Manual-Audi-8Vel0BW Hybrid Four-Wheel Drive PDF

Service
Workshop Manual
Audi Q5 2008
8-speed automatic gearbox 0BW hybrid, four-wheel

drive
Edition 01.2014
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2014 Audi AG, Ingolstadt
D3E803B605A
Audi Q5 2008
8-speed automatic gearbox 0BW hybrid, four-wheel drive - Edition 01.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
3.3
3.4
4
4.1
4.2
5
5.1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . .
Safety precautions when using testers and measuring instruments during a road test . . . .
Notes on tow-starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allocation of gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission layout - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
6
7
7
8
9
9
9
10
12
13
13
13
15
15
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
4
5
6
Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual release from
position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
permittedselector
unless authorised
by AUDI AG. AUDI
Removing and installing
mechanism
. . . AG
. . does
. . . not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
............
Dismantling and assembling
selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detaching selector lever boot from selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing selector lever position display Y26 . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting selector lever cable to basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing tunnel cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing gearbox support with gearbox mounting . . . . . . . . . . . . . . . . . . . .
Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
17
17
19
20
21
23
24
29
32
35
35
35
40
41
45
48
48
61
70
72
72
72
74
75
76
77
78
Audi Q5 2008
6.1
6.2
6.3
7
7.1
7.2
7.3
7.4
Exploded view - ATF drain and inspection plugs in gearbox . . . . . . . . . . . . . . . . . . . . . . . .

Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - ATF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing ATF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning ATF lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing ATF lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
78
84
88
88
90
91
92
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1
1.1
1.2
1.3
2
2.1
3
3.1
3.2
3.3
3.4
3.5
3.6
ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing auxiliary hydraulic pump for gearbox oil . . . . . . . . . . . . . . . . . . . .
Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description - electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing basic setting for electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking hub of electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing oil seal for electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
93
95
100
105
105
110
110
111
111
112
119
119
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
3.2
4
4.1
4.2
4.3
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
ii
Contents
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - gear oil drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing ball bearing and mounting bracket for flange shaft (left-side) . . . . . . . . . . . . . .
Centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exploded view - centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing oil seal for rear splined shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear splined shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewingpermitted
ball bearing
for rear
splined
shaft
. . guarantee
. . . . . .or. accept
. . . .any
. . liability
....................
unless authorised
by AUDI
AG. AUDI
AG does. not
to the correctness of information in this document. Copyright by AUDI AG.
Renewing with
ballrespect
bearing
for centre differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of fitting locations - gearbox control system . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121
121
123
125
125
125
129
136
136
139
141
141
142
145
148
148
149
154
159
162
163
166
166
Audi Q5 2008
00
Technical data
Identification
(ARL003554; Edition 01.2014)

1.1 Gearbox identification, page 1
1.1
Gearbox identification
Location of code letters on gearbox

The gearbox code letters are located on the identification plate
on the underside of the gearbox. Fitting location of identifica
tion plate -arrow-.
Code letters and gearbox serial number

Example:
1-
Serial number of gearbox
2-
Model number
3-
Manufacturer's gearbox designation: 8P-55AH
4-
Gearbox code, in this example: NUL

Note
The code letters for the gearbox are also given on the vehicle data
stickers.
1. Identification
Audi Q5 2008
Safety precautions
2.1 Safety precautions when working on high-voltage vehi

cles, page 2
2.2 Safety precautions when working on vehicle, page 6
2.3 Safety precautions when working on vehicles with start/
stop system, page 7
2.4 Safety precautions when using testers and measuring in
struments during a road test, page 7
2.5 Notes on tow-starting and towing, page 8
2.1
Safety precautions when working on

high-voltage vehicles
2.1.1 Safety precautions for de-energising high-voltage sys

tem, page 2
2.1.2 Safety precautions for re-energising high-voltage sys
tem, page 3
2.1.3 General safety precautions and repair instructions, page
4
2.1.1
Safety precautions for de-energising

high-voltage system
The high-voltage system may only be de-energised by a suit

ably qualified person (Audi high-voltage technician). For a
definition and explanation of the relevant qualifications, please
refer to Electrical system, hybrid; Rep. gr. 93 ; General
warning instructions for work on the high-voltage system .
The system must first be de-energised before any work is done

on the high-voltage system Electrical system, hybrid; Rep.
gr. 93 ; De-energising high-voltage system .
The types of work for which the high-voltage system has to be

de-energised are indicated in the instructions for the proce
dure. For further information on the procedure for de-energis
ing the high-voltage system please refer to Electrical
system, hybrid; Rep. gr. 93 ; General warning instructions for
work on the high-voltage system .
Read and observe all additional warnings and descriptions for

work on the high-voltage system Electrical system, hybrid;
Rep. gr. 93 ; General warning instructions for work on the highvoltage system .
Note
In the event of queries or uncertainty regarding the terms elec

trically instructed person, Audi high-voltage technician, Audi
specialist for work on high-voltage systems or the high-voltage
system itself, the relevant importer must be contacted prior to the
start of all work.
For work that requires de-energising of the high-voltage system,
please note:
The high-voltage system must be de-energised according
to the
Guided Fault Finding routine in the vehicle diagnostic test
er , and ONLY by this method.
Rep. gr.00 - Technical data
Audi Q5 2008
DANGER!
High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
It must be definitely confirmed that the high-voltage sys
tem is de-energised. The system may only be de-ener
gised using the vehicle diagnostic tester via Guided Fault
Finding.
The qualified person (Audi high-voltage technician) con
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that it cannot be re-energised.
The ignition key and the maintenance connector for highvoltage system - TW - are then stored in a safe place by
the qualified person.
The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.
2.1.2
Safety precautions for re-energising

high-voltage systemProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The high-voltage system may only be
re-energised by a suit
ably qualified person (Audi high-voltage technician). For a
definition and explanation of the relevant qualifications, please
refer to Electrical system, hybrid; Rep. gr. 93 ; General
warning instructions for work on the high-voltage system .
Re-energising the high-voltage system Electrical system,

hybrid; Rep. gr. 93 ; Re-energising high-voltage system .

Note

start of all work.
The high-voltage system must be re-energised according to the
2. Safety precautions
Audi Q5 2008
DANGER!

The high-voltage system may only be re-energised by a
The system may only be re-energised using the vehicle
diagnostic tester via Guided Fault Finding.
The vehicle is then made ready for operation again by the
qualified person (Audi high-voltage technician).
2.1.3
General safety precautions and repair

instructions

Note

start of all work.
Audi Q5 2008
For work in the vicinity of high-voltage components and when vis
ually inspecting the high-voltage components:
DANGER!
Risk of fatal injury if high-voltage components are damaged.

Observe the following when working in the vicinity of high-volt
age components or wiring:
It is not permitted to use cutting or forming tools, other
sharp-edged tools or heat sources such as welding, braz
ing, soldering, hot air or thermal bonding equipment.
Before starting work, visually inspect the high-voltage
components in the areas involved.
Before working in the engine compartment, visually in
spect the power and control electronics for electric drive JX1- , electric drive motor - V141- , air conditioner
compressor - V470- and high-voltage wiring.
Before working on the underbody, visually inspect the
high-voltage wiring and covers.
Before working on the rear section of the vehicle, visually
inspect the high-voltage wiring and the electro-box with
the maintenance connector for high-voltage system - TW
-.
Visually inspect all potential equalisation

lines.
with respect to
the correctness of information in this document. Copyright by AUDI AG.
Check the following when making the visual inspection:
There must be no external damage on any component.
The insulation of the high-voltage wiring and potential
equalisation lines must not be damaged.
There must be no unusual deformation of the high-voltage
wiring.
All high-voltage components must be identified by a red
warning sticker.
For work that requires the ignition to be switched on, please note:
DANGER!
When working on a vehicle with the ignition switched on or

while the drive system is active, the engine can start unex
pectedly and exhaust fumes can cause a health hazard in
closed rooms. Moving parts can trap or draw in parts of the
body and/or clothing (safety hazard).
Before switching on the ignition, perform the following steps:
Move selector lever to position P
Activate parking brake
Switch off ignition.
Open bonnet
Connect battery charger (e.g. - VAS 5095A- ) to jump-start
connections of 12 V electrical system.
Switch on ignition
Audi Q5 2008
General safety precautions and safety precautions for work that
requires the ignition to be switched off
WARNING
Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.
WARNING
Working on vehicles with high-voltage wiring:
Do not support yourself or tools on high-voltage wiring or

associated components --> this can damage the insula
tion.
permitted
unless authorisedbent
by AUDI
High-voltage wiring must not
be excessively
orAG. AUDI AG does not guarantee or accept any liability
with respect
kinked --> this can damage the
insulation.
The round high-voltage connectors are colour-coded with

an external coloured ring and are provided with mechan
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec
tors, otherwise the connectors can be damaged.
2.2
Safety precautions when working on ve

hicle
Observe the following precautions to avoid possible injury and/or

damage to the vehicle:
WARNING
Accidents and injury can be caused if a gear is inadvertently

engaged while the engine is running.
Before performing any work with the engine running, set
the gearbox to position P and pull up the parking brake
button to apply the electromechanical parking brake.
Danger from toxic exhaust gases when engine is running.
When the engine is running, the exhaust system must al
ways be connected to the exhaust gas extractor.
Observe the following precautions to avoid possible injury and/or
irreparable damage to electrical and electronic components:
Switch off ignition before disconnecting and connecting test
equipment.
Audi Q5 2008
Caution
When disconnecting the battery there is a risk of serious dam

age to electronic components:
Observe the correct procedure for disconnecting the bat
tery.
Always switch off the ignition before disconnecting the
battery.
Disconnect battery Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
2.3
Safety precautions when working on ve

hicles with start/stop system
Please note the following when working on vehicles with start/stop

system:
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
On vehicles with activated start/stop system (this is indi
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
Therefore it is important to ensure that the start/stop sys
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
2.4
Safety precautions when using testers

and measuring instruments during a
road test
Observe the following precautions if test equipment has to be

used when road-testing the vehicle.
WARNING
Accidents can be caused if the driver is distracted by test

equipment or if test equipment is not secured.
Injuries can be caused if the passenger's airbag is triggered in
a collision.
The use of test equipment while driving causes distraction.
There is an increased risk of injury if test equipment is not

secured.
Always secure test equipment to the rear seat with a strap

and have it operated from there by a second person.
Audi Q5 2008
2.5
Notes on tow-starting and towing

Caution
Risk of irreparable damage to gearbox.

The selector lever must be in position N when the vehicle
is towed.
The vehicle must not be towed further than 50 km or faster
than 50 km/h.
Note
It is not possible to start the engine by tow-starting, for instance

if the battery charge is low or if the starter is not working.
Audi Q5 2008
Repair instructions
3.1 Rules for cleanliness, page 9

3.2 General notes, page 9
3.3 General repair instructions, page 10
3.4 Contact corrosion, page 12
3.1
Rules for cleanliness
Thoroughly clean all joints and connections and the surround

ing areas before dismantling.
Use cleaning fluid - D 009 401 04- to clean the gearbox and
its components.
Use lint-free cloths for cleaning; Audi recommends the WY
PALL X70 / WORKHORSE cloth from Kimberly-Clark Pro
fessional.
Seal off open lines and connections immediately with clean
plugs or sealing caps from engine bung set - VAS 6122- im
mediately.
Place removed parts on a clean surface and Protected
cover them
over.
by copyright.
Copying for private or commercial purposes, in part or in whole, is not
Use sheeting or 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.
Protect unplugged electrical connectors against dirt and mois
ture and make sure connections are dry when attaching.
3.2
General notes
Gearbox
The 8-speed automatic gearbox 0BW hybrid has eight hy
draulically actuated forward gears.
The 8-speed automatic gearbox 0BW hybrid has NO torque
converter. The electric drive motor - V141- is installed in its
place.
Driving off in 1st gear is controlled by clutch B in the gearbox
(also referred to as drive-away clutch B).
The disengagement clutch in the electric drive motor - V141disengages the engine from the electric drive motor - V141- .
The disengagement clutch is also designated disengagement
clutch F, or just clutch F.
Mechatronic unit
The mechatronic unit incorporates the following components as
a complete synchronised unit:
Hydraulic control system, automatic gearbox control unit J217 Sensors and actuators
The mechatronic unit is installed inside the gearbox in the ATF oil
pan.
Automatic gearbox control unit - J217The control unit is part of the mechatronic unit in the gearbox.
3. Repair instructions
Audi Q5 2008
The gear change points are calculated automatically (depending
on the driving situation and the resistance to motion).
Advantages:
Gear change points controlled for enhanced fuel economy
Maximum engine output is always available
Gear-change points are adapted individually in all driving sit
uations
Gear-change points are infinitely variable
Self-diagnosis
Before performing repairs to the automatic gearbox, determine
the cause of the fault as precisely as possible using Guided Fault
Finding.
To perform Guided Fault Finding, use vehicle diagnostic tester .
Variation of gear-change points for gradients
An additional gear change map automatically selects gear
changes for gradients. The gear changes are selected according
to accelerator pedal position and road speed.
Gear change map for extreme uphill gradients is matched to
engine output.
Gear change map for extreme downhill gradients is matched
to the braking effect of the engine.
The driver can achieve an increased engine braking effect by
directly selecting a specific gear via the tiptronic function, e.g.
when towing a trailer on downhill gradients.
3.3
General repair instructions
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
To avoid repetition, a number of generally applicable instructions
for the various repair procedures are summarised here. They ap
ply to the work described in this Manual.
Guided Fault Finding, Vehicle self-diagnosis and Test Instru
ments
Before servicing
the gearbox,
the by
cause
of AUDI
the AG
fault
should
be or accept any liability
permitted
unless authorised
AUDI AG.
does
not guarantee
with respect
the correctness
of information
in this document.
Copyright by AUDI AG.
identified as precisely
as to
possible
using
the vehicle
diagnostic
tester via Guided Fault Finding , Vehicle Self-diagnosis and Test Instruments .
Environmental and waste disposal regulations for oil
ATF, gear oil and any other type of oil must be handled with
care.
Dispose of drained oil properly.
Always adhere to statutory environmental and waste disposal
regulations.
Observe the information shown on the packaging of the oil.
Special tools
For a complete list of special tools used in this Workshop Manual
"Special tools, Workshop equipment"
10
Audi Q5 2008
Gearbox
Observe rules for cleanliness when working on gearbox
page 9 .
The engine must not be run and the vehicle must not be towed
if the centre differential housing has been removed or if there
is no ATF in the gearbox.
After installing, the following fluid levels must be checked and
topped up if necessary: ATF in gearbox page 78 and gear
oil in gearbox page 125 . Capacities page 13 , specifi
cations Electronic parts catalogue .
O-rings, oil seals and gaskets
Always renew 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
or for other signs of damage.
Thoroughly clean housing joint

surfaces
beforebyassembling.
permitted
unless authorised
AUDI AG. AUDI AG does not guarantee or accept any liability
Lightly lubricate the outer circumference and sealing lip of oil

seals with ATF before installing.
Lightly lubricate O-rings with ATF before installation to prevent

them from being 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 seal should face the side containing
the fluid.
When installing a new oil seal, position the seal such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
After installing, the following fluid levels must be checked and
topped up if necessary: ATF in gearbox page 78 and gear
oil in gearbox page 125 . Capacities page 13 , specifi
cations Electronic parts catalogue .
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.
Renew self-locking nuts and bolts.
Use a wire brush to clean the threads of bolts which are se
cured with locking fluid. Then apply locking fluid AMV 185 101 A1- to bolt threads before installing.
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.
The tightening torques stated apply to non-oiled nuts and
bolts.
Locking elements
Do not over-stretch circlips.
Renew circlips which have been damaged or over-tensioned.
3. Repair instructions
11
Audi Q5 2008
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
Protected
by copyright.
Copying
for privatemanufacturer.
or commercial purposes, in part or in whole, is not
Shims
Use a micrometer to measure the shims at several points.

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.
3.4
Contact corrosion
Contact corrosion can occur if unsuitable fasteners are used on

the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts Electronic parts catalogue .
Please note:
We recommend only genuine spare parts: these have been
fully tested.
We recommend the use of accessories approved by Audi.
Damage resulting from contact corrosion is not covered by the
warranty.
12
Audi Q5 2008
Technical data
4.1 Allocation of gearbox to engine, page 13

4.2 Capacities, page 13
4.1
Allocation of gearbox to engine
The following data can be found in the Electronic parts cata

logue .
Date of manufacture
Correct type of flange shafts
Correct type of electric drive motor - V141 Correct type of rear final drive according to code letters and
PR number
Designation
Gearbox
Allocation
8-speed automatic gearbox 0BW hybrid, four-wheel drive

Code letters
Manufac
fro
tured
m
to
Model
Engine
NUL, NWS, PFU

06.2011
Audi Q5 2008
2.0 ltr. TFSI - 155 kW
33 : 29 = 1.138
31 : 29 = 1.069
34 : 11 = 3.091
3.760
Primary drive
Spur gear drive to front axle
Front axle bevel gearing
Overall front drive ratio =
Primary drive x spur gear drive x
bevel gearing
Rear axle bevel gearing
43 : 13 = 3.308
Overall rear drive ratio =
3.764
Rear axle bevel gearing x primary
drive
Oil filling in front final
drive/transfer Separate
box
4.2
Capacities
ATF section in gearbox

Capacities
Initial filling by manufacturer
Fluid filling after gearbox has been
drained in workshop
Fluid change
Lubricant
8-speed automatic gearbox 0BW hybrid

Approx. 8.6 ltr.
Approx. 4.0 ltr.
Change interval for ATF Maintenance tables
ATF for 8-speed automatic gearbox 0BW hybrid
Electronic parts catalogue
4. Technical data
13
Audi Q5 2008
Caution
Risk of malfunction or gearbox failure.

Use only the ATF supplied as a replacement part for the
8-speed automatic gearbox 0BW hybrid Electronic
parts catalogue .
6 ATF, page 78
Protected byoil
copyright.
for private or commercial
Front final drive with separate
filling;Copying
for allocation
refer to purposes, in part or in whole, is not
page 13
Capacities
8-speed automatic gearbox 0BW hybrid
Initial filling
Oil filling after oil has been drained in
workshop
Oil change
No change required
1.0 ltr.
Approx. 0.9 ltr.
Lifetime filling; change only after repairs, e.g. if cover for front final
drive has been removed
Lubricant
Gear oil for automatic gearbox 0BW

2 Gear oil, page 125

Transfer box with separate oil filling; for allocation refer to
page 13
Capacities
8-speed automatic gearbox 0BW hybrid, four-wheel drive
Initial filling
Oil filling after oil has been drained in
workshop
Oil change
No change required
1.0 ltr.
Approx. 0.8 ltr.
Lifetime filling; change only after repairs, e.g. if centre differential

housing has been removed
Lubricant
2 Gear oil, page 125
14
Gear oil for 8-speed automatic gearbox 0BW hybrid

Audi Q5 2008
Transmission layout
5.1
Transmission layout - four-wheel drive
1 - Rear final drive

2 - Propshaft
3 - 8-speed automatic gearbox
0BW hybrid, four-wheel drive
With electric drive motor
- V141-
5. Transmission layout
15
Audi Q5 2008
32
Torque converter
Torque converter
The 8-speed automatic gearbox 0BW hybrid has NO torque con

verter. The electric drive motor - V141- is installed in its place
3 Electric drive motor, page 110 .
16
Rep. gr.32 - Torque converter
Audi Q5 2008
37
Controls, housing
Selector mechanism
1.1 Exploded view - selector mechanism, page 17

1.2 Exploded view - selector lever handle, page 19
1.3 Exploded view - selector lever cable, page 20
1.4 Checking selector mechanism, page 21
1.5 Manual release from position P, page 23
1.6 Removing and installing selector mechanism, page 24
1.7 Dismantling and assembling selector mechanism,
page 29
1.8 Removing and installing selector lever handle,
page 32
1.9 Detaching selector lever boot from selector lever handle,
page 35
1.10 Removing and installing selector lever position display
Y26 , page 35
1.11 Removing and installing selector lever cable,
page 35
1.12 Checking and adjusting selector lever cable, page 40
1.13 Adjusting selector lever cable to basic setting,
page 41
1.14 Renewing selector shaft oil seal, page 45
1.1
Exploded view - selector mechanism

WARNING

Prior to performing work with engine running, move se
lector lever to position P and pull up parking brake button
to apply the electromechanical parking brake.
Check selector mechanism before dismantling page 21 .
1. Selector mechanism
17
Audi Q5 2008
1 - Selector lever handle
1.2 Exploded view selector lever handle,
page 19
2 - Trim ring
page 19
3 - Selector lever boot
page 19
4 - Clamp
page 19
5 - Selector lever position dis
play - Y26 1.10 Removing and
installing selector lever
position display Y26 ,
page 35
6 - Nut
Secures selector mech
anism to body
4x
10 Nm
7 - Gasket
8 - Selector lever sensors con
trol unit - J587- and tiptronic
switch - F189 1.7.2 Removing and
sensors control unit J587 and tiptronic switch F189 , page 31
9 - Shift unit
Can only be renewed as a complete unit
1.6 Removing and installing selector mechanism,
page 24
Protected by copyright.
Copying for private or commercial purposes, in part or in whole, is not
10 - Selector lever lock solenoid - N110with respect to the correctness of information in this document. Copyright by AUDI AG.
1.7.1 Removing and installing selector lever lock solenoid N110 , page 29
11 - Gear selector position P switch - F305 Consists of two reed contacts on printed circuit board in selector lever lock solenoid - N110 Can only be renewed together with selector lever lock solenoid - N110- ,
1.7.1 Removing and installing selector lever lock solenoid N110 , page 29
12 - Noise insulation
Not fitted on all vehicles; allocation Electronic parts catalogue
13 - Retaining washers
For securing noise insulation to shift unit
4x
Renew
14 - Retaining clip
Secures selector lever cable to shift unit
18
Rep. gr.37 - Controls, housing
Audi Q5 2008
15 - O-ring
Renew
16 - Selector lever cable
Do not bend or kink
1.3 Exploded view - selector lever cable, page 20
17 - Sealing cap
Above selector lever lock solenoid - N110-
1.2
Exploded view - selector lever handle
1 - Clamp
To secure selector lever
handle to selector lever
Renew
1.8 Removing and in
stalling selector lever
handle, page 32
2 - Trim ring
1.9 Detaching selec
tor lever boot from se
lector lever handle,
page 35
3 - Selector lever handle
1.8 Removing and in
stalling selector lever
handle, page 32
4 - Selector lever boot
1.9 Detaching selec
tor lever boot from se
lector lever handle,
page 35
5 - Selector lever position dis

play - Y26 1.10 Removing and
position display Y26 ,
page 35
19
Audi Q5 2008
1.3
Exploded view - selector lever cable
1 - Bolt
For adjusting selector
lever cable
Secured to shift unit
13 Nm
2 - O-ring
Renew
3 - Retaining clip
Secures selector lever
cable to shift unit
4 - Bolt
8 Nm
2x
5 - Support bracket for selector
lever cable
6 - Nut
2x
Permanently mounted
on selector lever cable
Lock nuts secure selec
tor lever cable to sup
port bracket
13 Nm
7 - Selector lever cable
Do not bend or kink
1.11 Removing and
cable, page 35
Selector lever cable
must be renewed if rub
ber sleeve is damaged
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
1.12 Checking and adjusting selector lever cable, page 40
8 - Gearbox selector lever
20
Audi Q5 2008
1.4
Checking selector mechanism

WARNING

Before performing any work with the engine running, set
the gearbox to position P and pull up the parking brake
button to apply the electromechanical parking brake.
Observe safety precautions when the vehicle is moving
page 2 .
You must work through all the tests listed. If the specified
results are not obtained, perform Guided Fault Finding
using vehicle diagnostic tester .
Overview:
1. Checking operation
of selector
mechanism
or
page
21 purposes, in part or in whole, is not
Protected
by copyright.
Copying for private
commercial
2. Checking ignition key
page
22
with removal
respect to thelock
correctness
of information
in this document. Copyright by AUDI AG.
3. Checking interlock button on selector lever handle

page 23
1. Checking operation of selector mechanism
It should not be possible to operate the starter while the se

lector lever is in positions R, D/S 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 2 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.
The selector lever cannot be shifted out of N position until
the brake pedal is depressed.
Selector lever in position P:

Pull up parking brake button to apply electromechanical park
ing brake.
The selector lever is locked and cannot be shifted out of P

position, even when the interlock button on the handle is
pressed in.
Switch on ignition.
Do not depress brake pedal.
The selector lever is locked and cannot be shifted out of P

position, even when the interlock button on the handle is
pressed in. Selector lever lock solenoid - N110- blocks selec
tor lever.
Press and hold brake pedal.
Selector lever lock solenoid - N110- releases selector lever. It

is possible to shift into a driving gear. With interlock button on
selector lever handle pressed, shift selector lever slowly from
P position through R, N, and D/S and check whether the
selector lever position display - Y6- in the instrument cluster
shows the correct selector lever position in each case.
21
Audi Q5 2008
Pull selector lever from D/S towards the rear and release
selector lever.
The selector lever will return automatically to the position D/

S. The selector lever position display - Y6- in the instrument
cluster should change from D to S1 and then back to D
when the selector lever is pulled back once again.
Selector lever in position N and ignition switched on:

After a short delay: Selector lever is locked and cannot be

shifted out of N position even when pressing the interlock
button on the selector lever handle. Selector lever lock sole
noid - N110- blocks selector lever.
Depress brake pedal.
Selector lever lock solenoid - N110- releases selector lever.

Shifting into position D/S is possible.
Selector lever in position D/S, ignition switched on:

Shift selector lever into tiptronic gate.
The illuminated D/S symbol in the selector lever position dis

play - Y26- should go out and the + and symbols should
light up.
The selector lever position display - Y6- in the instrument clus

ter should change from D to M1 when the selector lever is
moved into the tiptronic gate.
If the specified results are not obtained, perform Guided Fault

Finding using vehicle diagnostic tester .
Adjust selector lever cable page 40 .
Check interlock button on selector lever handle page 23 .
Check ignition key removal lock.
2. Checking ignition key removal lock
ing brake.
Briefly press ignition key in ignition lock to reach position ig
nition on.
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.
It should not be possible to remove the ignition key when the

selector lever is in any position other than P.
Shift selector lever into position P.

Pull out ignition key.
It should only be possible to remove ignition key in selector

lever positionProtected
P. by copyright. Copying for private or commercial purposes, in part or in whole, is not
respect to to
the shift
correctness
of information
this document.
It should not bewith
possible
selector
leverinout
of P posi
tion with interlock button pressed and foot brake depressed.
If the ignition key removal lock does not function as described,

perform Guided Fault Finding using vehicle diagnostic tester .
22
Audi Q5 2008
3. Checking interlock button on selector lever handle
Check that interlock button moves freely:
Interlock button should move easily when pressed without

force.
Interlock button should spring back fully on its own when re

leased.
If specified results are not obtained, check that selector lever

handle is correctly installed page
32 by
. copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
Check whether selector rod or selector

lever
iscorrectness
bent. of information in this document. Copyright by AUDI AG.
with respect
to the
Function test:
Ignition switched on
Press the interlock button on the selector lever handle to move

the handle into the positions listed below; it should not be possible
to move the selector lever into these positions unless the interlock
button is pressed.
P to R (also depress brake pedal)
N to R (brake pedal also has to be depressed after a short
delay when vehicle is stationary)
R to P
If specified results are not obtained, check that selector lever
handle is correctly installed page 32 .
Check electrical connectors on selector mechanism.
Perform Guided Fault Finding using vehicle diagnostic
tester and check selector lever lock solenoid - N110- .
1.5
Manual release from position P

Note
If the battery is disconnected or discharged, the selector lever
cannot be shifted from position P. In this case, the vehicle

cannot be pushed or towed.
When you operate the manual release mechanism the selec
tor lever lock solenoid - N110- will release the lock without
current supply.
Procedure
Remove front ashtray insert.
Use screwdriver to pry off the cover cap in the ashtray housing
-arrow-.
Note
The shape of the cover cap may differ from the illustration.
23
Audi Q5 2008
Carefully insert tool (e.g. screwdriver) through centre opening
in ashtray housing and into cylinder -arrow- on selector lever
lock solenoid - N110- and at the same time press and hold
interlock button and move selector lever out of position P.
Note
This releases the selector lever lock in position P by way of
the locking lever -1-.
The cylinder -arrow- on selector lever lock solenoid - N110-
may be partially concealed by noise insulation or wiring (move

clear to one side).
1.6
Removing and installing selector mech

anism
Special tools and workshop equipment required

Removal lever - 80 - 200-
Engine and gearbox jack - V.A.G 1383 A-
Counterhold tool - T10172- with -T10172/5Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
24
Audi Q5 2008
Gearbox support - T10337-
Removing
Remove ashtray (front) General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing ashtray
(front) .
Unplug electrical connectors -2- and -4-.

Note
Insulating mat is not shown in illustration.

Remove insulating mat above shift unit.
Remove bolts -1, 3, 5, 6- and lower shift unit, keeping hold of
selector lever.
25
Audi Q5 2008
Remove rear noise insulation -2- General body repairs, ex
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
Detach electrical wiring at cross brace -1- and -2-.

Caution
Risk of damage to parts of the running gear.

Do NOT let the vehicle down on the wheels if the subframe,
steering rack or subframe cross brace are not properly instal
led.
Do NOT support the vehicle at the subframe or the subframe
cross brace (e.g. with a trolley jack).
Remove bolts -arrows- and detach subframe cross brace.
If fitted, remove bolts -arrows- and detach heat shield -1- for
propshaft.
Remove propshaft Rear final drive; Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .
26
Audi Q5 2008
Remove front silencer(s) Rep. gr. 26 ; Exhaust pipes/si
lencers; Removing and installing front silencer .
Set up gearbox support - T10337- on engine and gearbox jack

- V.A.G 1383 A- and position underneath gearbox.
Raise gearbox slightly.
WARNING
RiskProtected
of accident.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
Engine
and
gearbox
jack
- V.A.Gin this
1383
A- must
remain
with respect
to the
correctness
of information
document.
Copyright
by AUDIin
AG.
position when work is being carried out and must not be
left unattended.
Remove bolts -arrows- for tunnel cross member.
Lower gearbox by dimension -a- using engine and gearbox

jack - V.A.G 1383 A- .
Dimension -a- = 100 mm (maximum)
27
Audi Q5 2008
If fitted, remove heat shield -1- under shift unit General body
repairs, exterior; Rep. gr. 66 ; Strips / trim panels / extensions;
Exploded view - heat shield .
Use removal lever - 80 - 200- to press ball socket -1- on se

lector lever cable off gearbox selector lever.
Loosen nuts -2- on selector lever cable; this allows selector
lever cable to be detached from cable support bracket.
Note
Do not bend or kink the selector lever cable.

Take off shift unit.
Installing
Installation is carried out in reverse sequence; note the following:
Tightening
torques
page
17for private or commercial purposes, in part or in whole, is not
Protected
by copyright.
Copying
Note
Before installing, lightly lubricate ball socket on selector lever
cable with polycarbamide grease - G 052 142 A2- .

Install heat shield General body repairs, exterior; Rep. gr.
66 ; Strips / trim panels / extensions; Exploded view - heat
shield .
Install tunnel cross member page 72 .
Check selector mechanism page 21 .
Perform stress-free alignment of exhaust system Rep. gr.
26 ; Exhaust pipes/silencers; Stress-free alignment of exhaust
system .
Install propshaft Rear final drive; Rep. gr. 39 ; Propshaft;
Exploded view - propshaft .
Install subframe cross brace Running gear, axles, steering;
Rep. gr. 40 ; Subframe; Exploded view - subframe .
Install noise insulation General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
Install ashtray (front) General body repairs, interior; Rep.
(front) .
28
Audi Q5 2008
1.7
Dismantling and assembling selector

mechanism
1.7.1 Removing and installing selector lever lock solenoid

N110 , page 29
1.7.2 Removing and installing selector lever sensors control
unit J587 and tiptronic switch F189 , page 31
1.7.3 Removing and installing gear selector position P switch
F305 , page 32
1.7.1
Removing and installing selector lever

lock solenoid - N110-
Removing
(front) .
Unscrew nuts -1, 3, 5, 6- a few turns, but do not remove com

pletely.
Note
This will lower the shift unit slightly and facilitate removal.
29
Audi Q5 2008
Caution
The selector mechanism can be damaged by broken retaining

clips, retaining tabs or other objects.
Make sure that no parts or objects drop into the selector
mechanism. If this happens, the selector mechanism will
have to be renewed!
Release retaining tabs -2- and -3- in direction of -arrow-, lift
front of sealing cap -A- slightly and hold in that position.
Note
This prevents the retaining tabs from engaging again.

Using a screwdriver, release top retaining tab -1- of sealing
cap from retainer -B- in direction of -arrow- and lift out sealing
cap -A-.
Unplug electrical connector on selector lever lock solenoid N110- .
Press retaining hook -A- in direction of -arrow- and hold in this
position.
Note
The shift unit must be renewed if the retaining hook -A- breaks
off.
Tilt bottom part of selector lever lock solenoid - N110- out in

direction of -arrow- so that ball head -1- disengages from op
erating lever on selector mechanism.
Detach selector lever lock solenoid - N110- .
Installing
Tightening torque page 17
Turn ball head -1- into correct position for installation.

Guide selector lever lock solenoid - N110- into selector mech
anism at an angle from above and tilt bottom part in opposite
direction of -arrow-.
30
Audi Q5 2008
Ball head -1- must engage fully in operating lever on selector

mechanism; press home with a small screwdriver if necessary.
Secure selector lever lock solenoid - N110- to retaining hook

-A-.
Place cover -A- over selector lever lock solenoid - N110- and
carefully engage -1 ... 3-.
Attach electrical connectors.
Check function of selector mechanism before continuing as
sembly page 21 .
(front) .
1.7.2

sensors control unit - J587- and tiptronic
switch - F189-
Note
Protected
by copyright.
for private
commercialswitch
purposes,-in part or in whole, is not
Selector lever sensors
control
unitCopying
- J587andortiptronic
F189- are integrated
in
one
unit.
Removing
Remove selector lever handle page 32 .
Remove multimedia system operating unit - E380- Com
munication; Rep. gr. 91 ; Infotainment system; Removing and
installing multimedia system operating unit - E380- .
(front) .
31
Audi Q5 2008
Unplug electrical connector -1-.
Release 4 retaining tabs -arrows- and lift out selector lever
sensors control unit - J587- with tiptronic switch - F189- .
Note
-Arrows A- can be disregarded.

Installing
Installation is carried out in reverse sequence; note the
following:
Make sure selector lever sensors control unit - J587- with tip
tronic switch - F189- clicks in place with 4 retaining tabs
-arrows-.
Secure wiring for selector lever position display - Y26-arrows-.
(front) .
Install selector lever handle page 32 .
1.7.3
Removing and installing gear selector

position P switch - F305-
Fitting location: Gear selector position P switch - F305- con

sists of two reed contacts (-1- and - 2-) and is installed on
printed circuit board -B- in selector lever lock solenoid - N110-A-.
Gear selector position P switch - F305- can only be renewed to
gether with selector lever lock solenoid - N110- .
N110 , page 29 .
1.8

handle

Removal wedge - 3409-
32
Audi Q5 2008
Hose clip pliers - V.A.G 1275-
Removing
ing brake.
Shift selector lever into position N.
Note
The selector lever handle is removed together with the selector

lever boot.
Carefully pry out selector lever boot at the side -arrows- using
removal wedge - 3409- or a small screwdriver and turn boot
inside out over selector lever handle.
Use a cable tie to secure the interlock button in pulled-out po
sition -arrow-, as shown in the illustration.
33
Audi Q5 2008
Turn selector lever boot -1- inside out over selector lever han
dle -2-.
Release clamp -arrow- and detach selector lever handle to
gether with selector lever boot. Avoid touching the interlock
button.
Installing
Note
To install the selector lever handle the interlock button has to
be pulled out to the stop and must be secured with either a

cable tie -arrow- or with the assembly aid supplied together
with the new handle.
If, by mistake, the interlock button has not been secured, it
must not be pulled out of the selector lever handle by means

of mechanical tools. Apply a compressed-air gun at the bottom
of the handle and press the interlock button out with com
pressed air.
Attach new clamp -arrow- to selector lever handle.

Place selector lever handle fully on selector lever - interlock
button points towards the driver.
The handle must engage in the annular groove on the selector

lever.
Remove the cable tie or assembly aid, allowing the interlock

button mechanism to engage in the vertical groove on the se
lector lever. If necessary, press the interlock button into the
selector lever handle.
Move selector lever to positions R and S to check button
mechanism.
If the selector lever cannot be moved into the above positions,

the handle must be removed again page 32 .
Secure selector lever handle -2- on selector lever by tightening

clamp -arrow- using hose clip pliers - V.A.G 1275- .
Clip retaining frame for selector lever boot -1- onto centre con
sole.
34
Audi Q5 2008
1.9
Detaching selector lever boot from se

lector lever handle
Removing
Remove selector lever handle page 32 .
Tie together spring tips -1- on selector lever handle using cable
tie -3- as shown in illustration.
Slide sleeve -2- of selector lever boot past retaining tabs on
spring tips -arrow-.
Remove cable tie and detach sleeve with selector lever boot
from selector lever.
Installing
Fitting position of selector lever boot:
The longer side of the retaining frame for the selector lever
boot faces the driver's side.
Protected lever
by copyright.
Copying
private32
or commercial
purposes, in part or in whole, is not
Install selector
handle
for
page
.
1.10

position display - Y26-
Removing
ing brake.
Shift selector lever to position S.
Release retaining spring -2- and detach selector lever position

display - Y26- -item 1- -arrow-.
Unplug electrical connector.
Installing
Perform installation in reverse sequence of removal.
1.11

cable
35
Audi Q5 2008
Socket and key - T40031Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing
ing brake.
Shift selector lever to position D/S.
36
Audi Q5 2008
Insert socket and key - T40031- through access hole -arrowin selector mechanism and slacken bolt on selector lever cable
approx. one turn.
Note
Only loosen clamping bolt do not remove.
Clamping bolt can only be accessed with selector lever in po
sition D/S.
With clamping bolt loosened, selector lever must remain in
position D/S.
If fitted, remove bolts -arrows- and detach heat shield -1- for
propshaft.

lector lever cable off gearbox selector lever -4-.
Loosen nuts -2- on selector lever cable; this allows selector
lever cable to be detached from cable support bracket -3-.
Note
If fitted, remove heat shield -1- under shift unit General body
repairs, exterior; Rep. gr. 66 ; Strips / trim panels / extensions;
Exploded view - heat shield .Protected
37
Audi Q5 2008
If fitted, remove four retaining washers -1-.
Note
Renew retaining washers.

If fitted, pull off noise insulation -2- and slide forwards or detach
from selector lever cable.
Pull out retaining clip -1- for selector lever cable from the side.
Pull selector lever cable -2- out of selector mechanism.
Installing
Tightening torques page 20

Note
Renew O-ring on selector lever cable.

Before installing, lightly grease cable eye and ball socket on
selector lever cable with polycarbamide grease - G 052 142

A2- .
Slide selector lever cable -3- through hole in noise insulation

-2- (if originally fitted).
38
Audi Q5 2008
Fit O-ring -1- on selector lever cable.
Insert selector lever cable -2- into shift unit -arrow-.
Secure selector lever cable -2- with retaining clip -3-.
Installation position: angled end of retaining clip -1- must point

towards selector mechanism.
If originally fitted, secure noise insulation -2- with four new re

taining washers -1-.
Press gearbox selector lever -1- on gearbox towards the rear

as far as it will go -arrow- until parking lock engages.
Note
When the parking lock has engaged it should no longer be pos

sible to rotate both front wheels in one direction at the same time.
Then push gearbox selector lever forward 3 notches so that
gearbox is in position D.
Check that the selector lever inside the vehicle is in position
D/S.
39
Audi Q5 2008
Press selector lever cable -1- onto cable support bracket -3-,
slightly loosening both nuts -2- if necessary.
Carefully press ball socket of selector lever cable -1- onto
gearbox selector lever -4- in this position.
Note
Take care not to bend gearbox selector lever when pressing on

cable; support lever if necessary, as otherwise selector mecha
nism can no longer be adjusted accurately. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Secure selector lever cable on cable support bracket by lock

ing both nuts -2-.
Note

Check selector lever cable and adjust if necessary
page 40 .
1.12
Checking and adjusting selector lever

cable

Socket and key - T40031-
40
Audi Q5 2008
Procedure

ing brake.
approx. one turn.
Note
Only loosen clamping bolt approx. one turn - do not remove.
sition D/S.
position D/S.
Carefully move selector lever slightly forwards and backwards,

without shifting lever into a different selector lever position.
The selector lever cable is thereby slackened.
Use socket and key - T40031- to tighten clamping bolt in this
position, taking care not to touch selector lever.
If selector mechanism is not functioning correctly after adjusting
selector lever cable, proceed as follows:
Adjust selector lever cable to basic setting page 41 .
1.13
Adjusting selector lever cable to basic

setting
Protected
copyright.
Copying forequipment
private or commercial
Special
toolsbyand
workshop
required
Diagnostic
tester , e.g. vehicle diagnostic, testing and infor
mation system - VAS 5051B-
41
Audi Q5 2008
Socket and key - T40031-
42
Audi Q5 2008
Procedure
Guided Fault Finding using the vehicle diagnostic tester has

been completed; all faults repaired.

ing brake.
Using the vehicle diagnostic tester in Guided Functions
mode, select the following menu items:
02 - Gearbox electronics 0BW I J217
02 - Read measured values
Select the value for Gear position from the menu on the
vehicle diagnostic tester .
Compare the following readings:
Value for Gear position on vehicle diagnostic tester
Selector lever position
Gear indicated on selector lever position display - Y26- (on

selector mechanism)
Selector lever position display - Y6- in instrument cluster
Requirement:
The displays should match
If the displays do not match:

If the displays cannot be matched by adjusting the selector lever
cable:
Adjust selector lever cable to basic setting:

lector lever cable off gearbox selector lever -4-.
Loosen nuts -2- at selector lever cable.
Note

Press gearbox selector lever -1- on gearbox towards the rear
as far as it will go -arrow- until parking lock engages.
Note
When the parking lock has engaged it should no longer be pos

sible to rotate both front wheels in one direction at the same time.
Then push gearbox selector lever forward 3 notches so that
gearbox is in position D.
43
Audi Q5 2008
Selector lever must be in position D/S.
approx. one turn.
Note
Only loosen clamping bolt approx. one turn - do not remove.
sition D/S.
position D/S.
Leave
socket
and key
- T40031to clamping
permitted
unless authorised
by AUDI
AG. AUDI attached
AG does not guarantee
or acceptbolt.
any liability
Carefully move selector lever slightly forwards and backwards,

without shifting lever into a different selector lever position.
The selector lever cable is thereby slackened.

Select the value for Gear position from the menu on the
vehicle diagnostic tester .
Compare the following readings:
Value for Gear position on vehicle diagnostic tester
Selector lever position
Gear indicated on selector lever position display - Y26- (on
selector mechanism)
Selector lever position display - Y6- in instrument cluster
Requirement:
The displays should match
44
Audi Q5 2008
Carefully press ball socket of selector lever cable -1- onto
gearbox selector lever in this position.
Note
Take care not to bend gearbox selector lever when pressing
on cable; support lever if necessary, as otherwise selector

mechanism can no longer be adjusted accurately.
Item -3- can be disregarded.

Secure selector lever cable on cable support bracket by lock
ing both nuts -2-.
Use socket and key - T40031- to tighten clamping bolt in this
position, taking care not to touch selector lever.
1.14
by copyright.
Copyingoil
for private
RenewingProtected
selector
shaft
sealor commercial purposes, in part or in whole, is not
respect to the correctness

Special tools and workshopwith
equipment
requiredof information in this document. Copyright by AUDI AG.
45
Audi Q5 2008
Procedure
Unscrew nuts -arrows- and remove front silencer(s) Rep.
gr. 26 ; Exhaust pipes/silencers; Removing and installing front
silencer .
Remove ATF oil pan page 95 .
Remove ATF filter page 90 .
Remove mechatronic unit page 105 .

Note
Knock roll pin -2- out of shaft

of unless
gearbox
selector
using
permitted
authorised
by AUDIlever
AG. AUDI
AG does not guarantee or accept any liability
a suitable punch -1-.
Pull off gearbox selector lever with shaft -arrow-.

Pry out oil seal with small screwdriver.
Lubricate outer circumference and space between sealing lips
of new oil seal with ATF.
Installation position: open side of oil seal points towards gear

box
46
Audi Q5 2008
Fit oil seal on gearbox housing and press in as far as stop
-arrow- using a suitable socket.
Insert gearbox selector lever with shaft.
Note
If the operating rod for the locking pawl has slipped too far towards
the rear, it can only be pulled forward again -arrow 2- if the locking
pawl is pressed at the same time -arrow 1-.
Drive roll pin -2- into shaft of gearbox selector lever until flush
using a suitable punch -1- .
Install mechatronic unit page 105 .
Install ATF filter page 90 .
Install ATF oil pan page 95 .
Install front silencer(s) Rep. gr. 26 ; Exhaust pipes/silenc
ers; Exploded view - silencers .
Fill up with ATF page 84 .
47
Audi Q5 2008
Removing and installing gearbox
2.1 Removing gearbox, page 48

2.2 Installing gearbox, page 61
2.3 Tightening torques for gearbox, page 70
2.1
Removing gearbox
Special tools and workshop

equipment required
Support bracket - 10 - 222
A Removal lever - 80 - 200 Engine and gearbox jack V.A.G 1383 A Used oil collection and ex
traction unit - V.A.G 1782 Engine bung set - VAS
6122 Counterhold tool - T10172with -T10172/5-
Hose clamps, up to 25 mm - 3094-
48
Audi Q5 2008
Counterhold tool - T10355-
WARNING
Before using the gearbox support - T40173- it is important to

check that you have the correct version of this tool.
Older versions of this tool must not be used and must be re
placed with the latest version.
Distinguishing features of latest version:
On the latest version of this tool, the parts shown in -red- in the
illustration -arrows- have a yellow chromated finish.
If the support does not meet the specifications, proceed as fol
lows:
Germany: Contact Matra to have the tool replaced.
All countries except Germany: Contact your Importer to
have the tool replaced.
2. Removing and installing gearbox
49
Audi Q5 2008
Preparing gearbox support - T40173- :
Mounting block attached at -position 1- must be rotated so that
the shorter side faces upwards.
Mounting block attached at -position 2- must be rotated so that
the longer side faces upwards.
Mounting blocks attached at -position 3- must be rotated so
that the shorter side faces upwards.
Removing gearbox
Observe safety precautions page 2 .
Electromechanical
parking
brakeCopying
is released.
Protected
by copyright.
for private or commercial purposes, in part or in whole, is not
Shift selector lever with

to position
D/S.
respect to the
correctness of information in this document. Copyright by AUDI AG.
Bring front wheels into straight-ahead position.

De-energising high-voltage system
WARNING
Observe general warning instructions for work on the highvoltage system Electrical system, hybrid; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys
tem .
The high-voltage system must be de-energised according to the
DANGER!

Finding.
50
Audi Q5 2008
Note
De-energising high-voltage system:
Connect vehicle diagnostic tester.
Select Guided Fault Finding mode.
Using the GoTo button, select the following menu options in
succession.
Function/Component Selection
Body
Electrical system
Self-diagnosis-compatible systems
8C - Hybrid battery management -J840
8C - Hybrid battery management, functions
51 - De-energise high-voltage system (Rep. Gr. 93)
Remove engine cover panel -arrows-.
Loosen wheel bolts on both front wheels.
Raise vehicle.
Remove both front wheels.
Remove noise insulation -1- and -2- General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Removing and instal
ling noise insulation .
Remove rear silencer with centre silencer Rep. gr. 26 ;
Exhaust pipes/silencers; Exploded view - silencers .
51
Audi Q5 2008
Remove bolts -arrows- and detach heat shield -1- for prop
shaft.

Remove front silencer(s) Rep. gr. 26 ; Exhaust pipes/si

lencers; Removing and installing front silencer .
Detach electrical wiring at cross brace -1- and
-2-.
Caution

led.
cross brace (e.g. with a trolley jack or similar).
52
Audi Q5 2008
Remove noise insulation -1- for drive shaft from wheel housing
on both sides.
Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).
Note
The installation position is shown with the gearbox removed.

Remove subframe shield (below drive shaft, right-side)
Running gear, axles, steering; Rep. gr. 40 ; Subframe; Re
moving and installing subframe shield .
Unbolt drive shafts (left and right) from flange shafts on gear
box.
Remove bolt -3- and detach potential equalisation line -2- from
gearbox.
53
Audi Q5 2008
Caution
Risk of damage to coil connector for airbag.

Front wheels must be in straight-ahead position when uni
versal joint is detached from steering rack.
Do not change position of steering wheel or steering rack
after this step (if necessary, fix steering wheel in position
with adhesive tape).
Remove bolt -arrow- for universal joint Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Exploded view steering column .
Detach intermediate steering shaft -1- from steering rack -2-.
Unplug electrical connector -1- for vehicle signals (CAN bus
and terminal 15) from power steering control unit - J500- (to
do this, release retainer and press down release catch).
Unplug electrical connector -2- for supply voltage (terminal 30)
from power steering control unit - J500- (to do this, release
retainer -arrow- and press down release catch).
Unplug electrical connector -A- for auxiliary hydraulic pump 1

for gearbox oil - V475- from right side of gearbox.
Then unclip wire from gearbox -arrows- and tie up to one side.
Unplug connector -A- for high-voltage wiring harness for drive

motor - PX2- and connector -B- on drive motor rotor position
sender 1 - G713- at top left of gearbox.
Unplug connector -C- for Lambda probe after catalytic con
verter - G130- and detach from cable tie -arrow-.
Detach high-voltage wiring harness for drive motor - PX2- from
electric drive motor - V141- on gearbox as follows:
54
Audi Q5 2008
Take care not to damage red warning label.
WARNING

tion.
High-voltage wiring must not be excessively bent or

kinked --> this can damage the insulation.

Remove bolts -arrows- and remove cover -1- from connection

box.
Note
Connector -2- has already been removed.
Remove bolts -2-.

Note
Bolts -2- secure the high-voltage wiring harness for drive motor PX2- to the electric drive motor - V141- .
Unscrew bolts -arrows- securing wiring retainer -1Caution
Risk of damage to high-voltage wiring.
The high-voltage wires must always be pulled off upwards.
Do NOT rotate or tilt the wiring; otherwise this can damage

the mechanical coding of the high-voltage wires.
for private or
commercial
purposes, in box
part orone
in whole, is not
Pull high-voltage
wiresCopying
-1- upwards
out
of connection
permitted
unless
authorised
by AUDI AG. AUDI AG does not guarantee or accept any liability
after the
other
and
tie
up.
55
Audi Q5 2008
Unscrew bolts -1- and -2- and remove bracket for catalytic
converter.
Remove catalytic converter Rep. gr. 26 ; Emission control

system; Removing and installing catalytic converter .
Clamp off coolant hoses -1- and -2- for cooling hybrid drive
using hose clamps, up to 25 mm - 3094- .
Mark coolant hoses -1- and -2- for reinstallation.
WARNING
Risk of scalding from hot steam and hot coolant.

The cooling system is under pressure when the engine is
hot.
Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
Release hose clips at hose connections using spring-type clip
pliers and disconnect coolant hoses.
Seal off coolant connections and hose connections with suit
able plugs from engine bung set - VAS 6122- .
with reg
respect to the correctness of information in this document. Copyright by AUDI AG.
Then remove bolts -arrows- securing bracket for coolant
ulator unit.
56
Audi Q5 2008
At top left of gearbox, loosen bolts -arrows- securing bracket
for engine wiring harness -B- and bracket for coolant regulator
unit -A- and tie up brackets with coolant hoses.
Then remove bolts -1- and -2- securing ATF lines to gearbox.
Remove bolts securing ATF lines on engine -arrow 1- and

gearbox -arrow 2-.
Note
Place used oil collection and extraction unit - V.A.G 1782- or drip
tray below gearbox to catch escaping ATF.
Disconnect ATF lines from gearbox and tie up.
Seal off open lines and connections with clean plugs from en
gine bung set - VAS 6122- .
Caution
The gearbox control unit (mechatronic unit) can be damaged

by electrostatic discharge.
Do not touch contact pins in gearbox connector with bare
hands.
Touch gearbox housing with your hand (without gloves) to dis
charge any static electricity.
Turn fastener anti-clockwise -arrow- and unplug electrical con
nector on gearbox.
Remove bolts -3- and detach selector lever cable with cable
support bracket from gearbox. Tie cable up if necessary.
Note
57
Audi Q5 2008
Remove bolts -2 5- securing engine to gearbox from gear
box side.
Note
Bolts -3- and -5- also secure brackets for pipes and/or wiring
on gearbox.
Bolt -2- secures the starter to the gearbox and has an addi
tional spacer sleeve -arrow-.
Take off this sleeve when pulling out the top securing bolt for
the starter.
Set up support bracket - 10 - 222 A- with racks - 10 - 222 A /

1- and adapters - 10 - 222 A /3- as shown in illustration.
Hook spindles - 10 - 222 A /11- onto engine lifting eyes (front
and rear).
Remove torque reaction support (bolts -1-) and torque cross

member -3- (bolts -2-) Rep. gr. 10 ; Assembly mountings;
Exploded
view
- assembly
mountings
. purposes, in part or in whole, is not
Protected by
copyright.
Copying for private
or commercial
58
Audi Q5 2008
Pull cover -1- off bottom of gearbox -arrow-.
To slacken bolts for electric drive motor - V141- , counterhold

crankshaft with counterhold tool - T10355- .
Note
When you then turn the crankshaft, only turn crankshaft in di
rection of engine rotation.
-Arrow- can be disregarded.
Remove 3 bolts -arrow- securing electric drive motor - V141to drive plate (turn crankshaft 120 in direction of engine
rotation each time).
Remove bottom securing bolt -arrow 1- for starter from engine

side.
Remove starter -A- (pay attention to end seal -B- in starter
aperture) Electrical system; Rep. gr. 27 ; Starter; Removing
and installing starter .
Note
The starter must be removed so that the end seal -B- can be fitted
correctly in the starter aperture when the gearbox is installed.
Remove engine/gearbox securing bolt -arrow 2-.
59
Audi Q5 2008
Remove engine/gearbox securing bolts -7 10-.
Note
Do not remove securing bolts -6- at this stage.

Caution
Risk of leaks on ATF oil pan.

Do not apply gearbox support - T40173- at ATF oil pan.
Protected
Position
engine and gearbox jack - V.A.G 1383 A- with gear
box support
- T40173(already
page
50any
) under
permitted
unless authorised
by AUDI AG.
AUDI AG prepared
does not guarantee
or accept
liability
neath
gearbox.
with
respect
Gearbox support must be positioned as follows at front of
gearbox:
On left side of gearbox, mounting block -2- must be positioned

against gearbox housing behind aperture for electric drive mo
tor - V141- .
On right side of gearbox, mounting block -1- is positioned

against front final drive.
Use tensioning strap -1- to secure gearbox.
Note
For illustration purposes, the gearbox support - T40173- is not

shown.
Remove last bolt securing engine to gearbox.
60
Audi Q5 2008
Separate gearbox from engine and carefully push gearbox
slightly towards the rear.
When doing so, pay attention to steering pinion/steering rack
on left side of gearbox.
When lowering gearbox, adjust position of gearbox using spin
dles on gearbox support - T40173- .
Note
When lowering the gearbox, make sure that no wires or hoses are
trapped on the top of the gearbox.
Note
For further repairs, secure gearbox to engine and gearbox
support - VAS 6095- page 77 .
Removing and installing electric drive motor - V141-
page 112 .
2.2
Installing gearbox

All special tools and workshop equipment already required for
gearbox removal, plus the following additional tools.
Vehicle diagnostic tester
Ring spanner insert, 16 mm - V.A.G 1332/14-
Transportation lock - T40170-
61
Audi Q5 2008
Procedure
DANGER!

All work on the de-energised high-voltage system must be
performed by an "electrically instructed person (EIP)"
Electrical system, hybrid; Rep. gr. 93 .
Work on the de-energised high-voltage system may only
be performed when the vehicle is clearly identified with
signs to confirm that it has been de-energised, and safety
measures have been taken to prevent re-energisation.
WARNING
tem .
Note
Renew bolts which are tightened by turning through a speci
fied angle. The aluminium bolts securing the engine to the

gearbox can be re-used once page 71 .
Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
Secure all hose connections with the correct hose clips (as
original equipment); refer to Electronic parts catalogue .
Re-attach all cable ties at the same locations when re-instal
ling.
Tightening torques for installing gearbox: page 70

Before fitting a replacement gearbox, always blow through the
ATF cooler and ATF lines with compressed air (not more than
10 bar) page 91 .
Before installing gearbox, clean residue from threads for en
gine/gearbox connection in cylinder block using a thread tap.
When fitting a replacement gearbox: attach gearbox support,
gearbox mounting and tunnel cross member to new gearbox
page 72 .
If not already fitted, install cable support bracket on replace
ment gearbox page 20 .
62
Audi Q5 2008
Caution
Risk of leaks on ATF oil pan.

Do not apply gearbox support - T40173- at ATF oil pan.
Position gearbox on gearbox support - T40173- (already pre
pared page 50 ) and secure with tensioning strap -1-, as
shown in illustration.
Use tensioning strap -1- to secure gearbox.
The following preparations must be made before joining the
engine and gearbox:
Rotate electric drive motor - V141- so that hole next to notch
-arrow- is visible in recess at bottom of gearbox housing, as
Note
There is only one notch on the circumference; turn the electric

drive motor - V141- accordingly.
Insert transportation lock - T40170- into gearbox housing from

below and clamp onto flange shaft -1-.
63
Audi Q5 2008
Check that dowel sleeves -A- for centralising engine/gearbox
are in the cylinder block; install any missing dowel sleeves.
Check whether aluminium bolts for engine/gearbox connec
tion can be reused and mark bolts if necessary page 71 .
Join gearbox with engine and tighten bolts -6 ... 11-.
Remove transportation lock - T40170- .
Raise gearbox and tighten bolts -arrows- for tunnel cross

member page 72 .
Slacken tensioning strap and move engine and gearbox jack
- V.A.G 1383 A- with gearbox support - T40173- out from un
derneath gearbox.
Clip end seal -1- into starter aperture.
The end seal -1- must be correctly fitted -arrows- before the
starter is installed.
Note
Apply a small amount of lubricant to the end seal if the starter

cannot be installed easily.
Install starter; when doing so fit spacer sleeve -arrow- onto bolt
-2- between starter and gearbox Electrical system; Rep. gr.
27 ; Starter; Exploded view - starter .
Press electric drive motor - V141- slightly against drive plate
on engine.
64
Audi Q5 2008
Secure electric drive motor - V141- to drive plate as follows:
Note
Use ring spanner insert, 16 mm - V.A.G 1332/14- to tighten bolts.

Install first bolt -arrow- and tighten hand-tight (2 Nm).
Turn crankshaft at vibration damper 240 in direction of engine

rotation using counterhold tool - T10355- .
Tighten bolt -arrow- accessible in this crankshaft position to

specified torque Item 12 (page 111) .
Turn crankshaft 120 further each time and tighten remaining
2 bolts to specified torque Item 12 (page 111) .
Tighten remaining gearbox/engine securing bolts -3 5-.

Note
Bolts -3- and -5- also secure brackets for pipes and/or wiring on
gearbox.
65
Audi Q5 2008
Connect coolant hoses -1- and -2- to connection on hybrid
drive and remove hose clamps - 3094- .
Hand-tighten bolts -arrows- securing bracket for coolant reg
ulator unit on right side of gearbox.
Then secure brackets for engine wiring harness -B- and cool
ant regulator unit -A- on left side of gearbox with bolts
-arrows-. Then tighten bolts securing bracket for coolant reg
ulator unit on right side of gearbox Rep. gr. 19 ; Coolant
Protected.by copyright. Copying for private or commercial purposes, in part or in whole, is not
pump/thermostat assembly
Secure ATF lines to gearbox
with bolts -1- and -2 page 88 .
WARNING

tion.


Connect high-voltage wiring harness for drive motor - PX2-1- in connection box and install cover for connection box
Electrical system, hybrid; Rep. gr. 93 ; High-voltage wires;
Removing and installing high-voltage wiring harness for drive
motor .
Note
Bolts -2- secure the high-voltage wiring harness for drive motor PX2- to the electric drive motor - V141- .
Install catalytic converter Rep. gr. 26 ; Emission control
system; Exploded view - emission control system .
66
Audi Q5 2008
Attach connector -A- for high-voltage wiring harness for drive
motor - PX2- and connector -B- on drive motor rotor position
sender 1 - G713- at top left of gearbox.
Plug in connector -C- for Lambda probe after catalytic con
verter - G130- and fit cable tie -arrow-.
Secure potential equalisation line -2- to gearbox with bolt -3 Electrical system, hybrid; Rep. gr. 93 ; Potential equalisa
tion lines .
Install torque cross member -3- (bolts -2-) and torque reaction
support (bolts -1-) Rep. gr. 10 ; Assembly mountings; Ex
ploded view - assembly mountings .
The remaining installation steps are carried out in reverse se
quence; note the following:
Install selector lever cable on gearbox page 35 .
by copyright.
Secure steering column to steering rack Protected
Running
gear,Copying for private or commercial purposes, in part or in whole, is not
axles, steering; Rep. gr. 48 ; Steering column;
Exploded
view
- steering column .
Secure drive shafts (left and right) to flange shafts of gearbox

Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft .
67
Audi Q5 2008
68
Audi Q5 2008
Install heat shield for drive shaft (right-side) and tighten bolts
-arrows- to 23 Nm.
Install subframe shield (below drive shaft, right-side) Run
ning gear, axles, steering; Rep. gr. 40 ; Subframe; Exploded
view - subframe .
Install propshaft and secure heat shield for propshaft to gear
box Rear final drive; Rep. gr. 39 ; Propshaft; Exploded view
- propshaft .
Install exhaust system and perform stress-free alignment
Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc
ers .
Fit front wheels Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Tightening torque for wheel bolts .
Re-energising high-voltage system
The high-voltage system must be re-energised according to the
Guided Fault Finding routine in the vehicle diagnostic tester ,
and ONLY by this method.
DANGER!

The high-voltage system may only be re-energised by a
The system may only be re-energised using the vehicle
diagnostic tester via Guided Fault Finding.
The vehicle is then made ready for operation again by the
qualified person (Audi high-voltage technician).
Note
Re-energising high-voltage system:
succession.
Body
Electrical system
8C - Hybrid
battery management, functions
51 - Re-energise high-voltage system (Rep. Gr. 93)
69
Audi Q5 2008
Observe measures required after connecting battery Elec
trical system; Rep. gr. 27 ; Battery; Disconnecting and con
necting battery .
Caution
Overvoltage can cause irreparable damage to control units.

Do not use charger for boost starting.
Check selector lever cable and adjust if necessary
page 40 .
Check ATF level and top up as required page 78 .
Check coolant level and top up if necessary Rep. gr. 19 ;
Cooling system/coolant; Draining and filling cooling system .
Check whether basic setting for electric drive motor - V141- is
required and perform basic setting if necessary
3.3 Performing basic setting for electric drive motor, page
111 .
2.3
Tightening torques for gearbox

Note
Tightening torques apply only to lightly greased, oiled,
phosphated or black-finished nuts and bolts.
Additional lubricant such as engine or gear oil may be used,
but do not use graphite lubricant.
Do not use parts which have been degreased.

Tolerance for tightening torques is 15 %.
Other tightening torques:
Component
Nm
Bolts and nuts
M6
M7
M8
M10
M12
9
15
20
40
65
70
Audi Q5 2008
Engine/gearbox securing bolts
Item
Bolt
Nm
1 1)
M10 x 50 2)
65
2 1), 7
M12 x 100 3)
30 + 90
3 4), 6
M12 x 75 3)
30 + 90
4, 5 4)
8, 10
M12 x 120 3)
15 + 90
M10 x 75 3)
15 + 90
M10 x 60 3)
15 + 90
11
A
5)
30 + 90
M12 x 50
Dowel sleeves for centralising
3)
1)
2)
3)
Aluminium bolts can be used twice only page 71 .
4)
With bracket for wiring
5)
Installed from engine side.
Also secures starter.
Property class 10.9; the steel bolt can be re-used any

number of times.
Aluminium bolts -2 11- can be used twice only. After they

have been used once, an X -arrow- must therefore be chi
selled onto the bolts.
To prevent damage to the bolts, they must not be clamped in
a vice when marking them. Clamp a 14 mm socket with 1/2"
drive in the vice instead, and insert the bolt into the socket, as
Bolts marked with an X must not be used again.
71
Audi Q5 2008
Assembly mountings
3.1 Exploded view - assembly mountings, page 72

3.2 Removing and installing tunnel cross member,
page 72
3.3 Removing and installing gearbox support with gearbox
mounting, page 74
3.4 Removing and installing gearbox mounting, page 75
3.1
Exploded view - assembly mountings
1 - Nut
Only remove if gearbox
mounting has to be de
tached from gearbox
support
20 Nm
2 - Bolt
70 Nm
3 - Bolt
40 Nm
4 - Gearbox
5 - Nut
20 Nm
6 - Gearbox support
3.3 Removing and in
stalling gearbox support
with gearbox mounting,
page 74
7 - Gearbox mounting
3.4 Removing and in
stalling gearbox mount
ing, page 75
8 - Stop (bottom)
For gearbox mounting
9 - Bolt
Only remove if gearbox
mounting has to be de
tached from gearbox
support
Renew
20 Nm and then turn 90
further
10 - Tunnel cross member
3.2 Removing and installing tunnel cross member, page 72
3.2
Removing and installing tunnel cross

member
72
Audi Q5 2008
Removing
noise insulation .
3. Assembly mountings
73
Audi Q5 2008
- V.A.G 1383 A- .
Apply gearbox support - T10337- below gearbox.
Slightly lift gearbox with engine and gearbox jack - V.A.G 1383
A- .
WARNING
Risk of accident.
Engine and gearbox jack - V.A.G 1383 A- must remain in
left unattended.
Unscrew nuts -arrows- and remove
tunnel cross
member.
with respect
Installing
Tightening torques
Install rear noise insulation General body repairs, exterior;

Rep. gr. 66 ; Noise insulation; Exploded view - noise insula
tion .
3.3
Removing and installing gearbox sup

port with gearbox mounting
Removing
Remove tunnel cross member page 72 .
Remove bolts -arrows- and detach gearbox support from gear
box together with gearbox mounting.
Installing
Tightening torques
74
Audi Q5 2008
3.4
Removing and installing gearbox

mounting
Removing
Remove gearbox support together with gearbox mounting
page 74 .
Remove bolts -1- and detach stop -2- (bottom) for gearbox
mounting.
Remove nut -4- and detach gearbox mounting -5- from gear
box support.
Installing
Tightening torques
Fit gearbox support -3- on gearbox mounting -5-.

Hand-tighten nut -4-.
Secure stop (bottom) -2- with bolts -1-.
Tighten nut -4-.
Install gearbox support with gearbox mounting page 74 .
3. Assembly mountings
75
Audi Q5 2008
Transporting gearbox

Hook and support tool - 3311- with bolt -3311/1-
Workshop hoist - VAS 6100-
Procedure
Gearbox removed
Caution
Risk of damage to gearbox components if gearbox is not sup

ported correctly when removed.
Do not set down the gearbox on its ATF oil pan.
If not already removed, detach support bracket for selector lever
cable from gearbox page 20 .
WARNING
Risk of accident if gearbox is not secured sufficiently.

Replace bolt of hook and support tool - 3311- with new,
longer bolt -3311/1- .
Otherwise the gearbox is not secured properly.
Secure gearbox to hook and support tool - 3311- (using new,
longer bolt -3311/1- ).
The workshop hoist - VAS 6100- can be used to lift and move
the gearbox.
76
Audi Q5 2008
Securing to engine and gearbox sup

port

Support plate - VW 309-
Hook and support tool - 3311- with bolt -3311/1-
Engine and gearbox support - VAS 6095-
Procedure
Gearbox is on workshop hoist - VAS 6100- page 76 .
Secure support plate - VW 309- to hook and support tool 3311- .

Using workshop hoist - VAS 6100- , insert gearbox into engine
and gearbox support - VAS 6095- .
Note
If the filled gearbox with ATF oil pan is to be turned upside-down

on the engine and gearbox support, the breathers for the gearbox
housing and final drive must be sealed.
5. Securing to engine and gearbox support
77
Audi Q5 2008
ATF
6.1 Exploded view - ATF drain and inspection plugs in gear

box, page 78
6.2 Checking ATF level, page 78
6.3 Draining and filling ATF, page 84
6.1
Exploded view - ATF drain and inspection plugs in gearbox
1 - ATF drain plug

Renew
12 Nm
2 - Drain plug
For gear oil in transfer
box
Tightening torque
Item 4 (page 125)
3 - Screw plug
For inspection and filler
hole
box
Tightening torque
Item 1 (page 125)
4 - ATF plug
hole
For ATF in gearbox
Renew
30 Nm
5 - Screw plug
hole
For gear oil in front final
drive
Tightening torque
Item 2 (page 125)
6 - Drain plug
drive
Tightening torque Item 3 (page 125)
6.2
Checking ATF level
78
Audi Q5 2008
Used oil collection and extraction unit - V.A.G 1782-
Adapter for oil filling - VAS 6262 AProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Flexible hose adapter - VAS 6262/5 If necessary, additional adapter -VAS 6262/6 1 litre ATF container (genuine replacement part); for part num
ber refer to Electronic parts catalogue .
Safety goggles
Protective gloves (acid resistant)
Measure length of breather pipe on adapter for oil filling - VAS
6262 A- and shorten if necessary.
To ensure that breather pipe of adapter for oil filling -VAS 6262
A- does not make contact with bottom of oil container, breather
pipe must be shortened to dimension -a-.
Dimension -a- = 210 mm

Note
Dimension -a- is measured from stem (green area in magnified

view) of adapter for oil filling -VAS 6262 A- .
6. ATF
79
Audi Q5 2008
Mark length on breather pipe and shorten breather pipe using
pipe cutter -6056/2- .
Clean adapter for oil filling - VAS 6262 A- .
Procedure

WARNING
Risk of injury
Wear safety goggles.
Wear protective gloves (acid resistant).
When working close to the radiator maintain a safe dis
tance from the fan - fan may switch on automatically.
Accidents can be caused if a gear is inadvertently engaged
while the engine is running.
Caution
Risk of damage to gearbox

The engine must NOT be started if there is only little or no
ATF left in the gearbox after repair work or after excessive
loss of ATF.
After repair work or after excessive loss of ATF, put a suit
able amount of ATF into the gearbox beforeProtected
proceeding
page 84 .

8-speed automatic gearbox 0BW hybrid.
Other types of oil cause malfunctions and/or failure of the

gearbox.
For the correct type, refer to Electronic parts catalogue .
The adapter for oil filling - VAS 6262 A- must be clean; the
ATF must not be mixed with any other types of lubricant.
80
Audi Q5 2008
6262 A- and shorten if necessary page 79 .
Attach flexible hose adapter - VAS 6262/5- to adapter for oil
filling - VAS 6262 A- .
Test conditions
Gearbox must not be in emergency running (backup) mode.
Vehicle must be absolutely horizontal (on a four-pillar lifting

platform or over an inspection pit).
Selector lever at position P.
Parking brake button must be pulled up to apply the electro

mechanical parking brake.
Extractor hose(s) of an exhaust gas extractor (switched on)

must be connected.
Air conditioner and heating system switched off.
Vehicle diagnostic tester is connected.
The ATF temperature must not be higher than 30 at the

beginning of the test. If the temperature is higher, allow the
gearbox to cool down before proceeding.
Note
The ATF temperature is taken from the reading on the vehicle
diagnostic tester .
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 ATF 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.
Procedure
Select the value for Gear oil temperature from the menu
on the vehicle diagnostic tester .
Read off ATF temperature.
Checking and correcting ATF level
The engine must be running on vehicles with hybrid drive. To

start the engine, open the bonnet or operate the kickdown
function on the accelerator pedal module.
Tightening torque
6.1 Exploded view - ATF drain and inspection plugs in
Protected
by copyright.
Copying
gearbox,
page
78for private or commercial purposes, in part or in whole, is not
6. ATF
81
Audi Q5 2008
Note
The ATF level can be checked at the ATF inspection and filler
hole.
The ATF level is correct if a small amount of fluid comes out
at the ATF inspection and filler hole when ATF temperature is

between 35C and 45C, or 50C in hot climates (the fluid level
rises due to expansion as it warms up).
Renew plug for ATF inspection and filler hole.

noise insulation .
Start engine with selector lever in position P.
With brake pedal still depressed, select all selector lever po
sitions (P, R, N, D/S) one after the other at idling speed,
maintaining each position for at least 10 seconds.
Allow engine to continue running at idling speed.
Place used oil collection and extraction unit - V.A.G 1782- be
low gearbox.
WARNING
Risk of eye injury.

When an ATF temperature of 35 C is reached, unscrew plug
for ATF inspection and filler hole -arrow A- and drain off any
surplus ATF.
If ATF comes out of the ATF inspection and filler hole

-arrow A- before the ATF has reached 40 C, the ATF level is
OK.
Note
The ATF inspection and filler hole must be sealed again before
the ATF temperature reaches 45 C (or 50 C in hot climates).
Tighten new plug for ATF inspection Protected
and filler
hole. The ATF
level check is now completed.

If no fluid comes out of the ATF inspection and filler hole

-arrow A- when the temperature reaches 40 C:
82
Audi Q5 2008
Filling up ATF
Note
The ATF inspection and filler hole must be sealed again before
the ATF temperature reaches 45 C (or 50 C in hot climates). If
necessary, switch off engine, allow gearbox to cool down and re
peat test.
with respect
to the correctness
of informationbefore
in this document.
Shake
ATF container
opening.
Screw 1 litre ATF container onto adapter for oil filling - VAS
6262 A- ; for part number refer to Electronic parts catalogue .
Note
If thread on ATF container does not fit onto adapter for oil filling VAS 6262 A- , use additional adapter -VAS 6262/6- .
Secure ATF container with adapter for oil filling - VAS 6262 Aas high as possible on vehicle.
Insert flexible hose adapter - VAS 6262/5- into ATF inspection
and filler hole -arrow-.
Fill up with ATF via adapter until ATF comes out of inspection
and filler hole.
Note
The ATF level must not be too low or too high, otherwise this
would impair the function of the gearbox.
Tighten new plug for ATF inspection and filler hole -arrow A-.
The ATF level check is now completed.
6. ATF
83
Audi Q5 2008
6.3
Draining and filling ATF

Adapter for oil filling - VAS 6262 A-
Flexible hose adapter - VAS 6262/5 If necessary, additional adapter -VAS 6262/6Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 litre ATF container (genuine replacement

part
numof information in this document. Copyright by AUDI AG.
withpart);
respectfor
to the
correctness
ber refer to Electronic parts catalogue .
Protective gloves (acid resistant)
Safety goggles
Procedure

WARNING
Risk of injury
Wear protective gloves (acid resistant).
When working close to the radiator maintain a safe dis
tance from the fan - fan may switch on automatically.
Accidents can be caused if a gear is inadvertently engaged
while the engine is running.
84
Audi Q5 2008
Caution

The engine must NOT be started if there is only little or no
ATF left in the gearbox after repair work or after excessive
loss of ATF.
After repair work or after excessive loss of ATF, put a suit
able amount of ATF into the gearbox before proceeding.
8-speed automatic gearbox 0BW hybrid.
Other types of oil cause malfunctions and/or failure of the
gearbox.
For the correct type, refer to Electronic parts catalogue .
The adapter for oil filling - VAS 6262 A- must be clean; the
ATF must not be mixed with any other types of lubricant.
6262 A- and shorten if necessary page 79 .
Attach flexible hose adapter - VAS 6262/5- to adapter for oil
filling - VAS 6262 A- .
Requirements
Engine not running.

Selector lever at position P.
Parking brake button must be pulled up to apply the electro

mechanical parking brake.
Tightening torques
6.1 Exploded view - ATF drain and inspection plugs in
gearbox, page 78

noise insulation .
6. ATF
85
Audi Q5 2008
low gearbox.
Remove ATF drain plug -arrow B- and allow ATF to drain off.
Note
Always adhere to waste disposal regulations.
Renew ATF drain plug with seal.
Renew plug for ATF inspection and filler hole.
Tighten new drain plug -arrow B-.
Filling gearbox with ATF
Shake ATF container before opening.
Screw 1 litre ATF container onto adapter for oil filling - VAS
6262 A- ; for part number refer to Electronic parts catalogue .
Note
If thread on ATF container does not fit onto adapter for oil filling VAS 6262 A- , use additional adapter -VAS 6262/6- .
Secure ATF container with adapter for oil filling - VAS 6262 Aas high as possible on vehicle.
Unscrew plug for ATF inspection and filler hole -arrow A-.
86
Audi Q5 2008
Insert flexible hose adapter - VAS 6262/5- into ATF inspection
and filler hole -arrow-.
Fill up with ATF via adapter until ATF comes out of inspection
and filler hole; for capacities see page 13 .
Start engine and turn off after 20 seconds.
The engine must be running on vehicles with hybrid drive. To

start the engine, open the bonnet or operate the kickdown
function on the accelerator pedal module.
Continue filling with ATF using adapter until ATF comes out of
inspection hole.
Start engine.
Continue filling with ATF via adapter until ATF comes out of
inspection and filler hole again.
Tighten old plug for ATF inspection and filler hole.
With brake pedal depressed, select all gear positions (P, R,
N, D/S) in succession at idling speed, maintaining each po
sition for 3 seconds.
Check ATF level and top up as required page 78 .
Note
Observe all notes and test requirements for Checking and cor
recting ATF level.
Install rear noise insulation General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula
tion .
6. ATF
87
Audi Q5 2008
ATF circuit
7.1 Exploded view - ATF circuit, page 88

7.2 Removing and installing ATF filter, page 90
7.3 Cleaning ATF lines, page 91
7.4 Removing and installing ATF lines, page 92
7.1
Exploded view - ATF circuit

Note
Rules for cleanliness when working on the automatic gearbox page 9

General repair instructions page 10 .
Seal off open lines and connections with clean plugs from engine bung set - VAS 6122- .
Check ATF level after renewing ATF lines page 78 .
Caution
88
Audi Q5 2008
1 - ATF cooler
Integrated in radiator for
engine coolant
Rep. gr. 19 ; Radia
tor/radiator fans; Re
moving and installing ra
diator
2 - O-ring
Renew
Lightly lubricate with
ATF before inserting
3 - ATF line (return)
From ATF cooler to
gearbox
Mark relative position of
ATF lines before remov
ing to avoid interchang
ing
4 - O-ring
Renew
Lightly lubricate with
ATF before inserting
5 - ATF line (supply)
copyright. Copying
Protected
Frombygearbox
to ATF
permitted
coolerunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Mark relative position of
ATF lines before remov
ing to avoid interchang
ing
6 - Bolt
9 Nm
Secures ATF line to en
gine
7 - ATF line (supply)
From gearbox to ATF cooler
Mark relative position of ATF lines before removing to avoid interchanging
Nut on ATF line, 29 Nm
ATF lines are locked together
8 - Bolt
9 Nm
Secures ATF lines to gearbox (top)
9 - ATF line (return)
From ATF cooler to gearbox
Mark relative position of ATF lines before removing to avoid interchanging
Nut on ATF line, 29 Nm
ATF lines are locked together
10 - Bolt
20 Nm
First push in ATF lines with new O-rings by hand as far as stop
Retaining tab on bottom ATF line should rest on thread of gearbox
Retaining tab on top ATF line should rest on retaining tab on bottom ATF line
7. ATF circuit
89
Audi Q5 2008
11 - O-rings
Renew
Lightly lubricate with ATF before inserting
12 - Bolt
9 Nm
Secures ATF lines to gearbox (at front final drive)
13 - Bolt
9 Nm
Secures ATF lines to engine
7.2
Removing and installing ATF filter

Removing
Note
Rules for cleanliness when working on the automatic gearbox
page 9

low gearbox.
Carefully pull ATF filter downwards off mechatronic unit and
auxiliary hydraulic pump 1 for gearbox oil - V475- in opposite
direction to -arrows-.
90
Audi Q5 2008
Installing
Fit new O-ring -2- on ATF filter -1- and lubricate lightly with
ATF.
Clean both magnets -arrows-. Ensure that magnets make full

contact with recesses in ATF filter.
Fit ATF filter on mechatronic unit as follows.

The intake neck -1- of the ATF filter must be inserted as far as
the stop in aperture -2- of the mechatronic unit.
The retainer -4- on the reverse side must engage on the bolt
-3- located opposite on the mechatronic unit.
the stop in the aperture of the auxiliary hydraulic pump 1 for
gearbox oil - V475- .
7.3
Cleaning ATF lines
Special tools and workshop equipment

required
7. ATF circuit
91
Audi Q5 2008
Hose, approx. 18 mm dia.

Compressed-air gun (commercially available)
Safety goggles
Procedure
Note

page 9
Before fitting a replacement gearbox, always blow through the
ATF cooler and ATF lines with compressed air (not more than
10 bar).
low gearbox.
Note
If the ATF which emerges during cleaning is very dirty, the ATF
cooler and ATF lines must additionally be flushed out with Protected
clean by copyright. Copying for private or commercial purposes, in part or in whole, is not
ATF.
7.4
Removing and installing ATF lines
The gearbox must first be removed before removing and installing

the ATF lines page 48 .
92
Audi Q5 2008
38
Gears, control
ATF system
1.1 Exploded view - ATF system, page 93

1.2 Removing and installing oil pan, page 95
1.3 Removing and installing auxiliary hydraulic pump for gear
box oil, page 100
1.1
Exploded view - ATF system

Caution

The engine must not be started when there is no more ATF
in the gearbox or the ATF oil pan has been removed.
Note
Always renew mechatronic unit if contaminated or defective.
page 9

Coat O-rings and seals with ATF. Other types of lubricant will
cause the gearbox hydraulics to malfunction.
1. ATF system
93
Audi Q5 2008
1 - ATF oil pan
1.2 Removing and in
stalling oil pan,
page 95
2 - Gasket
Renew
3 - ATF filter
7.2 Removing and in
stalling ATF filter,
page 90
4 - O-ring
Renew
5 - Bolt
Fig. Tightening tor
que and sequence for
mechatronic unit ,
page 95
6 - Mechatronic unit
2.1 Removing and in
stalling mechatronic
unit, page 105
7 - O-ring
Renew
8 - O-rings
Renew
9 - Seals
Renew
Insert in connector
housing
Item 10 (page 94)
10 - Connector housing
11 - Bolt
5.5 Nm
12 - ATF pipe
13 - Bolt
10 Nm
Secures gearbox output speed sender - G195- to gearbox housing
14 - O-ring
Renew
On connection of auxiliary hydraulic pump 1 for gearbox oil - V47515 - Auxiliary hydraulic pump 1 for gearbox oil - V475 Removing and installing page 100
16 - Bolt
10 Nm
3x
Secures auxiliary hydraulic pump 1 for gearbox oil - V475- to gearbox housing
17 - Magnets
Ensure full contact with ATF filter
Clean before installing
94
Rep. gr.38 - Gears, control
Audi Q5 2008
18 - Bolt
Renew
Tightening torque and sequence page 95
19 - Drain plug
For ATF in gearbox
Tightening torque Item 1 (page 78)
ATF oil pan - tightening torque and sequence
Note
Renew bolts for ATF oil pan.

Tighten bolts in 3 stages in the sequence shown:
Stage
Bolts
1.
-1 12-
2.
3.
-1 12-1 12-
Tightening torque/tightening angle

Screw in new bolts by hand until bolt
heads make contact
4 Nm
Turn 45 further
Tightening torque and sequence for mechatronic unit

Tighten bolts to 10 Nm in sequence -1 ... 19-.
Note
Bolts -18- and -19- are shorter.
Bolt -18- secures gearbox output speed sender - G195- to
gearbox housing.
Bolt -19- (if fitted) secures connector for mechatronic unit to
gearbox housing.
1.2
Special
Removing and installing oil pan

toolsProtected
and workshop
equipment required
1. ATF system
95
Audi Q5 2008
Guide pin - T40199-
Removing
Note
page 9

Observe safety precautions page 2 .
Switch off ignition and take out ignition key.
96
Audi Q5 2008
Remove noise insulation -1- and -2- General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Removing and instal
ling noise insulation .
Detach electrical wiring at cross brace -1- and -2-.

Caution

led.
cross brace (e.g. with a trolley jack).

- V.A.G 1383 A- and position underneath gearbox.
Raise gearbox slightly.
WARNING
Risk of accident.
left unattended.
Remove gearbox support together with gearbox mounting
(rear) page 74 .
Drain ATF page 84 .
1. ATF system
97
Audi Q5 2008
Remove bolts for ATF oil pan in the sequence -12 ... 1-.
Remove ATF oil pan.
Installing
Note
Renew gasket and bolts for ATF oil pan.
If the vehicle mileage is high, it is recommended to renew the
ATF filter when removing the ATF oil pan page 90 . Other
wise the ATF filter only has to be renewed if it has been
damaged.
Clean both magnets -arrows-. Ensure that magnets make full

contact with recesses in ATF filter.
Clean sealing surface thoroughly; remaining material from the
previous gasket must be removed completely.
Make sure that the ATF filter is fitted correctly on the mecha
tronic unit, otherwise the ATF oil pan cannot be seated prop
erly on the entire surface.
the stop in aperture -2- of the mechatronic unit.
The retainer -4- on the reverse side must engage on the bolt
-3- located opposite on the mechatronic unit.
the stop in the aperture of the auxiliary hydraulic pump 1 for
gearbox oil - V475- .
98
Audi Q5 2008
3 Screw in guide pins - T40199- hand-tight, as shown in illus
tration.
Fit ATF oil pan with new gasket over guide pins - T40199- and
onto gearbox.
Screw in bolts -1 and 2- by hand until bolt heads make contact.
Remove guide pins - T40199- and tighten bolts in specified

sequence page 95 .

Install gearbox mounting page 75 .
Install noise insulation -1- and -2- General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
1. ATF system
99
Audi Q5 2008
1.3
Removing and installing auxiliary hy

draulic pump for gearbox oil
1.3.1 Removing and installing auxiliary hydraulic pump for

gearbox oil, page 100
1.3.2 Removing and installing electrical wiring harness for
auxiliary hydraulic pump 1 for gearbox oil, page 102
1.3.1
Removing and installing auxiliary hy

draulic pump for gearbox oil
Removing
Gearbox in vehicle
Note
page 9

Caution

in the gearbox and the mechatronic unit has been re
moved.
Shift gearbox into position P.
Switch off ignition and take out ignition key.
Caution

Before handling electrical connectors, mechanic must dis
charge static. To do so, touch an earthed metal object,
such as a heater radiator or lifting platform, with your hand.
hands.
100
Audi Q5 2008
Carefully unplug electrical connector -B- for auxiliary hydraulic
pump 1 for gearbox oil - V475- -A-.
Remove securing bolts in the sequence -3 ... 1-.
Detach auxiliary hydraulic pump 1 for gearbox oil - V475- -Afrom gearbox housing.
Note
Due to O-ring -D-, the auxiliary hydraulic pump 1 for gearbox oil
- V475- fits tightly in the gearbox housing.
Installing
The connector contacts -2- and -3- of electrical wire -1- must
be pressed properly into the gearbox housing.
Note
The connector contacts must not be interchanged.

The illustration shows the electrical wire -1- with the mecha
tronic unit removed; the items marked -4, 5- and -arrows- can
therefore be disregarded.
1. ATF system
101
Audi Q5 2008
Carefully renew O-ring -D- on auxiliary hydraulic pump 1 for
gearbox oil - V475- by hand, without using tools.
Note
If the seat of the O-ring is damaged or scratched, the auxiliary

hydraulic pump 1 for gearbox oil - V475- must be renewed.
Fit auxiliary hydraulic pump 1 for gearbox oil - V475- with new
O-ring -D-.
Tighten securing bolts in the sequence -1 ... 3-.
Plug in electrical connector -B- for auxiliary hydraulic pump 1
for gearbox oil - V475- -A-.
Note
Make sure that electrical connector is properly engaged and se

cured.
Route electrical wiring -C- as shown in illustration and secure
-arrows-.
1.3.2
Removing and installing electrical wiring

harness for auxiliary hydraulic pump 1
for gearbox oil
Removing
Remove mechatronic unit page 105 .
Unplug electrical connector -A- for auxiliary hydraulic pump 1
for gearbox oil - V475- from right side of gearbox.
Then unclip wire from gearbox -arrows- and tie up to one side.
102
Audi Q5 2008
Detach securing clip -A- from connector -B- for wiring harness
for auxiliary hydraulic pump 1 for gearbox oil - V475- in direc
tion of -arrow-.
Note
Before removal, mark connector contacts -2- and -3- in relation
to holes in gearbox housing.
Transfer these markings to the new wiring harness -1- when
installing.
Caution
Risk of damage to auxiliary hydraulic pump 1 for gearbox oil V475 The auxiliary hydraulic pump 1 for gearbox oil - V475- will
be damaged if the connector contacts -2- and -3- are in
terchanged on re-installation.
Disconnect connector contacts -2- and -3- from gearbox hous
ing.
Detach wiring harness -1- from retainers -arrows-.
Then unplug connector -4- from gearbox housing -5-.
Installing
If the existing wiring harness -1- is being re-installed, renew Orings on connector -4-.
Installation position of connector -4-: flat surface fits against

rib -5- on housing, as shown in illustration.
1. ATF system
103
Audi Q5 2008
Press securing clip -A- onto connector -B- for wiring harness
for auxiliary hydraulic pump 1 for gearbox oil - V475- in oppo
site direction of -arrow- and secure connector.
Press connector contacts -2- and -3- into holes in gearbox
housing according to marks made upon removal.
Install mechatronic unit page 105 .
Install auxiliary hydraulic pump 1 for gearbox oil - V475 page 100 .
104
Audi Q5 2008
Mechatronic unit
2.1 Removing and installing mechatronic unit, page 105
2.1
Removing and installing mechatronic

unit

Extractor tool - T10271-
Guide pin - T40199-
Removing
Gearbox in vehicle
Note
page 9

Always renew mechatronic unit if contaminated or defective.
Caution

in the gearbox and the mechatronic unit has been re
moved.
Shift gearbox into position P.
2. Mechatronic unit
105
Audi Q5 2008
Caution

charge static. To do so, touch an earthed metal object,
such as a heater radiator or lifting platform, with your hand.
hands.
Turn fastener anti-clockwise -arrow- and unplug electrical con
nector on gearbox.
Remove bolt -1-.
Turn connector housing -2- anti-clockwise -arrow- and detach.
Carefully unplug electrical connector -B- for auxiliary hydraulic

pump 1 for gearbox oil - V475- -A-.
Detach auxiliary hydraulic pump 1 for gearbox oil - V475- -Afrom gearbox housing.
Note
Due to O-ring -D-, the auxiliary hydraulic pump 1 for gearbox oil
- V475- fits tightly in the gearbox housing.
106
Audi Q5 2008
Remove bolts in the sequence -19 ... 1-.
Caution
Risk of damage to mechatronic unit.

Loosen only the bolts with Torx T40 head.
If other bolts are loosened, this may affect the operation
of the mechatronic unit or the mechatronic unit could come
apart.
Detach mechatronic unit from gearbox.
Caution
Risk of damage to senders on rear side of mechatronic unit.

When setting down

the
mechatronic
unit,AG.the
side
withnotthe
permitted
unless
authorised by AUDI
AUDI
AG does
guarantee or accept any liability
the correctness of information in this document. Copyright by AUDI AG.
bolt heads must with
be respect
facingto downwards.
Installing

Note
Renew O-rings and bolts for mechatronic unit.

Fit new O-rings -1- and -3- in grooves on ATF pipes.
Fit ATF pipe -2- in mechatronic unit.
Check ATF pipes for damage and make sure they are firmly
seated in mechatronic unit.
2. Mechatronic unit
107
Audi Q5 2008
Pull out sealing sleeve using puller - T10271- and fit new seal
ing sleeve.
Screw in 4 guide pins - T40199- hand-tight, as shown in illus

tration.
Note
The guide pins - T40199- ensure that the mechatronic unit is
kept straight while it is being installed. This prevents damage

to the ATF pipes on the reverse side of the mechatronic unit.
Because of the spring clip on its reverse side, the mechatronic
unit cannot initially be brought into full contact with the gearbox
housing.
For this reason, it is advisable to have the assistance of a sec
ond mechanic when installing the mechatronic unit with the

gearbox in the vehicle.
Fit mechatronic unit carefully onto gearbox housing.
Gearbox selector lever -A- must engage in actuator -C- at gear

sensor - G676- -arrow 1-; if necessary move actuator -C- ac
cordingly.
Gearbox selector lever -A- must engage in selector slide -B-arrow 2-; if necessary move selector slide -B- accordingly.
108
Audi Q5 2008
Screw in bolts -1 4- by hand until bolt heads make contact.
Remove the 4 guide pins - T40199- .
Tighten bolts for mechatronic unit in specified sequence
Fig. Tightening torque and sequence for mechatronic
unit , page 95 .
Further assembly is carried out in reverse sequence; note the fol
lowing:
Caution

charge
static.
To do Copying
so, touch
an orearthed
metal
object,
Protected
by copyright.
for private
commercial
purposes,
in part or in whole, is not
unless authorised
AG. AUDI
AG doeswith
not guarantee
or accept any liability
such permitted
as a heater
radiatorbyorAUDI
lifting
platform,
your hand.

hands.
Make sure that electrical connector is properly engaged and

secured.
Install auxiliary hydraulic pump 1 for gearbox oil - V475 page 100 .
2. Mechatronic unit
109
Audi Q5 2008
Electric drive motor
3.1 Exploded view - electric drive motor, page 110

3.2 General description - electric drive motor, page 111
3.3 Performing basic setting for electric drive motor,
page 111
3.4 Removing and installing electric drive motor, page 112
3.5 Checking hub of electric drive motor, page 119
3.6 Renewing oil seal for electric drive motor, page 119
3.1
Exploded view - electric drive motor
1 - Gearbox housing
2 - Connection for coolant lines
for electric drive motor - V1413 - Bolt
20 Nm
4 - Bolt
20 Nm
5 - Connection box housing for
high-voltage wires
Connection for highvoltage wires to electric
drive motor - V141 Coding of high-voltage
wires to electric drive
motor - V141- Electri
cal system, hybrid; Rep.
gr. 93 ; High-voltage
wires; Identification of
high-voltage wiring
6 - Cover for connection box
for high-voltage wires
Renew seal on cover for
connection box
Electrical system, hy
brid; Rep. gr. 93 ; Highvoltage wires; Remov
ing and installing highvoltage wiring harness
for drive motor
7 - Bolt
Tightening torque
Electrical system, hy
brid; Rep. gr. 93 ; Highvoltage wires; Removing and installing high-voltage wiring harness for drive motor
8 - Electric drive motor - V141 3.4 Removing and installing electric drive motor, page 112
Checking hub of electric drive motor - V141- page 119
9 - Protective cap for high-voltage connections
To be fitted during removal and installation of electric drive motor - V141-
110
Audi Q5 2008
10 - Bolt
Renew
10 Nm +75
11 - Bolt
10 Nm
12 - Bolt
Renew
3x, for securing electric drive motor - V141- to drive plate
Tightening sequence 2 Removing and installing gearbox, page 48
60 Nm
13 - Protective cap for coolant line connections
To be fitted during removal and installation of electric drive motor - V14114 - Protective cap for connection to gearbox
To be fitted after removal of electric drive motor - V141 Remove before installing electric drive motor - V14115 - O-ring
For input shaft
Renew
16 - Oil seal
For electric drive motor - V141 3.6 Renewing oil seal for electric drive motor, page 119
3.2
General description - electric drive mo

tor
The electric drive motor - V141- -1- is located between the com
bustion engine and the gearbox.
It acts directly on the input shaft and has the following functions:
A drive motor to propel the vehicle with electric power only
A generator to supply the electrical system with power and
charge the drive battery - A2- .
A starter to start the combustion engine.
The disengagement clutch in the electric drive motor - V141- dis
engages the engine from the electric drive motor - V141- . The
disengagement clutch is also designated disengagement
The disengagement clutch F in the electric drive motor
- V141with respect to the correctness of information in this document. Copyright by AUDI AG.
cannot be renewed separately; there is no provision for opening
and dismantling the electric drive motor - V141- .
Driving off in 1st gear is controlled by clutch B in the gearbox (also

referred to as drive-away clutch B).
Potential equalisation line on electric drive motor - V141- Elec
trical system, hybrid; Rep. gr. 93 ; Potential equalisation lines .
3.3
Performing basic setting for electric

drive motor

3. Electric drive motor
111
Audi Q5 2008
Requirements
The basic setting for the electric drive motor - V141- must be per
formed after the following work
When the electric drive motor - V141- has been renewed
When the gearbox with electric drive motor - V141- has been
renewed
When the electric drive control unit - J841- has been renewed
Electrical system, hybrid; Rep. gr. 93 ; Power and control
electronics for electric drive; Removing and installing power
and control electronics for electric drive .
By performing the basic setting, the rotor position sensor in the

electric drive motor - V141- is adapted and adjusted.
Procedure
It is important to observe all test conditions and follow all in

structions given by the vehicle diagnostic tester exactly.
Using the diagnostic tester in Guided Fault Finding mode, go

to Function/Component Selection and select the following
menu items:
Body (Rep. Gr. 01; 27; 50 - 97)
Electrical system (Rep. Gr. 01; 27; 90 - 97)
51 - Electric drive control unit | J841
51 - Electric drive, functions
51 - Basic setting (Rep. Gr. 93)
3.4
Removing and installing electric drive

motor
Special tools
and workshop
equipment
required
permitted
unless authorised
by AUDI AG. AUDI
Workshop hoist - VAS 6100-
Torque wrench - V.A.G 1331-
112
Audi Q5 2008
Eye-head bolt - VAS 3368-
Multi-purpose tool - VW 771- adapter 40
Washer, M8
WARNING

tion.

The round high-voltage connectors

are colour-coded with
an external coloured ring and arepermitted
provided
mechan
unlesswith
authorised
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect
to the correctness
ical coding or guide lugs. It is important
to observe
this of information in this document. Copyright by AUDI AG.
Removing
The electric drive motor - V141- is a component of the gearbox,
so the gearbox first has to be removed.
De-energising high-voltage system
WARNING
tem .
The high-voltage system must be de-energised according to the
113
Audi Q5 2008
DANGER!

Finding.
Note
De-energising high-voltage system:
succession.
Body
Electrical system
8C - Hybrid battery management, functions
51 - De-energise
high-voltage
system
Gr.purposes,
93) in part or in whole, is not
Protected
by copyright. Copying
for private(Rep.
or commercial
Remove gearbox page 48 .
Secure gearbox to engine and gearbox support - VAS 6095 page 77 .

Remove flange shaft (left-side) page 141 .
114
Audi Q5 2008
Remove bolts -2- and detach housing -1- of connection box
for high-voltage wiring from gearbox.
Remove
boltto -2and pryofconnection
for
coolant
linesby-1offAG.
with respect
the correctness
information in this
document.
Copyright
AUDI
gearbox housing.
Cover high-voltage connections -1- and cooling connections

-2- on electric drive motor - V141- with protective caps.
Note
For illustration purposes shown with the electric drive motor V141- removed. The protective cap -3- for the connection to the
gearbox can only be fitted when the electric drive motor - V141has been removed.
Turn gearbox so that electric drive motor - V141- faces verti
cally upwards.
Preparing transport and lifting equipment:
Assemble eye-head bolt - VAS 3368- with adapter 40 of multipurpose tool - VW 771- and washer (M8) -1-.
Maximum depth for screwing in: dimension x = 8 mm

Caution
Risk of damaging damper module in electric drive motor V141If the eye-head bolt - VAS 3368- with adapter 40 of multi-pur
pose tool - VW 771- is screwed in deeper than 8 mm, the
damper module in the electric drive motor - V141- will be dam
aged.
The electric drive motor - V141- must be renewed if the damper
module in the electric drive motor - V141- is damaged.
115
Audi Q5 2008
Attach eye-head bolt - VAS 3368- with adapter 40 of multipurpose tool - VW 771- and washer (M8) -1- at top of electric
drive motor - V141- .
Unscrew bolt -3- at drive motor rotor position sender 1 - G713- .

Remove bolts -2- on electric drive motor - V141- -1-.
Carefully lift electric drive motor - V141- vertically out of gear

box using workshop hoist - VAS 6100- .
Caution
Risk of damage to electric drive motor - V141 The drive motor rotor position sender 1 - G713- and the
high-voltage connection with protective cap -1- must not
be allowed to knock against the gearbox housing when the
motor is being lifted out.
Make sure that no coolant is allowed to enter the opening for
the input shaft; cover the opening if necessary.
Make sure that all protective caps are fitted.
1-
Protective cap for high-voltage connections
2-
Protective caps for coolant connections
3-
Protective cap for connection to gearbox
Carefully set down electric drive motor - V141- .
116
Audi Q5 2008
Installing
Installation is carried out in reverse sequence; note the fol
lowing:
Thoroughly clean area of gearbox housing leading to differ
ential -arrow A-, and oil seal -arrow B-.
Note
If oil seal between differential and gearbox housing -arrow B- is

damaged, it must be renewed page 121 .
Pack space between sealing lip and dust lip half-full with seal
ing grease - G 052 128 A1- .
Renew O-ring -arrow- on input shaft.

Check oil seal for electric drive motor - V141- for damage and
renew if necessary page 119 .
Check hub of electric drive motor - V141- page 119 .
Assemble eye-head
bolt - VAS 3368- with adapter 40 of multiProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
purpose tool - permitted
VW 771and
washer
(M8)
unless
authorised
by AUDI
AG. -1-.
AUDI AG does not guarantee or accept any liability
Maximum depth for screwing in: dimension x = 8 mm
Installing a new electric drive motor - V141A new electric drive motor - V141- is delivered in a special trans
port pallet.
Caution
Risk of damaging damper module in electric drive motor V141If the eye-head bolt - VAS 3368- with adapter 40 of multi-pur
pose tool - VW 771- is screwed in deeper than 8 mm, the
damper module in the electric drive motor - V141- will be dam
aged.
The electric drive motor - V141- must be renewed if the damper
module in the electric drive motor - V141- is damaged.
117
Audi Q5 2008
Attach eye-head bolt - VAS 3368- with adapter 40 of multipurpose tool - VW 771- and washer (M8) -1- at top of electric
drive motor - V141- .
permitted out
unless
by AUDI
AG. AUDI
Lift electric drive motor - V141ofauthorised
transport
pallet
using
with
workshop hoist - VAS 6100. respect to the correctness of information in this document. Copyright by AUDI AG.
Detach base plate -3- and support -2- for torsion damper from
electric drive motor - V141- -1-.
Continue with instructions for installing a previously removed
electric drive motor - V141- page 118 .
Installing a previously removed electric drive motor - V141-
118
Audi Q5 2008
Remove protective cap on connection for gearbox -3-.
Caution
Risk of damage to electric drive motor - V141 The drive motor rotor position sender 1 - G713- and the
high-voltage connection with protective cap -1- must not
be allowed to knock against the gearbox housing when the
motor is being lowered into the gearbox.
Using workshop hoist - VAS 6100- , lower electric drive motor
- V141- vertically into gearbox housing until four lugs on elec
tric drive motor - V141- rest against contact surfaces in gear
box housing. Align axial bores in lugs and gearbox housing.
Caution
Risk of damage to electric drive motor - V141 When guiding the electric drive motor - V141- onto the
gearbox
input
shaftCopying
and the
hollow
oil pump
shaft,
theor in whole, is not
Protected
by copyright.
for private
or commercial
purposes,
in part
permitted
authorised
by AUDI
AUDI AG
does not guarantee
accept any liability
splines
on unless
the shafts
may
be AG.
directly
opposite
each or
other,
withthe
respect
to the cannot
correctnessbe
of information
in this document.
so that
motor
fully located
at the Copyright
first atby AUDI AG.
tempt.
If the electric drive motor - V141- is lowered further it can
then drop down suddenly as the splines come into en
gagement, thus allowing the lugs to impact against the
surfaces in the gearbox housing.
This must be avoided, otherwise the lugs and the roller
bearings can be damaged.
Install flange shaft (left-side) page 141 .
Install gearbox page 61 .
3.5
Checking hub of electric drive motor
Check hub -arrow- of electric drive motor - V141- for scoring.

Note
The electric drive motor - V141- must be renewed as a complete

unit if it is damaged or defective.
3.6
Renewing oil seal for electric drive motor
119
Audi Q5 2008
Extractor hook - T20143/2-
Thrust piece - T40240-
Procedure
Remove electric drive motor - V141- page 112 .
Pry out oil seal for electric drive motor - V141- using extractor
hook -T20143/2- .
Lightly lubricate outer circumference and sealing lips of oil seal
with ATF.
Installation position: open side of oil seal points towards gear

box
Drive in oil seal for electric drive motor - V141- using thrust
piece - T40240- until thrust piece -1- reaches stop.
Install electric drive motor - V141- page 112 .
120
Audi Q5 2008
39
Final drive - front differential
Final drive
1.1 Exploded view - final drive, page 121

1.2 Renewing O-ring on cover for front final drive, page 123
1.1
Exploded view - final drive

Note
page 9

1 - Flange shaft (right-side)
4.2 Removing and in
stalling flange shaft
(right-side), page 142
2 - Circlip
Renew
3 - Oil seal
For flange shaft (rightside)
3.2 Renewing oil seal
(right-side), page 139
4 - Screw plug
hole
drive
Tightening torque
Item 2 (page 125)
5 - Cover
For front final drive
Pay attention to dowel
sleeves
6 - Shim
Behind tapered roller
bearing outer race
7 - Tapered roller bearing outer
race
8 - O-ring
On cover for front final
drive
Renew
1.2 Renewing O-ring on cover for front final drive, page 123
1. Final drive
121
Audi Q5 2008
9 - Differential
10 - Gearbox
11 - Oil seal
For gearbox selector lever
1.14 Renewing selector shaft oil seal, page 45
12 - Gearbox selector lever
Removing and installing page 45
13 - Roll pin
Removing and installing page 45
14 - Flange shaft (left-side)
4.1 Removing and installing flange shaft (left-side), page 141
15 - Bolt
Renew
9 Nm + 60
16 - Mounting bracket for flange shaft (left-side)
Secured to flange shaft together with bearing Item 17 (page 122) via retaining clip
Item 18 (page 122)
If wear is visible, renew mounting bracket for flange shaft (left-side)
17 - Bearing
For flange shaft (left-side)
4.3 Renewing ball bearing and mounting bracket for flange shaft (left-side), page 145
18 - Retaining clip
Forby bearing
on flange
shaft
(left-side)
Protected
copyright. Copying
for private
or commercial
permitted
unless
authorised
by
AUDI
AG.
AUDI
AG
does not guarantee or accept any liability
Renew
19 - Electric drive motor - V141 3.4 Removing and installing electric drive motor, page 112 Electric drive motor - V14120 - O-ring
For input shaft
Renew
21 - Oil seal
For electric drive motor - V141 3.6 Renewing oil seal for electric drive motor, page 119
22 - Oil seal
For flange shaft (left-side)
Between final drive and gearbox housing
3.1 Renewing oil seal (left-side), page 136
23 - Shim
Behind tapered roller bearing outer race
24 - Tapered roller bearing outer race
25 - Bolt
11x
Tightening torque and sequence page 123
122
Rep. gr.39 - Final drive - front differential
Audi Q5 2008
Cover for front final drive - tightening torque and sequence
Stage
1.
2.
Bolts
-1- and -6-1 11-
1.2
Tightening torque
3 Nm
27 Nm
Renewing O-ring on cover for front final

drive
Note
page 9

Procedure

low gearbox.
Remove flange shaft (right-side) page 142 .
Remove bolts securing cover for front final drive in the se
quence -11 ... 1-.
Remove cover for front final drive together with outer race for
tapered roller bearing and shim.
Note
Thickness of shim has been measured to fit; the shim must not
be replaced with another shim of different thickness.
1. Final drive
123
Audi Q5 2008
Renew O-ring -arrow-.
Install differential in gearbox housing.
Note the following if the outer race for tapered roller bearing and
the shim have dropped out of the front final drive cover:
Lubricate shim and outer race for tapered roller bearing with
gear oil and insert in front final drive cover as far as the stop.
Tighten bolts for front final drive cover page 123 .

Install flange shaft (right-side) page 142 .
Fill up gear oil in gearbox after repairs page 129 .
124
Audi Q5 2008
Gear oil
2.1 Exploded view - gear oil drain and inspection plugs, page
125
2.2 Checking gear oil level, page 125
2.3 Draining and filling gear oil, page 129
2.1
Exploded view - gear oil drain and inspection plugs
1 - Screw plug
hole
box
Renew
27 Nm
2 - Screw plug
hole
drive
Renew
27 Nm
3 - Drain plug
drive
Renew
8 Nm
4 - Drain plug
box
Renew
12 Nm
2.2
Checking gear oil level
2.2.1 Checking gear oil level, front final drive, page 125
2.2.2 Checking gear oil level, transfer box, page 127
2.2.1
Checking gear oil level, front final drive
2. Gear oil
125
Audi Q5 2008
Hand pump for filling gearbox - VAS 6617-
Safety goggles
Procedure
Gear oil about 20 (room temperature)


Note
page 9
The prescribed oil level is to be adhered to exactly; the gear
box reacts very sensitively to over-filling.
Renew plug for inspection and filler hole.

low gearbox.
WARNING
Risk of eye injury.

126
Audi Q5 2008
Unscrew plug for inspection and filler hole -arrow A- on front
final drive.
Specification: The oil level is correct when the front final drive
is filled up to the bottom lip of the filler hole.
If oil level is not up to bottom lip of filler hole:

Screw adapter - VAS 6617/6- with adapter - VAS 6617/2hand-tight into gearbox.
Connect hand pump for gear oil - VAS 6617- and fill up with
gear oil.
Gear oil specifications Electronic parts catalogue
Then detach adapter - VAS 6617/6- from gearbox and allow

excess gear oil to drain off.
Tighten new plug -arrow A- on front final drive.
2.2.2
Checking gear oil level, transfer box

2. Gear oil
127
Audi Q5 2008
Safety goggles
Procedure

The vehicle must be stationary with the engine switched off for
at least 15 minutes to allow the oil level to stabilise.

Note

page 9

low gearbox.
WARNING
Risk of eye injury.

Unscrew plug for inspection and filler hole -arrow A- on centre
differential housing.
Specification: Oil level is correct when oil in transfer box is up

to lower edge of filler hole.
128
Audi Q5 2008
If oil level is not up to bottom lip of filler hole:
Screw adapter - VAS 6617/6- with adapter - VAS 6617/2hand-tight into inspection and filler hole for transfer box.
Connect hand pump for gear oil - VAS 6617- and fill up transfer
box with gear oil.
Wait for 5 minutes.

Note
The transfer box incorporates a number of internal oil cham
bers. These must be filled evenly.
The top-up period of at least 5 minutes is necessary so that
the internal oil level can be balanced out between centre dif
ferential and baffle chamber.


to lower edge of filler hole. Top up with gear oil once again if
necessary.
Tighten new plug -arrow A- on housing for centre differential.
2.3
Draining and filling gear oil
2.3.1 Draining and filling gear oil, front final drive, page 129
2.3.2 Draining and filling gear oil, transfer box, page 132
2.3.1
Draining and filling gear oil, front final

drive
permitted
authorised unit
by AUDI
AG. AUDI1782AG does not guarantee or accept any liability
Used oil collection
andunless
extraction
- V.A.G
2. Gear oil
129
Audi Q5 2008
Safety goggles
Draining
Engine not running.


Note

page 9

Renew drain plug with seal.
130
Audi Q5 2008
low gearbox.
WARNING
Risk of eye injury.

Protected
by copyright.
Copying for
or commercial
purposes,
in part
or in whole,
Unscrew
drain
plug -arrow
B-private
on front
final drive
and
drain
off is not
gear oil.
Caution

The engine must not be started when there is no more
gear oil in the front final drive.
Tighten new drain plug -arrow B- on front final drive.
Filling

low gearbox.
WARNING
Risk of eye injury.

Unscrew plug for inspection and filler hole -arrow A- on front
final drive.
2. Gear oil
131
Audi Q5 2008
Screw adapter - VAS 6617/6- with adapter - VAS 6617/2hand-tight into gearbox.
Connect hand pump for gear oil - VAS 6617- and fill up front
final drive with approx. 0.9 ltr. of gear oil.
Wait for 5 minutes.

Note
The fill-up period of at least 5 minutes is necessary so that the

internal oil level can be balanced out between the differential and
the baffle chamber.
Specification: The oil level is correct when the front final drive
is filled up to the bottom lip of the filler hole. Top up with gear
oil once again if necessary.
Tighten new plug -arrow A- on front final drive.

Note
The level does not need to be re-checked after this step.
2.3.2
Draining and filling gear oil, transfer box

132
Audi Q5 2008
Safety goggles
Draining
Engine not running.


Note

page 9

Renew drain plug with seal.
2. Gear oil
133
Audi Q5 2008
low gearbox.
WARNING
Risk of eye injury.

Remove drain plug -arrow B- and allow gear oil to drain off.
Caution

The engine must not be started when there is no gear oil
in the transfer box.
Tighten new drain plug -arrow B-.
Filling up and adjusting oil level

low gearbox.
WARNING
Risk of eye injury.

Unscrew plug for inspection and filler
hole by
-arrow
A-Copying
on centre
Protected
copyright.
differential housing.
134
Audi Q5 2008
Screw adapter - VAS 6617/6- with adapter - VAS 6617/2hand-tight into inspection and filler hole for transfer box.
Connect hand pump for gear oil - VAS 6617- and fill up transfer
box with approx. 0.8 ltr. of gear oil.
Wait for 5 minutes.

Protected
Note by copyright. Copying for private or commercial purposes, in part or in whole, is not
The transfer box incorporates a number of internal oil cham
bers. These must be filled evenly.
The top-up period of at least 5 minutes is necessary so that
the internal oil level can be balanced out between centre dif
ferential and baffle chamber.


to lower edge of filler hole. Top up with gear oil once again if
necessary.
Tighten new plug -arrow A- on housing for centre differential.

Note
The level does not need to be re-checked after this step.
2. Gear oil
135
Audi Q5 2008
Oil seals
3.1 Renewing oil seal (left-side), page 136

3.2 Renewing oil seal (right-side), page 139
3.1
Renewing oil seal (left-side)

Note
A defective oil seal allows gear oil to enter the torque converter
bellhousing.
Oil seal extractor lever - VW 681-
Procedure
Gearbox must be removed and secured to engine/gearbox

support page 77 .
136
Audi Q5 2008
Note
page 9

Caution
Do not set down the gearbox on the ATF oil pan.

low gearbox.
Drain off gear oil in front final drive
2.3.1 Draining and filling gear oil, front final drive,
page 129 .
Remove bolts securing cover for front final drive in the se
quence -11 ... 1-.
Remove cover for front final drive together with outer race for
tapered roller bearing and shim.
Note
Remove differential -arrow-.
Remove tapered roller bearing outer race -1- for differential

and shim -2- (behind outer race) from gearbox housing by
hand.
Note
3. Oil seals
137
Audi Q5 2008
Pull out oil seal.
Note
The oil seal extractor lever must be applied behind the two sealing
lips of the oil seal. Do not position at outer circumference of oil
seal as the contact surface in the gearbox housing could be dam
aged. Guide the lever carefully when removing the seal.
Examine oil seal seat in gearbox housing for damage; reface
surface if necessary.
Lightly lubricate outer circumference and sealing lip of oil seal
with gear oil.
Note
Push oil seal onto thrust piece with the protruding sealing lip on
the oil seal facing towards the tool.
Drive in new oil seal as far as stop.
Insert shim -2- and tapered roller bearing outer race -1- for
differential onto stop in gearbox housing by hand.
Renew O-ring -arrow-.

Install differential in gearbox housing.
Note the following if the outer race for tapered roller bearing and
the shim have dropped out of the front final drive cover:
Lubricate shim and outer race for tapered roller bearing with
gear oil and insert in front final drive cover as far as the stop.
138
Audi Q5 2008
Tighten bolts for front final drive cover page 123 .
3.2
Renewing oil seal (right-side)

Oil seal extractor lever - VW 681-
3. Oil seals
139
Audi Q5 2008
Procedure
Note
page 9

low gearbox.
Pull out oil seal for flange shaft (right-side).
Lubricate outer circumference of new oil seal with gear oil.
Installation position: the open side of the oil seal should face
the gearbox.
Drive in new oil seal as far as stop. Make sure that oil seal
always remains straight when driving in.
140
Audi Q5 2008
Differential
4.1 Removing and installing flange shaft (left-side),

page 141
4.2 Removing and installing flange shaft (right-side),
page 142
4.3 Renewing ball bearing and mounting bracket for flange
shaft (left-side), page 145
4.1
Removing and installing flange shaft

(left-side)

Sealing grease - G 052 128 A1Removing flange shaft (left-side)
Gearbox is secured to engine and gearbox support - VAS

6095- page 77 .
Tilt gearbox to rear on engine and gearbox support to prevent

gear oil from escaping.
Unscrew bolts -arrows- on mounting bracket for flange shaft.
Remove flange shaft (left-side) -1- from gearbox in direction

of -arrow A-.
Note
-Arrow B- can be disregarded.

Remove electric drive motor - V141- page 112 .
4. Differential
141
Audi Q5 2008
Installing flange shaft (left-side)
Thoroughly clean flange shaft (left-side), area of torque con

verter bellhousing leading to differential -arrow A-, and oil seal
-arrow B-.
Note
If oil seal between differential and gearbox housing -arrow B- is

damaged, it must be renewed page 121 .
ing grease Protected
- G 052by128
A1-Copying
.
copyright.
Install electricwith
drive
motor
- V141-ofinformation
page 112
respect
to the correctness
in this. document. Copyright by AUDI AG.
Slide flange shaft (left-side) -1- into gearbox in direction of

-arrow B- (keep end of shaft centred while guiding it into oil
seal on front final drive -arrow-).
Note
The splines -2- on the flange shaft will damage the oil seal
between the final drive and the gearbox housing if you do not
keep the flange shaft centred.
If the oil seal is damaged, it must be renewed.

-Arrow A- can be disregarded.
Tighten flange shaft mounting bracket -arrows-.

After installing gearbox refer to
2.2.1 Checking gear oil level, front final drive, page 125 .
4.2
Removing and installing flange shaft

(right-side)
142
Audi Q5 2008
Drift - VW 295-
Multi-purpose tool - VW 771-
Counterhold tool - 3419-
Protected
by copyright. and
Copying
for private or commercial
purposes,
in part or in whole, is not
Used
oil collection
extraction
unit - V.A.G
1782-
Nut M10 (2x)

Sealing grease - G 052 128 A1-
4. Differential
143
Audi Q5 2008
Removing
noise insulation .
Remove front right wheel.
Remove cover -1- for drive shaft (right-side) from wheel hous
ing.
Note
Some versions are fitted with an additional heat shield -B- for
the drive shaft.
The additional heat shield can have different shapes, depend
ing on the engine and vehicle version.
To ensure that the additional heat shield is aligned correctly
when installing, the installation position relative to the heat

shield -A- must be marked with paint before removing.
If fitted, mark installation position of heat shield -B- relative to

heat shield -A- with paint.
Remove bolts -1, 2, 3- and detach heat shields for drive shaft
(right-side).
Unbolt drive shaft (right-side) from flange shaft on gearbox and
move drive shaft to rear.
low gearbox.
Screw eye bolt from counterhold tool - 3419- into one of the
threaded holes on flange shaft (right-side) with 2 nuts M10
-item 1- attached.
Attach multi-purpose tool - VW 771- with -VW 771/13- to eye
bolt and pull flange shaft off gearbox.
144
Audi Q5 2008
Installing
Note
Renew circlip for flange shaft (right-side).

Clamp flange shaft in vice, using jaw protectors. Use new cir
clip -A- to press old circlip out of groove in flange shaft.
Check flange shaft oil seal (right-side) for damage and renew
if necessary page 139 .
ing grease - G 052 128 A1- .
Drive in flange shaft (right-side) with drift - VW 295- .
Install drive shaft (right-side) Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Exploded view - drive shaft .
Install heat shield for drive shaft and tighten bolts to 23 Nm.
Check oil level in front final drive and top up as required
page 125 .
4.3
Renewing ball bearing and mounting

bracket for flange shaft (left-side)

Thrust plate - VW 401-
4. Differential
145
Audi Q5 2008
Press tool - VW 412-
Tube - VW 516-
Procedure
Remove circlip -1- from flange shaft.
Press ball bearing -A- off flange shaft.
146
Audi Q5 2008
Place mounting bracket -B- on ball bearing.
Installation position of mounting bracket: lettering on mounting

bracket faces towards flange.
Press new ball bearing -A- onto flange shaft as far as stop.
Fit new circlip -1- in annular groove on flange shaft.

4. Differential
147
Audi Q5 2008
Centre differential
5.1 Exploded view - centre differential, page 148

5.2 Removing and installing centre differential, page 149
5.3 Renewing oil seal for rear splined shaft, page 154
5.4 Removing and installing rear splined shaft, page 159
5.5 Renewing ball bearing for rear splined shaft, page 162
5.6 Renewing ball bearing for centre differential, page 163
5.1
Exploded view - centre differential

Caution

Do not run the engine or tow the vehicle if the centre dif
ferential has been removed or if the gear oil has been
drained.
1 - Bolt
20 Nm + 90
Renew
2 - Bolt
Tightening torque and
sequence page 149
Renew
3 - Centre differential housing
5.2 Removing and in
stalling centre differen
tial, page 149
4 - O-ring
Renew
Lubricate with gear oil
5 - Centre differential
6 - Ball bearing
For centre differential
5.6 Renewing ball
bearing for centre differ
ential, page 163
7 - Circlip
For ball bearing for rear
splined shaft
8 - Circlip
For rear splined shaft
9 - Ball bearing
5.5 Renewing ball
bearing for rear splined
shaft, page 162
148
Audi Q5 2008
10 - Damper weight
Depending on version
11 - Oil seal
5.3.1 Renewing oil seal for rear splined shaft, vehicles with rear splined shaft without vibration damp
er, page 154
5.3.2 Renewing oil seal for rear splined shaft, vehicles with rear splined shaft and vibration damper,
page 156
12 - Rear splined shaft
Without vibration damper
For correct version, refer to Electronic parts catalogue
Renew oil seal when renewing rear splined shaft
13 - Dust ring
Renew if removed
14 - Rear splined shaft
With vibration damper
For correct version, refer to Electronic parts catalogue
Renew oil seal when renewing rear splined shaft
Centre differential housing - tightening torque and sequence
Note
Renew the bolts for the centre differential housing.

Stage
1.
2.
3.
5.2
Bolts
-1- and -6-1 6-1 6-
Tightening torque/tightening angle

3 Nm
10 Nm
Turn 90 further
Removing and installing centre differen

tial

5. Centre differential
149
Audi Q5 2008
Gearbox support - 3282-
Safety goggles
Removing
Gearbox in vehicle
Caution

The engine must not be run and the vehicle
mustauthorised
not beby AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
towed without gear oil.
Note
Refer to general repair instructions page 10 .
Note rules for cleanliness when working on automatic gearbox
page 9 .
150
Audi Q5 2008
noise insulation .
Caution
Risk of damage to flexible joint in front silencer.

The flexible joint in the front silencer must not be bent fur
ther than 10.
Unscrew bolts -arrows-, push clamp towards rear and tie up
front silencer to one side.
If fitted, remove bolts -arrows- and detach heat shield for prop
shaft.
151
Audi Q5 2008
Caution
There is a risk of damage to the gearbox oil pan.

Do not place gearbox down on the gearbox oil pan.
Attach two flat support mountings -1- and -2- to gearbox sup
port - 3282- .
Set up gearbox support - 3282- on engine and gearbox jack V.A.G 1383 A- .
Support gearbox at bolted surface of gearbox oil pan as shown
in illustration, using rubber packing -3- on each side.
Slightly lift gearbox with engine and gearbox jack - V.A.G 1383
A- .
WARNING
Risk of accident.
left unattended.
Unscrew nuts -arrows- and remove tunnel cross member.
152
Audi Q5 2008
low gearbox.
Drain off gear oil in transfer box
2.3.2 Draining and filling gear oil, transfer box, page 132 .
Lower gearbox using engine and gearbox jack - V.A.G 1383

A- until gearbox oil pan is just above cross brace -A- but does
not make contact.
Slacken bolts securing centre differential housing in the se

quence -6 ... 1- and remove bolts.
Caution
Gearbox components must be handled with care, otherwise

they will be damaged.
Detach centre differential housing from gearbox carefully
towards the rear. Take care that centre differential does
not drop out of gearbox.
153
Audi Q5 2008
Secure centre differential -1- to prevent it from falling out, or
pull it off output shaft towards rear.
Installing
Note
Renew O-ring for centre differential housing.

If centre differential has been removed -1-:
Fit centre differential onto splines of output shaft. At the same
time turn centre differential slightly.
Check whether centre differential can be turned by hand after
being fitted.
Fit housing with new O-ring and output shaft installed onto
centre differential. Turn housing slightly if necessary.
Tighten bolts for centre differential housing page 149 .
Install exhaust system and perform stress-free alignment
Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silenc
ers .
Fill up gear oil in transfer box page 132 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5.3
Renewing oil seal for rear splined shaft
5.3.1 Renewing oil seal for rear splined shaft, vehicles with rear
splined shaft without vibration damper, page 154
5.3.2 Renewing oil seal for rear splined shaft, vehicles with rear
splined shaft and vibration damper, page 156
5.3.1
Renewing oil seal for rear splined shaft,

vehicles with rear splined shaft without
vibration damper
154
Audi Q5 2008
Assembly tool - T40239-
Sealing grease - G 052 128 A1Procedure

Note
Refer to general repair instructions page 10 .
Note rules for cleanliness when working on automatic gearbox
page 9 .

Pry off dust ring -1-.
Note
The dust ring cannot be removed without being damaged.
155
Audi Q5 2008
Pull out oil seal for rear splined shaft.
Clean contact surface and sealing surface.
Lubricate outer circumference of seal with gear oil.
Fit guide sleeve - T40239/1- -item 1- onto rear splined shaft.

ing grease - G 052 128 A1- .
Push oil seal -2- over guide sleeve -item 1- and onto rear
splined shaft.
Installation position: the open side of the seal should face the
gearbox housing.
Drive in oil seal as far as stop using thrust piece - T40239- ,

-item 1-. Make sure oil seal remains straight.
Note
Pull guide sleeve - T40239/1- carefully out of oil seal so that seal
ing lip is not rolled back.
Clip on new dust ring -1-.

5.3.2
Renewing oil seal for rear splined shaft,

vehicles with rear splined shaft and vi
bration damper
156
Audi Q5 2008
Drift sleeve - 30 - 100-
157
Audi Q5 2008
Sealing grease - G 052 128 A1Procedure

Remove centre differential housing
5.2 Removing and installing centre differential, page 149 .
Remove circlip -arrow- on inside of housing.
Note
The circlip locates the rear splined shaft on the bearing in the
housing.
Carefully knock rear splined shaft out of centre differential
housing using copper drift.
Note
In order to drive out the rear splined shaft, clamp the centre dif
ferential housing in a vice or have a second mechanic hold it as
required.
Lever out oil seal -1-.
Note
-Item 2- can be disregarded.
158
Audi Q5 2008
Installing
Lightly lubricate outer circumference of oil seal with gear oil.
Installation position: the open side of the oil seal faces the
housing.

ing grease - G 052 128 A1- .
Press rear splined shaft into centre differential housing as fol

lows:
Insert rear splined shaft into centre differential housing from
below.
Place housing with rear splined shaft on thrust plate - VW 402under workshop press.
Position drift sleeve - 30 - 100- on inner race of ball bearing.
Press in rear splined shaft.
Fit circlip -arrow- into groove on rear splined shaft.

Install centre differential housing page 149 .
Fill up gear oil in transfer box page 132
5.4
Removing and installing rear splined

shaft

159
Audi Q5 2008
Drift sleeve - 30 - 100-
Sealing grease - G 052 128 A1-
160
Audi Q5 2008
Procedure
Remove centre differential housing
5.2 Removing and installing centre differential, page 149 .
Remove circlip -arrow- on inside of housing.
Note
The circlip locates the rear splined shaft on the bearing in the
housing.
Carefully knock rear splined shaft out of centre differential
housing using copper drift.
Note
In order to drive out the rear splined shaft, clamp the centre dif
ferential housing in a vice or have a second mechanic hold it as
required.
Lever out oil seal -1-.
Note
-Item 2- can be disregarded.
Installing
Lightly lubricate outer circumference of oil seal with gear oil.
Installation position: the open side of the oil seal faces the
housing.

ing grease - G 052 128 A1- .
Press rear splined shaft into centre differential housing as fol

lows:
Insert rear splined shaft into centre differential housing from
below.
Place housing with rear splined shaft on thrust plate - VW 402under workshop press.
Position drift sleeve - 30 - 100- on inner race of ball bearing.
Press in rear splined shaft.
161
Audi Q5 2008
Fit circlip -arrow- into groove on rear splined shaft.
5.5
Renewing ball bearing for rear splined shaft

equipment required
Thrust plate - VW 401 Thrust plate - VW 402 Press tool - VW 412 Tube - 2040 Tube - VW 415 A-
162
Audi Q5 2008
Procedure
Remove centre differential housing page 149 .
Remove circlip -A- for rear splined shaft and circlip -B- for ball
bearing.
Press rear splined shaft and oil seal for rear splined shaft out
of centre differential housing page 159 .
Press out ball bearing for rear splined shaft.
Press in ball bearing for rear splined shaft.
Collar of tube - VW 415 A- -arrow- faces press tool - VW 412- .
Fit circlip -B- for ball bearing.

Note
Item -A- can be disregarded.

Install oil seal for rear splined shaft and rear splined shaft in
centre differential housing page 159 .
5.6
Renewing ball bearing for centre differential
163
Audi Q5 2008
equipment required
Thrust plate - VW 401 Thrust plate - VW 402 Press tool - VW 412 Press tool - VW 432 Assembly tool - 3350 Splitter 22 ... 115 mm - Kuk
ko 17/2-
Procedure
Remove centre differential housing page 149 .
Pull centre differential -1- off output shaft towards the rear.
164
Audi Q5 2008
Press ball bearing off centre differential.
A - Splitter 22 ... 115 mm - Kukko 17/2
The collar of press tool - VW 432- points towards ball bearing.
Press ball bearing onto centre differential.
165
Audi Q5 2008
Gearbox control system
6.1 Overview of fitting locations - gearbox control system,

page 166
6.1
Overview of fitting locations - gearbox

control system
Diagnostic connection
Fitting location: the diagnostic connection for the diagnostic
tester , e.g. vehicle diagnostic, testing and information system
- VAS 5051B- , is located in the driver's footwell.
Mechatronic unit, automatic gearbox control unit - J217- , senders

Copying
for private
or commercial
and pressure
regulating
valves
- part
1
with location:
respect to thethe
correctness
of information
in this
Copyright
by AUDI AG.
Fitting
mechatronic
unit
is document.
bolted to
the underside
of the gearbox housing and covered by the ATF oil pan.
The mechatronic unit incorporates the hydraulic control system,

the electronic control unit and the sensors and actuators as a
complete synchronised unit. This includes:
1-
Solenoid valve 1 - N88-
2-
Automatic gearbox pressure regulating valve 7 - N443-
3-
4-
Gearbox output speed sender - G195-
5-
6-
7-
8-
9-
166
Audi Q5 2008
Mechatronic unit, automatic gearbox control unit - J217- , senders
and pressure regulating valves - part 2
1-
Gearbox input speed sender - G182-
2-
Automatic gearbox control unit - J217-
3-
Gearbox oil temperature sender - G93-
4-
Gear sensor - G676-
NoteCopying for private or commercial purposes, in part or in whole, is not
All components mentioned are tested via self-diagnosis.

The mechatronic unit can only be replaced as a complete unit.
2.1 Removing and installing mechatronic unit, page 105 .
Auxiliary hydraulic pump 1 for gearbox oil - V475 1.3.1 Removing and installing auxiliary hydraulic pump for
gearbox oil, page 100
Selector lever position display - Y6 Fitting location: The selector lever position display - Y6- is in
tegrated in the instrument cluster.
Note
If the selector lever position display is defective, the instrument

cluster must be renewed Electrical system; Rep. gr. 90 ; Dash
panel insert; Removing and installing dash panel insert - KX2- .
6. Gearbox control system
167
Audi Q5 2008
Selector lever sensors control unit - J587- and tiptronic switch F189 Fitting location: the selector lever sensors control unit - J587and the tiptronic switch - F189- are combined in a single
component -2- which is clipped onto the shift unit -arrows-.
Note
-Arrows A- can be disregarded.

1.7.2 Removing and installing selector lever sensors control
unit J587 and tiptronic switch F189 , page 31 .
Selector lever lock solenoid - N110 Fitting location: the selector lever lock solenoid - N110-item 1- is clipped onto the selector mechanism.
N110 , page 29 .
Gear selector position P switch - F305 Fitting location:

Gear
selector
position
F305-orcon
permitted unless
authorised
by AUDI
AG. AUDIP
AGswitch
does not -guarantee
accept any liability
sists of two
(-1- ofand
- 2-) inand
is installed
onby AUDI AG.
withreed
respectcontacts
to the correctness
information
this document.
Copyright
printed circuit board -B- in selector lever lock solenoid - N110-A-.
Note
Gear selector position P switch - F305- can only be renewed to

gether with selector lever lock solenoid - N110- .
N110 , page 29 .
168
Audi Q5 2008
Kick-down switch - F8Note
A specific value for the accelerator position sender - G79- and

accelerator position sender 2 - G185- is stored in the engine con
trol unit.
Fitting location: the accelerator
position senders are integrated
in the accelerator pedalpermitted
module
-arrow-.
unless
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
The accelerator pedal module must be renewed if one of the ac

celerator position senders is defective Fuel supply system;
Rep. gr. 20 ; Accelerator mechanism; Removing and installing
accelerator pedal module with accelerator position sender -G79- /
-G185- .
Selector lever position display - Y26 Fitting location: the display unit for selector lever position Y26- -item 1- is clipped into the centre console.
1.10 Removing and installing selector lever position display
Y26 , page 35 .
Electric drive motor - V141The disengagement clutch in the electric drive motor - V141- dis
engages the engine from the electric drive motor - V141- . The
disengagement clutch is also designated disengagement
Fitting location: electric drive motor - V141- is installed in the
gearbox housing in place of the torque converter -1 3 Electric drive motor, page 110 .
3.4 Removing and installing electric drive motor, page 112
6. Gearbox control system
169

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Service

8-speed automatic gearbox 0BW hybrid, four-wheel

Service Department. Technical Information

Exploded view - ATF drain and inspection plugs in gearbox . . . . . . . . . . . . . . . . . . . . . . . .

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

(ARL003554; Edition 01.2014)

Location of code letters on gearbox

Code letters and gearbox serial number

Serial number of gearbox

Manufacturer's gearbox designation: 8P-55AH

Gearbox code, in this example: NUL

2.1 Safety precautions when working on high-voltage vehi

Safety precautions when working on

2.1.1 Safety precautions for de-energising high-voltage sys

Safety precautions for de-energising

The high-voltage system may only be de-energised by a suit

The system must first be de-energised before any work is done

The types of work for which the high-voltage system has to be

Read and observe all additional warnings and descriptions for

In the event of queries or uncertainty regarding the terms elec

Rep. gr.00 - Technical data

High voltage can cause fatal injury.

Safety precautions for re-energising

Re-energising the high-voltage system Electrical system,

Read and observe all additional warnings and descriptions for

In the event of queries or uncertainty regarding the terms elec

High voltage can cause fatal injury.

General safety precautions and repair

Read and observe all additional warnings and descriptions for

In the event of queries or uncertainty regarding the terms elec

Rep. gr.00 - Technical data

Risk of fatal injury if high-voltage components are damaged.

Visually inspect all potential equalisation

When working on a vehicle with the ignition switched on or

Safety hazard: the engine can start unexpectedly.

Working on vehicles with high-voltage wiring:

Do not support yourself or tools on high-voltage wiring or

The round high-voltage connectors are colour-coded with

Safety precautions when working on ve

Observe the following precautions to avoid possible injury and/or

Accidents and injury can be caused if a gear is inadvertently

Rep. gr.00 - Technical data

When disconnecting the battery there is a risk of serious dam

Safety precautions when working on ve

Please note the following when working on vehicles with start/stop

Risk of injury due to automatic engine start on vehicles with

Safety precautions when using testers

Observe the following precautions if test equipment has to be

Accidents can be caused if the driver is distracted by test

The use of test equipment while driving causes distraction.

There is an increased risk of injury if test equipment is not

Always secure test equipment to the rear seat with a strap

Notes on tow-starting and towing

Risk of irreparable damage to gearbox.

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

Rep. gr.00 - Technical data

3.1 Rules for cleanliness, page 9

Rules for cleanliness

Thoroughly clean all joints and connections and the surround