Transmission Fluid, Adding to Transmission after Repair
Transmission Fluid, Adding to Transmission after Repair
Special tools, testers and auxiliary items required
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Engine/Transmission Jack (V.A.G 1383 A)
• Transmission Fluid Hand Pump (VAS 6617)
• Protective eye-wear
The transmission must be filled after the following work or repairs:
• The center differential housing - 3 - was removed and all of the transmission fluid drained.
• The front final drive cover - 6 - was removed and the transmission fluid was completely drained.
• The transmission fluid cooler - 1 - was removed.
• The oil spaces in the front final drive and transfer case are consolidated. Therefore, they must always be checked and filled together.
• Both insufficient filling and overfilling affect the transmission function.
• Follow all applicable disposal regulations.
• Automatic transmission clean working conditions, refer to => [ Clean Working Conditions ] Clean Working Conditions.
• General repair instructions, refer to => [ Repair Information ] 09EA Transmission.
Procedure
The transfer case and front final drive have a combined oil system, but must be filled and checked separately in succession due to the different oil levels.
- Transmission mount and transmission support, removing, refer to => [ Transmission Mounting and Transmission Support ] 09EA Transmission
• The transmission support must be removed to gain access to the transfer case oil inspection and filler plug.
CAUTION!
For the following steps, note:
Do not support on the transmission oil pan or damage could result.
- Install an M12 x 100 bolt - 1 - with a nut - 2 - into the rear mount on the transmission fluid pan.
• - a - = 13 mm
- Position the (V.A.G 1383 A) plunger on the bolt head and lift the transmission until it is horizontal.
• The transmission must be level to check the axle oil.
• It must be raised or lowered accordingly with the (V.A.G 1383 A) after removing the tunnel crossmember.
- Place the (V.A.G 1782) under the transmission.
• Follow all applicable disposal regulations.
CAUTION!
Wear protective eye-wear.
- Remove transfer case oil inspection and filler plug - arrow -.
• The transfer case oil inspection and filler plug is located at the side of the transfer case housing and is installed from below - arrow -.
• In the illustration, the transfer case is partially from behind so that the transmission fluid level with filler opening is visible.
- Remove front final drive oil inspection and filler plug - arrow -.
- Slowly and evenly fill front final drive with axle oil over a duration of at least 5 minutes using the (VAS 6617) until oil escapes at the lower edge of the oil filler hole.
• The filling time of at least 5 minutes is necessary for the internal oil level to even out.
- Fill the transfer case housing with axle oil over a period of 5 minutes through the oil fill hole in the transfer case housing - arrow - using the (VAS 6617).
• The filling time of at least 5 minutes is necessary for the internal fluid level to even out.
After removing the hose, a small amount of axle oil always escapes and stands in the oil channel above the bolt.
If axle oil then drains lightly from the opening, the oil level in the transfer case is correct.
If no axle oil comes out:
- Add transmission fluid again until oil level is correct.
- Allow extra transmission fluid to drain from the oil filler hole.
- Install the old fluid inspection and filler plug.
- Install transmission support, refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview
- Install tunnel crossmember, refer to => [ Tunnel Crossmember ] 09EA Automatic Transmission.
- Perform stress-free exhaust system assembly.
Performing a Road Test
CAUTION!
Overfilling or underfilling the axle oil leads to transmission damage.
Follow all instructions precisely.
Before checking the oil level, a short road test must be done to bleed the oil system.
- Drive vehicle for 5 minutes at approximately 24 mph (40 km/h), at least 4 km.
• Ensure the axle oil cooler is filled with transmission oil. The center differential must be filled internally with gear oil, for example after removing it. Because the transfer case oil pump is only operated when driving, a short drive is necessary.
After the road test:
- Transmission fluid level, checking and adjusting, refer to => [ Transmission Fluid, Checking and Topping Off ] Transmission Fluid, Checking and Topping Off
Tightening Specifications
