If you’re tackling transmission maintenance on your 2001 Audi A6, removing the valve body is a crucial step for various repairs, from cleaning to replacement. This guide, based on my experience as a seasoned auto repair content creator at keyfobprog.com, will walk you through the process. While similar to ZF 5HP19 transmissions found in BMWs, this guide is tailored for your Audi A6’s front-wheel-drive system. Remember to work carefully, as the valve body is a delicate component.
Valve Body Removal Steps for Your Audi A6
Before you begin, ensure you have a clean workspace and the necessary tools, including a Torx bit set and an 11mm socket. Let’s get started:
Step 1: Draining the Transmission Fluid
Begin by draining the transmission fluid. For the cleanest process, I recommend doing this while the transmission is still connected to the engine. Locate the drain plug on the transmission oil pan and unscrew it to allow the fluid to drain completely. This minimizes mess and gives you room to work.
Step 2: Oil Pan Removal
Once the fluid is drained, the next step is removing the oil pan. On your Audi A6 01, you’ll find approximately 27 bolts securing the oil pan. Use a Torx bit to carefully unscrew all these bolts. After removing the last bolt, gently detach the oil pan. With the pan removed, you’ll gain access to the oil filter.
Step 3: Oil Filter Removal
The oil filter is typically held in place by two bolts. Locate these bolts and unscrew them to release the filter. Once the bolts are out, gently pop the oil filter out. Now, you’re ready to focus on the valve body itself.
Step 4: Disconnecting Electrical Components
Before physically removing the valve body, you need to disconnect its electrical components. Carefully unplug the input speed sensor and what we’ll refer to for this guide as the output speed sensor. Next, disconnect the large output plug. This plug usually has a locking lug; disengage the lug and push the plug in to disconnect it. Handle these connectors gently to avoid damage.
Step 5: Identifying and Removing Valve Body Bolts
Now, you’ll encounter the bolts securing the valve body. It’s important to note that there are two different sizes of bolts, although they use the same socket size. To identify the correct bolts to remove, use an 11mm socket. If the socket fits snugly over the bolt head, leave it. The bolts you need to remove are those where the 11mm socket fits loosely, indicating a larger diameter bolt shank. Remove all these larger diameter bolts. This step is crucial to detach the valve body correctly.
Step 6: Valve Body Extraction
With all the correct bolts removed, you can now gently remove the valve body. Valve bodies can be somewhat heavy and awkward to handle. I find it easiest to start by gently pulling down the corner where you disconnected the large output plug (as pictured below in a similar transmission). This allows you to get a better grip as you carefully pull the valve body out. Once removed, your Audi A6 transmission case should resemble the second image, ready for the next stages of your repair.
This image illustrates the valve body area in a similar transmission, highlighting the electrical connectors and bolt locations you’ll encounter in your 01 Audi A6.
After removing the valve body from your 2001 Audi A6 transmission, the case should appear similar to this, revealing the internal components.
Transmission Disassembly: Moving Beyond the Valve Body on Your Audi A6
With the valve body out, you might need to proceed with further disassembly depending on your repair needs. In my experience, accessing the oil pump and drums requires removing some additional components. While specific guides for the Audi A6 01 transmission can be scarce, understanding the general process, often similar to BMW 5HP19 transmissions, is helpful. However, be prepared for minor differences specific to your Audi’s front-wheel-drive setup.
Removing Rubber Plugs and the Front Driver Side Axle
Before moving to the oil pump and drums, there are rubber plugs and the driver’s side axle that need attention.
Step 1: Locating and Removing Rubber Plugs
Refer to the image below for the location of the rubber plugs. These are circled in the picture for clarity. While pliers can work, I find a pick tool makes removing these plugs easier. If you’re using a transmission overhaul kit for your 01 Audi A6, you likely have replacement plugs, so minor damage during removal isn’t a major concern. There are typically five plugs towards the top of the transmission case and three towards the bottom. The top plugs interface with the oil pump, and the bottom ones with the D-Drum. Removing these is essential for drum disassembly. For the bottom three plugs, you’ll first need to remove the snap rings and springs that sit over them to gain access.
Step 2: Axle Removal on Your Audi A6
The driver’s side axle needs to be removed to free up the oil pump for removal. Typically, three bolts secure the axle. Remove these bolts, and you should be able to pull the axle out. Penetrating oil or WD-40 can be helpful if the bolts are stiff. Once the axle is removed, you’ll have the necessary clearance to proceed.
This image highlights the locations of the rubber plugs and driver’s side axle on a similar transmission, guiding you on where to look on your 2001 Audi A6.
Close-up view of the axle bolts on a comparable transmission, showing the type of fasteners you’ll need to remove on your Audi A6 01.
Oil Pump and Drum Removal in Your Audi A6 Transmission
This is often the most challenging part of the disassembly. Organization and cleanliness are paramount at this stage. Ensure you have ample clean space to lay out the components as you remove them. While the YouTube video linked below demonstrates a BMW transmission, the general principles of oil pump and drum removal are very similar to your Audi A6’s transmission.
Step 1: Oil Pump Removal – A Tricky Step
Removing the oil pump can be quite difficult due to an O-ring seal that can create a tight fit. First, ensure you’ve removed all nine bolts securing the oil pump. Then, using vice grips, grip one of the oil pump lugs and the edge of the transmission case. While pulling outwards, gently wiggle the oil pump to break the O-ring seal. In some cases, a rubber hammer might be needed to lightly tap and rotate the pump to help break the seal. Be patient and apply steady, controlled force.
Step 2: Drum Removal – Careful Handling Required
Once the oil pump is out, the drums should be removable by hand. The key here is meticulous organization. Pay close attention to the order and orientation of each drum as you remove it. Taking pictures at each step, like the example below, is highly recommended. Lay out the drums in the order of removal to ensure correct reassembly later.
Step 3: Next Steps: Cleaning Steel Plates and More
Further steps depend on the specific issue you’re addressing. In my case, replacing friction plates and cleaning steel plates was necessary. Cleaning steel plates involves removing any burnt or rough spots using fine sandpaper. Each gear pack is held together by snap rings, which can be carefully removed with a small flathead screwdriver. Again, maintain the order of gear packs for correct reinstallation. When cleaning steel plates, use very fine sandpaper to avoid removing too much material; the goal is to smooth out imperfections, not to significantly reduce plate thickness. The image below shows an example of steel plates before and after cleaning.
This image demonstrates a recommended layout for the transmission drums after removal from a similar transmission, emphasizing the importance of organization for your Audi A6 project.
Example of transmission steel plates before and after cleaning, illustrating the process you might undertake when servicing your 01 Audi A6 transmission.
In many cases, O-rings and seals will be in good condition. However, in transmissions with significant failures, the D-Drum might be damaged and require replacement. The YouTube video below provides guidance on drum disassembly and seal replacement if needed. Even if seals appear good, consider replacing them as preventative maintenance while you have the transmission disassembled.
YouTube Video: ZF 5HP19 Valve Body Removal
YouTube Video: 5HP19 Oil Pump and Drums Removal
YouTube Video: Drum Compression for Seal Replacement
I hope this guide provides valuable assistance with your Audi A6 transmission valve body removal and disassembly. If you have any questions, feel free to reach out. And one final piece of advice: if you’re removing your transmission, it’s always a good idea to consider replacing the torque converter as well.
