Filling up gear oil in gearbox after repairs: Audi A6 C6

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

• Opens: gearbox oil

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• Gearbox support must be removed in order to access oil filler/inspection plug for transfer box.
• Gearbox must be in horizontal installation position when checking gear oil.It must be raised or lowered accordingly using engine and gearbox jackV.A.G 1383 A after removing tunnel cross member.
• Observe relevant disposal regulations.
• Oil filler/inspection plug for transfer box is located on side of transfer box housing and is inserted from below (arrow).Illustration shows sectional view of transfer box from rear side with gear oil level and filler opening.
• The filling period of at least 5 minutes is necessary so that the internal oil level in the system has time to equalise.

📋 Procedure

1. Remove gearbox mounting and gearbox support [Note: Gearbox support must be removed in order to access oil filler/inspection plug for transfer box.]
2. ⚠ When performing the steps below, please note the following:Do not support the gearbox under the oil pan - risk of damage. — Insert a bolt M12x100 (item 1) with attached nut (2) into the mounting hole behind the oil pan on the gearbox.
3. Apply lifting column of engine and gearbox jackV.A.G 1383 A to bolt head and raise gearbox until it is in horizontal installation position again. [Note: Gearbox must be in horizontal installation position when checking gear oil.It must be raised or lowered accordingly using engine and gearbox jackV.A.G 1383 A after removing tunnel cross member.]
4. Place used oil collection and extraction unitV.A.G 1782 below gearbox. [Note: Observe relevant disposal regulations.]
5. ⚠ Wear safety goggles. — Remove oil filler/inspection plug (arrow) for transfer box. [Note: Oil filler/inspection plug for transfer box is located on side of transfer box housing and is inserted from below (arrow).Illustration shows sectional view of transfer box from rear side with gear oil level and filler opening.]

6. Remove oil filler/inspection plug (arrow) for front final drive.
7. Using hand pump for gear oilVAS 6617, fill front final drive slowly and evenly until gear oil emerges at bottom lip of oil filler hole (allow a filling period of at least 5 minutes). [Note: The filling period of at least 5 minutes is necessary so that the internal oil level in the system has time to equalise.]
8. Using hand pump for gear oilVAS 6617, fill gear oil into transfer box housing through oil filler hole on transfer box (arrow) (allow a filling period of at least 5 minutes). [Note: The filling period of at least 5 minutes is necessary so that the internal oil level in the system has time to equalise.]
9. Top up gear oil again until oil level is correct.
10. Allow excess gear oil to emerge from oil filler hole.
11. Screw the old oil filler/inspection plugs back in.
12. Install gearbox support .
13. Install tunnel cross member .
14. Assemble exhaust system so it is free of stress 26.
15. ⚠ The gearbox will be damaged if the gear oil level is too high or too low.Follow all specified procedures exactly.Before checking the oil level, it is necessary to test drive the vehicle briefly to allow air to escape from the oil system. — Drive vehicle for 5 minutes at approx. 40 km/h over a distance of at least 4 km. [Note: Make sure that gear oil cooler is filled with gear oil. Similarly, the centre differential must fill up internally with gear oil after it has been removed. A short test drive is necessary because the oil pump for the transfer box is operated only when the vehicle is driven.]
16. Check gear oil and top up if necessary Checking gear oil level in gearbox and topping up

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