nm
❑ Secures ATF pipes to
gearbox
❑ First push on ATF pipes
with new O-rings by
hand until they engage.
10 - O-rings
❑ Renew
when fitting
A - Auxiliary ATF cooler
⇒ page 78
B - Bracket
❑ For additional ATF filter
and additional ATF cool‐
er
⇒ page 81
C - Additional ATF filter
10.2 Cleaning ATF pipes and ATF cooler

10. Servicing ATF cooling system on vehicles with 3.0 ltr. MPI engine 75
Audi A8 2003 ➤
♦ Hose, approx. 18 mm dia.

♦ Compressed air gun (commercially available)
♦ Safety goggles
– Before installing a replacement gearbox, always blow through
the ATF cooler and ATF pipes with compressed air (not more
than 10 bar).
– Also always renew additional ATF filter before installing re‐
placement gearbox.
ProCarManuals.com
Note
♦ If the ATF which emerges during cleaning is very dirty, the

pipes and ATF cooler must additionally be flushed out with
clean ATF.
♦ Removing and installing ATF pipes ⇒ page 74 .
10.3 Removing and installing additional ATF

filter

Audi A8 2003 ➤
Removing
Note

⇒ page 9 .
10 bar) ⇒ page 75 and renew the additional ATF filter. If the
ATF which emerges during cleaning is very dirty, the pipes and
ATF cooler must additionally be flushed out with clean ATF.

– Raise vehicle.
ProCarManuals.com

insulation panels.
low gearbox.
Audi A8 2003 ➤
– Unscrew 2 bolts -4-.
– Loosen union nut -5- and detach additional ATF filter -C- from
ATF pipe.
– Remove bolt -4-.
ProCarManuals.com
– Detach pipe leading to additional ATF filter from additional

ATF cooler -A-.
Installing
– Renew O-ring -2-.
Tightening torques
Component Nm
Additional ATF filter -C- to bracket -B- 5
2 x bolt -4-
Pipe from additional ATF filter to additional ATF 5
cooler -A-
1 x bolt -1-
Union nut for ATF pipe to additional ATF filter 29

cooler

Audi A8 2003 ➤
♦ Hose clamps, up to Ø 25 mm -3094-

ProCarManuals.com
Removing
Note

⇒ page 9 .

– Raise vehicle.
Audi A8 2003 ➤

insulation panels.
low gearbox.
– If applicable, first remove additional ATF filter
– Remove bolts -2- and -4- and detach ATF pipes from addi‐
tional ATF cooler -A-.
– Clamp off cooling pipes -1- and -3- with hose clamps -3094-
and remove from additional ATF cooler.
ProCarManuals.com
– Unscrew bolts -3- (4 x) and remove additional ATF cooler.

Installing
– Renew O-rings on ATF pipes leading to additional ATF cooler.
– Check coolant level.
Tightening torques
Component Nm
Additional ATF cooler -A- to bracket -B- 5
4 x bolt -3-
ATF pipes to additional ATF cooler -A- 5

Audi A8 2003 ➤
10.5 Removing and installing bracket for ad‐

ditional ATF filter and additional ATF
cooler
Removing
– Remove the three bolts -6-.
– Remove bolts with washers -5-.
– Remove the four bolts -3-.
– Remove additional ATF cooler -A- (hoses remain connected).
– Detach bracket -B-.
Note
When renewing bracket first remove additional ATF filter and ad‐
ditional ATF cooler from bracket.
Installing
ProCarManuals.com
Note
Rubber buffers are fitted to the three attachment points at top of

bracket. Before installing, check they are seated correctly and re‐
new if necessary.
Tightening torques
Component Nm
Bracket -B- to body -D- 10
3 x bolt -6- with washer -5-
Additional ATF cooler -A- to bracket -B- 5
4 x bolt -3-
Audi A8 2003 ➤
11 Servicing ATF cooling system on ve‐

hicles with 3.2 ltr. FSI engine and 2.8
ltr. FSI engine
11.1 Removing and installing ATF pipes
Note

⇒ page 9 .
♦ Check ATF level after renewing ATF pipes ⇒ page 65 .
1 - Bolt, 9 Nm
2 - Bolt, 9 Nm
ProCarManuals.com
3 - O-ring
❑ Renew
when fitting
4 - Bolt, 5 Nm
5 - Union nut, 29 Nm
6 - Bolt, 21 Nm
❑ First push on ATF pipes
with new O-rings by
hand until they engage.
❑ Secures ATF pipes to
gearbox
7 - ATF pipe
tional ATF filter to gear‐
box
8 - O-rings
❑ Renew
when fitting
9 - ATF pipe
❑ Supply pipe from gear‐
box to additional ATF
cooler
10 - ATF pipe
❑ Supply pipe to addition‐
al ATF cooler
11 - ATF pipe
❑ Return pipe from additional ATF filter

Audi A8 2003 ➤

13 - Bolt, 9 Nm
15 - Nut, 5 Nm
A - Additional ATF filter
B - Bracket
❑ For additional ATF filter and additional ATF cooler
C - Auxiliary ATF cooler
11.2 Cleaning ATF pipes and ATF cooler

ProCarManuals.com
♦ Hose, approx. 18 mm dia.

♦ Compressed air gun (commercially available)
♦ Safety goggles
– Before installing a replacement gearbox, always blow through
the ATF cooler and ATF pipes with compressed air (not more
than 10 bar).
– Also always renew additional ATF filter before installing re‐
placement gearbox.
Note
♦ If the ATF which emerges during cleaning is very dirty, the

pipes and ATF cooler must additionally be flushed out with
clean ATF.
♦ Removing and installing ATF pipes ⇒ page 82 .

filter
11. Servicing ATF cooling system on vehicles with 3.2 ltr. FSI engine and 2.8 ltr. FSI engine 83
Audi A8 2003 ➤
Removing
Note

⇒ page 9 .
ProCarManuals.com


– Raise vehicle.

Audi A8 2003 ➤

insulation panels.
– Remove bolts -arrows- and detach ATF cooler with additional

ATF filter (hoses remain connected).
ProCarManuals.com
low ATF cooler.
– Remove bolt -10- and detach ATF pipe from ATF cooler -5-.
– Loosen union nut -12-.
– Remove bolts -2- and detach additional ATF filter -1-.
Installing
– Renew O-ring -8-.
Tightening torques
Component Nm
Additional ATF filter to bracket 9
Pipe to additional ATF cooler 5
Union nut for ATF pipe to additional ATF filter 29
Bracket for additional ATF cooler and additional 9
ATF filter to body

cooler
Audi A8 2003 ➤
♦ Hose clamps, up to Ø 25 mm -3094-

ProCarManuals.com
Removing
Note

⇒ page 9 .

– Raise vehicle.

Audi A8 2003 ➤

insulation panels.

ProCarManuals.com
low ATF cooler.
– Remove bolts -10- and -11- and detach ATF pipes from addi‐
tional ATF cooler -5-.
– Clamp off coolant hoses -7- with hose clamps -3094- and de‐
tach hoses from additional ATF cooler.
– Remove bolts -6- and take off additional ATF cooler.
Installing
– Renew O-rings -8- and -9- on ATF pipes leading to additional
ATF cooler.
– Check coolant level ⇒ Rep. Gr. 19 .
Tightening torques
Component Nm
Additional ATF cooler to bracket 9
Pipe to additional ATF cooler 5
ATF filter to body
Audi A8 2003 ➤
11.5 Removing and installing bracket for ad‐

ditional ATF filter and additional ATF
cooler
Removing
– Raise vehicle.

insulation panels.
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Audi A8 2003 ➤
– Remove bolts -2- and -6-.

– Detach bracket.
Note
When renewing bracket first remove additional ATF filter and ad‐
ditional ATF cooler from bracket.
Installing
Note
Rubber buffers are fitted to the three attachment points at top of

bracket. Before installing, check they are seated correctly and re‐
new if necessary.
Tightening torques
Component Nm
Additional ATF cooler to bracket 9
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Additional ATF filter to bracket 9

ATF filter to body
Audi A8 2003 ➤
38 – Gears, control
1 Dismantling and assembling gearbox
1.1 Removing and installing end cover

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Caution
Do not run engine or tow vehicle with end cover removed or

when there is no ATF in the gearbox.
90 Rep. Gr.38 - Gears, control

Audi A8 2003 ➤
Note

⇒ page 9 .
Removing
– Raise vehicle.
– Drain off ATF ⇒ page 70 .
ProCarManuals.com

and right).
Note

exhaust pipe must not be bent more than 10° – otherwise it can
be damaged.
– Loosen clamps -1- and -2- ...
1. Dismantling and assembling gearbox 91

Audi A8 2003 ➤
– ... and tie up front left and front right exhaust pipes onto body
-arrows-.

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– First remove bolts -2- and -3- and then subframe securing
bolts -1- and -4-.
– Using engine and gearbox jack -V.A.G 1383 A- , lower gearbox
far enough to be able to access selector lever cable at selector
shaft lever at top of gearbox.

Audi A8 2003 ➤
– Remove bolts -3- at support bracket for selector lever cable.

– Use removal lever -80-200- to prise ball head -1- on selector
lever cable off selector shaft lever -arrow-.
Note
– Release electrical connector -arrow- and detach from gear‐

box.
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– Remove bolts -arrows- and take off end cover.
Note
Fit new bolts when installing.
Installing
Note
Renew gaskets and seals.

Audi A8 2003 ➤
– Slide new twin-lip oil seal -A- onto connector of gearbox control
unit -J217- , with twin-lips facing outwards.
– Clean sealing surfaces on gearbox housing and end cover.
– If any dowel sleeves were removed from gearbox housing or
cover, these must be re-fitted in same places.
– Fit a new gasket -A- for end cover.
Note
ProCarManuals.com
♦ The gaskets can be made of metal or paper. The new gasket

must be made of the same material as the old one ⇒ Electronic
parts catalogue .
♦ Make sure dowel sleeves are correctly seated.

Audi A8 2003 ➤
– Fit end cover and make sure that gasket does not move out of
position.
– Fit new bolts -arrows-: tighten in diagonal sequence finger-
tight to start with and then tighten to specified torque (see
table).
Note
Fit new bolts when installing.
– Carefully check installation position of twin-lip oil seal -A-: It

must be flush (twin-lips must not fold over).
– Push selector shaft lever into position “D”.
Note
In order to securely set position “D” on selector shaft lever move

the selector shaft lever on gearbox forwards as far as it will go,
into position “P”. Then shift it three positions to the back (opposite
to direction of travel).
– Install selector lever cable and support bracket ⇒ page 28 .

ProCarManuals.com
Note

♦ Take care not to bend selector shaft lever when pressing on
cable; support lever if necessary, as otherwise selector mech‐
anism can no longer be adjusted accurately.
– Install subframe ⇒ Running gear, front-wheel drive and four-

– Install exhaust system and perform stress-free alignment ⇒
Rep. Gr. 26 .
– Fill up with fresh ATF ⇒ page 70 .
Tightening torque
Component Nm
End cover to gearbox 15 + 90° 1)2)
• 1) Renew bolts.
• 2) 90° is equivalent to a quarter turn.
1.2 Removing and installing automatic gear‐

box control unit -J217-
– Remove end cover ⇒ page 90 .
– Remove automatic gearbox control unit -J217- ⇒ Servicing
multitronic 01J and 0AN; Rep. Gr. 38 .

Audi A8 2003 ➤
1.3 Cleaning selector shaft

• Automatic gearbox control unit -J217- is removed
The description can be found under ⇒ Servicing multitronic 01J
and 0AN; Rep. Gr. 38
1.4 Removing and installing hydraulic con‐

trol unit
– Remove end cover ⇒ page 90 .
– Remove hydraulic control unit ⇒ Servicing multitronic 01J and
0AN; Rep. Gr. 38 .
1.5 Removing and installing input shaft

– Remove gearbox:
♦ ⇒ “5.1 Removing gearbox - vehicles with 3.0 ltr. MPI engine”,
page 36
♦ ⇒ “5.3 Removing gearbox - vehicles with 3.2 ltr. FSI engine
and 2.8 ltr. FSI engine”, page 49
Remove input shaft ⇒ Servicing multitronic 01J and 0AN; Rep.
Gr. 38 .
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Audi A8 2003 ➤
39 – Final drive - differential

1 Checking gear oil in front final drive
Note

⇒ page 9 .

ProCarManuals.com
♦ Safety goggles
Note
The prescribed oil level is to be adhered to exactly; the gearbox

reacts very sensitively to over-filling.
Test sequence
– Carry out a short test drive in order to heat gear oil to approx.
60 °C.
If applicable, activate jacking mode when raising the vehicle ⇒
Running gear, front-wheel drive and four-wheel drive; Rep. Gr.
43 ; Adaptive air suspension .
– Drive vehicle onto a lifting platform or over an inspection pit in
order for it to be absolutely horizontal.
– Switch off engine and let gear oil drip into gearbox housing for
5 minutes.
1. Checking gear oil in front final drive 97

Audi A8 2003 ➤

insulation panels.
low gearbox.
WARNING
Wear safety goggles.
– Remove screw plug -arrow-.

– Check the oil level with a suitable improvised tool, e.g. bent
wire.
ProCarManuals.com
• Specification: oil level 8.5 mm below bottom lip of oil filler hole.
– Top up gear oil if necessary.
• Gear oil specification ⇒ page 5 .
Note
When servicing at the workshop the oil can also be filled up to the
bottom lip of the oil filler hole. However, it will then be necessary
to extract 0.2 litre in order to reach the correct oil level.
– Tighten new screw plug.

Tightening torque
Component Nm
Screw plug to gearbox 20 1)
• 1) Renew screw plug.
98 Rep. Gr.39 - Final drive - differential

Audi A8 2003 ➤
2 Servicing front final drive
2.1 Removing and installing flange shaft (left-side)

equipment required
♦ Drift -VW 295-
♦ Puller -T10037-
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
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Removing
• Gearbox installed
– Remove front left wheel.
Note
Secure brake disc with wheel bolts.
2. Servicing front final drive 99

Audi A8 2003 ➤


insulation panels.
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– Remove noise insulation in wheel housing (left-side)

-arrows-.
– Remove heat shield -1- for drive shaft (left-side).

– Remove drive shaft (left-side) ⇒ Running gear, front-wheel

Audi A8 2003 ➤
low gearbox.
– Bolt bottom support of puller -T10037- onto differential cover
-arrow-.
Note
In order to prevent damage to the needle bearings (polygon bear‐

ings) or the differential during removal, the flange shaft must be
kept straight when removing (pull out evenly).
– Pull out left flange shaft using puller -T10037- only until bear‐
ing on shaft is removed from gearbox housing.
Installing
– Clamp flange shaft into vice with jaw protectors to renew circlip
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for flange shaft.

– Press old circlip from groove of flange shaft using new circlip
-A-.
– Clean flange shaft.
– If oil seal is damaged, it must be renewed ⇒ Servicing multi‐
tronic 01J and 0AN; Rep. Gr. 39 .
– Drive in flange shaft using drift -VW 295- .
– Install drive shaft (left-side) ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. Gr. 40 .
– Check gear oil level in front final drive ⇒ page 97 .
Tightening torque
Component Nm
2.2 Removing and installing flange shaft

(right-side)

Audi A8 2003 ➤
Removing
• Gearbox in vehicle
– Remove front right wheel.
Note


insulation panels.
ProCarManuals.com

-arrows-.
– Remove heat shield -1- for drive shaft (right-side).

– Remove drive shaft (right-side) ⇒ Running gear, front-wheel

Audi A8 2003 ➤
– Unbolt bearing bracket for flange shaft -arrows-.

low gearbox.
– Pull out flange shaft (right side) together with bearing bracket.
Installing
– Clean flange shaft.
– If oil seal is damaged, it must be renewed ⇒ Servicing multi‐
tronic 01J and 0AN; Rep. Gr. 39 .
– Renew O-ring -arrow A- in flange shaft bearing bracket.
– Push spring -C- with cap facing outwards into drilling at end of
flange shaft -arrow-.
– Insert flange shaft -B- into gearbox.
ProCarManuals.com
Note
Make sure that spring -C- remains in flange shaft when inserting,
otherwise it might drop into gearbox.
– Bolt on bearing bracket for flange shaft -arrows-.

– Install drive shaft (right-side) ⇒ Running gear, front-wheel
– Check gear oil level in front final drive ⇒ page 97 .
Tightening torques
Component Nm
Flange shaft bearing bracket (right-side) to 25
gearbox
2.3 Renewing flange shaft oil seal (left-side)

0AN; Rep. Gr. 39
2.4 Renewing oil seal and grooved ball

bearing for flange shaft (right-side)
0AN; Rep. Gr. 39
2.5 Removing and installing cover for front

final drive

Audi A8 2003 ➤
♦ Puller -T10037-
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Removing
• Gearbox installed
If applicable, activate jacking mode when raising the vehicle ⇒
Running gear, front-wheel drive and four-wheel drive; Rep. Gr.
43 ; Adaptive air suspension .
– Remove front left wheel.
Note

Audi A8 2003 ➤


insulation panels.
ProCarManuals.com
– Remove bolts -1- and detach noise insulation bracket.

-arrows-.

Audi A8 2003 ➤

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side).
side).


Audi A8 2003 ➤
– Remove heat shield -1- for drive shaft (left-side).

– Remove front exhaust pipe ⇒ Rep. Gr. 26 .
– If fitted, unscrew bolts -1- and -2- and remove heat shield (left-
side) from gearbox.
– Unbolt left drive shaft from gearbox flange.
– Move drive shaft to rear.
ProCarManuals.com
low gearbox.
– Bolt bottom support of puller -T10037- onto differential cover
-arrow-.
Note
In order to prevent damage to the needle bearings (polygon bear‐

ings) or the differential during removal, the flange shaft must be
kept straight when removing (pull out evenly).
– Pull out left flange shaft using puller -T10037- only until bear‐
ing on shaft is removed from gearbox housing.
Caution
Make sure that flange shaft (right-side) is installed before re‐

moving cover for front final drive. The differential may other‐
wise drop out of the gearbox housing.

Audi A8 2003 ➤
– Unscrew bolts for front final drive cover in sequence

-11 ... 1-.
Caution
♦ Detach cover for front final drive slowly and carefully from
gearbox housing. The differential may otherwise fall out of
the gearbox.
♦ A differential which has fallen to the ground can no longer
be installed. Renew gearbox if differential has fallen to the
ground.
♦ Make sure that the bearing races and shims for the differ‐
ential do not drop out of the gearbox housing and the front
final drive cover.
♦ Bearing races and shims cannot be re-allocated to their
original positions by the workshop if they have dropped
out.
– Carefully take out differential -arrow-.

– Guide out differential downwards between gearbox and sub‐
frame.
ProCarManuals.com
Installing
– Check that magnet -arrow- is fitted under plastic cover in cover
for front final drive.
Note
Shown without plastic cover in illustration.
– Renew O-ring -1- in cover for front final drive.

– Make sure plastic cover -2- is seated tightly in cover for front
final drive.

Audi A8 2003 ➤
– Carefully install differential -arrow-.
– Fit cover for front final drive onto gearbox housing.

– Renew all bolts in cover for front final drive.
Caution
♦ Fit the three bolts with spacers at the positions shown

-arrows-.
♦ Use only the correct bolts (same as original equipment) ⇒
Electronic parts catalogue .
ProCarManuals.com
– Tighten bolts securing cover for front final drive in two stages
in the sequence shown:
1. Initially hand-tighten bolts in sequence -1 ... 11-.
2. Tighten bolts in sequence -1 … 11- in several stages to final
torque.
• Tightening torque: 25 Nm.
– Install flange shaft (left-side) ⇒ page 99 .
– Install front exhaust pipe (left side) ⇒ Rep. Gr. 26 .
– Install gearbox support (left-side) ⇒ page 60 .
– Fill up with gear oil and check gear oil level in front final drive
⇒ page 97 .
Tightening torque
Component Nm
Cover for front final drive to gearbox 25 1)
Bracket for noise insulation to subframe 10
• 1) Renew bolts.

Audi A8 2003 Multitronic 01j Front Wheel Drive Workshop Manual Edition 112007

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Service

Service Department. Technical Information

3 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2 Notes on CVT gearbox type “multi‐

The multitronic 01J is also referred to as “Continuously Variable

Guided Fault Finding

2 Rep. Gr.00 - Technical data

3 Code letters, gearbox allocation, ra‐

multitronic 01J.M 01J.B 01J.B

Allocation Model Audi A8 2003 ▸ Audi A8 2003 ▸ Audi A8 2003 ▸

multitronic 01J.M 01J.M 01J.M

multitronic 01J.M 01J.C 01J.B

multitronic 01J.C 01J.B 01J.M

3. Code letters, gearbox allocation, ratios, equipment 3

multitronic 01J.C 01J.B 01J.M

4 Rep. Gr.00 - Technical data

The ATF required for the multitronic 01J gearbox is different to

Checking ATF level and changing ATF ⇒ page 65

Front final drive

Checking oil level in front final drive ⇒ page 97 .

When the vehicle is towed, the selector lever must be set to

It is not possible to start the engine by means of tow-starting, for

6 Rep. Gr.00 - Technical data

6.1 Contact corrosion!

♦ On gearboxes built of magnesium, the bolts must always be

♦ We recommend using only Audi Genuine Parts.

6.2 General repair instructions

Prior to performing work with engine running, move selector

places in the Workshop Manual - are summarised here. They ap‐

or for other signs of damage.

8 Rep. Gr.00 - Technical data

♦ Threaded holes which take self-locking bolts or bolts coated

Tolerance variations make it possible to obtain the exact shim

6.3 Rules for cleanliness when working on

10 Rep. Gr.13 - Crankshaft group

2. Selector lever lock solenoid -N110-

3. Control unit for automatic gearbox -J217-

♦ The automatic gearbox control unit -J217- is monitored via

4. Hydraulic control unit

Removing and installing hydraulic control unit ⇒ Servicing

♦ Solenoid valve 1 -N88- (clutch cooling/safety shut-off).

♦ The valves are checked by self-diagnosis

5. tiptronic switch -F189-

♦ If malfunctions occur in the tiptronic switch -F189- , first check

12 Rep. Gr.37 - Controls, housing

6. Kick-down switch -F8-

♦ The kick-down -F8- switch is tested via Self-diagnosis.

7. Selector lever position display -Y6-

♦ If all the characters in the display light up together, this indi‐

♦ A blank display indicates defective wiring or a defective se‐

2 Checking ignition key removal lock

Prior to performing work with engine running, move selector

• It should only be possible to remove ignition key in selector

14 Rep. Gr.37 - Controls, housing

3 Checking selector mechanism

Prior to performing work with engine running, move selector

♦ It should not be possible to operate the starter while the se‐

• Selector lever is locked and cannot be shifted out of “P”posi‐