DIY Guide: Audi A6 2.7 t 2003 Transmission Valve Body Removal and Disassembly

For Audi A6 2.7 T 2003 owners tackling transmission issues, understanding the valve body and its removal is often the first crucial step. This guide provides a detailed walkthrough for removing the valve body and beginning the transmission disassembly process on your Audi A6 2.7 t 2003. We’ve compiled this information, incorporating helpful references to assist you in this DIY repair. Remember to exercise caution when handling transmission components.

Valve Body Removal for Audi A6 2.7 t 2003

Removing the valve body from your Audi A6 2.7 t 2003 transmission is a relatively straightforward process, but careful handling is essential. The valve body is a delicate component of your automatic transmission. These steps are tailored for the Audi A6 2.7 t 2003 and are closely related to the ZF 5HP19 transmission family, commonly found in similar models. While referencing videos for BMW models with the same transmission type can be beneficial for a general understanding, always prioritize specifics for your Audi A6 2.7 t 2003.

Step-by-Step Valve Body Removal:

1. Drain Transmission Fluid: Begin by draining the transmission fluid. Ensure you drain as much fluid as possible for a cleaner workspace. This is best done while the transmission is still connected to the engine. Locate the drain plug on the transmission oil pan of your Audi A6 2.7 t 2003 and unscrew it to drain the fluid completely.

2. Remove Oil Pan: Once the fluid is drained, the next step is to remove the oil pan. On the Audi A6 2.7 t 2003 transmission, you’ll find approximately 27 bolts securing the oil pan. Use a Torx bit to unscrew all these bolts. After removing all bolts, carefully detach the oil pan.

3. Remove Oil Filter: With the oil pan removed, you’ll have access to the oil filter. The oil filter is typically held in place by two bolts. Unscrew these bolts and gently pull out the oil filter.

4. Disconnect Electrical Components: Before physically removing the valve body, disconnect all electrical components attached to it. For the Audi A6 2.7 t 2003, this involves unplugging the input speed sensor and output speed sensor. Identify and unplug the large output plug, ensuring to disengage any locking lug that secures it before pushing the plug in to disconnect.

5. Remove Valve Body Bolts: Now, focus on the bolts securing the valve body to the transmission housing of your Audi A6 2.7 t 2003. There are bolts of two different sizes. To identify the correct bolts for removal, use an 11mm socket. If the socket fits snugly over the bolt head, it’s one you should remove. Remove all bolts that fit the 11mm socket. This ensures you are removing the correct bolts for valve body detachment.

6. Detach Valve Body: With all the retaining bolts removed, you can now carefully detach the valve body. Since valve bodies have some weight, it’s best to gently pull down the corner where the large output plug was removed (as seen in the image above). This allows for a better grip and balanced removal. Once you gently pull it out, your Audi A6 2.7 t 2003 transmission case should now be exposed, ready for further disassembly.

Disassembling the Audi A6 2.7 t 2003 Transmission

With the valve body removed, you can proceed with further disassembly of your Audi A6 2.7 t 2003 transmission. While general guides and videos for the 5HP19 transmission (often in BMW applications) can be helpful, be aware of potential minor differences specific to the Audi A6 2.7 t 2003 model. Pay close attention to each step to avoid complications.

Removing Rubber Plugs and Front Driver Side Axle

Before removing the oil pump and drums, several rubber plugs and the front driver side axle need to be addressed.

1. Remove Rubber Plugs: Refer to the image below for the location of these rubber plugs on your Audi A6 2.7 t 2003 transmission. While pliers can be used, a pick tool often makes removal easier. If you are using a transmission overhaul kit for your Audi A6 2.7 t 2003, damaging these plugs during removal is not a concern as replacement plugs are typically included in the kit. There are five plugs located towards the top of the transmission case and three towards the bottom. The top plugs are inserted into the oil pump, and the bottom ones into the D-Drum. Removing these plugs is necessary to proceed with drum disassembly. For the bottom three plugs, you’ll first need to remove three snap rings and three springs that are positioned over them to gain access.

2. Remove Front Driver Side Axle: The driver’s side axle needs to be removed to free up the oil pump for removal. Locate the three bolts holding the driver’s side axle in place on your Audi A6 2.7 t 2003 transmission. Remove these bolts and pull the axle out. If the bolts are stiff, using WD-40 or a similar penetrating oil can help loosen them.

Removing Oil Pump and Drums

Removing the oil pump can be one of the more challenging steps in disassembling your Audi A6 2.7 t 2003 transmission. Organization and cleanliness are paramount during this stage. Ensure you have a clean and ample workspace to lay out the components as you remove them.

1. Remove Oil Pump: This step often requires some persistence. First, remove the bolts securing the oil pump to the transmission case. There should be approximately nine bolts. Use vice grips to grasp any of the oil pump’s lugs and the edge of the transmission case. The oil pump has an O-ring seal, which can sometimes make removal difficult due to suction. While pulling with the vice grips, gently jiggle the oil pump. If it’s still stuck, carefully use a rubber hammer to lightly tap and rotate the oil pump to break the O-ring seal.

2. Remove Drums: Once the oil pump is removed, the transmission drums can typically be removed by hand. As you remove each drum from your Audi A6 2.7 t 2003 transmission, pay close attention to its orientation and the order of components. Taking pictures as you disassemble can be extremely helpful for reassembly. Organize the drums and related parts in the order of removal to streamline the reassembly process.

3. Inspecting and Cleaning Components: The next steps depend on the specific issue you are addressing in your Audi A6 2.7 t 2003 transmission. Common repairs include replacing friction plates and cleaning steel plates within the gear packs. Each gear pack is held together by a snap ring, which can be removed using a small flathead screwdriver. Maintain the order of gear packs and their internal components to ensure correct reassembly. To clean steel plates, use fine sandpaper to gently remove any rough spots or burn marks, being careful not to remove too much material.

In many cases, O-rings and seals may be in good condition. However, in some Audi A6 2.7 t 2003 transmissions, the D-Drum might fail and require replacement, along with associated seals. If you suspect seal damage or are performing a comprehensive overhaul, consider inspecting and potentially replacing all seals.

Final Advice: When undertaking transmission work on your Audi A6 2.7 t 2003, especially if you’re removing the transmission, it is highly recommended to replace the torque converter as a preventative measure. This can save future labor costs and ensure the longevity of your transmission repair. If you encounter issues beyond your comfort level, consulting a professional mechanic experienced with Audi A6 2.7 t 2003 transmissions is always a prudent step.