Page 369 of 2492
AUTOMATIC TRANSMISSION
Automatic transmission (Removal - Refitting)
23
K7M
ENGINE
Lower the final drive until the tool touches the
ground.
Remove:
- the shock absorber upper mounting bolts,
- the sub-frame mounting bolts. Secure Mot. 1040-01 under the sub-frame.
Extract the engine and transmission assembly by
lifting the body.
Secure the spring-shock absorber assembly with
rope.
Separate the engine and transmission assembly
from the sub-frame by removing:
- the upper radiator hose,
- the power assisted steering reservoir and the
pump,
- the power assisted steering pipe mounting on
the automatic transmission.
Unclip the wiring loom from the sub-frame.
Position the lifting tool.
Remove:
- the right hand mounting,
- the engine tie-bar.
Release the driveshafts.
99588S
98755R
PRG23.3
23-18
Page 370 of 2492

AUTOMATIC TRANSMISSION
Automatic transmission (Removal - Refitting)
23
K7M
ENGINE
Separate the gearbox from the engine by :
- removing the starter motor,
- removing the bolts from the automatic trans-
mission sump.
Remove:
- the hoses on the exchanger, Lift the engine from the sub-frame.
91131S
- the converter bolts
- the bolts around the gearbox and the TDC sen-
sor.
Separate the automatic transmission from the en-
gine.
REFITTING (special notes)
Refit the converter by positioning it with respect
to the mounting bolts.
Tighten the bolts around the automatic transmis-
sion.
Refitting is the reverse of removal.
Aligning the engine sub-frame with the body will
be made easier by positioning two approximately
100 mmlong threaded rods in the two front sub-
frame-body mountings.
Tighten the sub-frame front mounting bolts to a
torque of 6 daN.m. and to a torque of 11 daN.m at
the rear.
Tighten all nuts and bolts to the re-
commended torque.
Fit the caliper mounting bolts using Loctite
FRENBLOC and tighten them to the correct tor-
que.
Press the brake pedal several times to bring the
pistons back into contact with the brake pads.
Fill:
- the cooling circuit and purge it (see chapter 19),
- the engine with oil if necessary.
NOTE : check that the steering shaft yoke spacer is
in place when refitting.
99586R2
23-19
Page 371 of 2492
AUTOMATIC TRANSMISSION
Differential output seal
23
REMOVAL
Using a screwdriver, remove the protective shield
(A).
1) REPLACING A LEFT OR RIGHT HAND LIP SEAL
SPECIAL TOOLING REQUIRED
B. Vi. 1322Tool for fitting differential
output seals
97725R
The shield is fitted tight.Using a screwdriver, remove the seal taking care
not to damage the differential bolt as well as the
output shaft.
97746S
PRG23.4
23-20
Page 372 of 2492
AUTOMATIC TRANSMISSION
Differential output seal
23
REFITTING
The lip seal (oiled) is positioned using toolB.Vi.
1322 (this determines the correct position of the
seal).
SPECIAL TOOLING REQUIRED
B. Vi. 1323Tool for fitting differential
output seals
97746-1S
Refit the protective heat shield in the opposite or-
der to removal using a 45 mm diameter socket.
95791-5R
2)REPLACING THE O-RING
The principle is the same on both sides, but only
one side must be removed at a time.
Special notes:
The is no flange on the driveshaft outputs, but ins-
tead a simple splined end piece protected by a
shield.
23-21
Page 373 of 2492
AUTOMATIC TRANSMISSION
Differential output seal
23
REFITTING
Refit the nut, turning the same number of turns as
when it was removed.
Align the marks made on the nut and the sump.
Replace the bolt (D) and the locking plate (E).
Refit the shield after having replaced the lip seal if
necessary (see paragraph 1).
Fill the final drive with oil.
95791-2R
REMOVAL
Drain the final drive and remove the shield, as ex-
plained in paragraph 1.
Locate the position of the nut (F) with respect to
the sump by putting a mark on one of the teeth
and on the face of the sump.
Remove bolt (D) and the locking plate (E) from the
nut using tool B.Vi. 1323, remove the nut, coun-
ting the number of turns it takes.Replace the O-ring on the nut, cleaning the seat
properly and lubricating the new seal with final
drive oil.
95791-6R
23-22
Page 374 of 2492
AUTOMATIC TRANSMISSION
Wiring
23
The new generation of A4.2 automatic transmission is fitted with monoblock wiring which means that many
of the intermediate connectors are no longer required. As a result, the method for repairing sensors or
switches is different.
PRG23.5
1 - 55 track connector on the automatic transmission computer
2 - Oil pressure sensor
3 - Electro-hydraulic interface (sealed connector)
4 - Inter engine unit connection
5 - Injection/diagnostic connector
6 - Pressure sensor connector
7 - Speed sensor
8 - Multifunction switch
23-23
Page 375 of 2492

AUTOMATIC TRANSMISSION
Wiring
23
REPAIRING COMPONENTS
Most of the components comprising the mono-
block wiring are not directly interchangeable.
Only the pressure sensor can be replaced without
having to cut the cable.
REPAIRING THE MULTIFUNCTION SWITCH
Initially, this is checked with the 55 track connec-
tor using the bornier Sus. 1228 and the table be-
low.
If this checking procedure highlights a fault, sec-
tion the cable 15 cm from the switch and check
between the section and the 55 track connector.
See the wiring diagram and table below. If one of the insulations or one of the continuities
is not assured, replace the multifunction switch
and refer to note 8074 for the repair procedure.
Refer to notes 8074 and 8075 for repairing the
speed sensor and using the locally made lifting
plate.
99613S4
NOTE: remember to distribute the connection
joints.
LEVER POSITION ASSURED CONTINUITIES ASSURED INSULATIONS
P/N Terminal 44 / EarthTerminals 51 and 52 / Earth
Terminal 27 / Terminal 46
R Terminal 27 / Terminal 46Terminals 44, 51 and 52 /
Earth
D NoneTerminals 44, 51 and 52 /
Earth
Terminal 27 / Terminal 46
3 Terminal 51 / EarthTerminals 44 and 52 / Earth
Terminal 27 / Terminal 46
2 Terminals 51 and 52 / EarthTerminal 44 / Earth
Terminal 27 / Terminal 46
1 Terminal 52 / EarthTerminals 44 and 51 / Earth
Terminal 27 / Terminal 46
99585S
23-24
Page 376 of 2492
AUTOMATIC TRANSMISSION
Wiring
23
Removing the wiring assembly is specific to the
AD4 A4.2.
REMOVAL
Put the vehicle on a two post lift.
Disconnect the battery.
Remove the front left hand wheel.
From the wheel arch:
Remove:
- the earth wire from the multifunction sensor,
- the multifunction sensor mounting bolt (A).
On the vehicle:
- position the lifting plate (tool made locally as
described on the next page).
99586R1
99182S
99613S
98750R1
Remove the engine torque traction link on the
gearbox side.
Remove the speed sensor (mounting bolt (B)).
Remove gear selector control ball joint (C).
Remove all the wiring assembly, taking note of its
position and mountings so that is refitted
correctly.
Disconnect the 52 track connector and the
connector in the inter engine unit. Fit the engine support tool with the support
bracket on the left hand side.
23-25