2016 Audi RS7 Sportback Download Service & Repair Manual
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Repair Manual
Audi A4 2008 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ ,
Audi A6 China 2012 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A8 2010 ➤ , Audi Q5 2008 ➤ ,
Audi Q5 China 2010 ➤
Rear Final Drive 0BC, 0BD, 0BE, 0BF
Edition 03.2020
Service
Service Department. Technical Information
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.
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
39 - Final Drive, 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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2020 Audi AG, Ingolstadt D3E800C3A1F
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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.
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Final Drive Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Overview - Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Component Location Overview - Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Safety Precautions when Working on High-Voltage Vehicles . . . . . . . . . . . . . . . . . . . . . . 10
6 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Safety Precautions and Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Vehicle Lift Mode, Vehicles with Air Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Overview - Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2 Driveshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Drive Shaft, Removing and Installing from Rear Final Drive . . . . . . . . . . . . . . . . . . . . . . . . 35
1.4 Driveshaft, Installing on Transmission and Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.5 Boot, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2 Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.1 Overview - Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Final Drive, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3 Final Drive, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Overview - Final Drive, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.2 Hydraulic Control Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.3 Hydraulic Control Unit, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.4 All Wheel Drive Pump V415 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5 Oil Pressure/Temperature Sensor G437 or Oil Pressure/Temperature Sensor 2 G640 ,
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.6 All Wheel Drive Clutch Valve N445 or All Wheel Drive Clutch Valve 2 N446 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.7 Torque Displacement, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1 Component Location Overview - Drain and Check Plugs, 0BE and 0BF . . . . . . . . . . . . . . 101
4.2 Gear Oil, Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3 Gear Oil, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1 Component Location Overview - Drain and Check Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2 ATF Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.3 ATF, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.1 Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.4 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
Contents i
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.
6.5 Flange Shaft Protective Ring, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.6 Flange Input Shaft Ring, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7 Flange/Driveshaft, Replacing, 0BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8 Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
8.1 Component Location Overview - Transmission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
8.2 All Wheel Drive Control Module J492 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 153
8.3 All Wheel Drive Control Module J492 , Additional Work after Replacing . . . . . . . . . . . . . . 154
9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
ii Contents
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.
00 – General, Technical Data
1 Identification
(Edition 03.2020)
⇒ “1.1 Final Drive Identification”, page 1
1.1 Final Drive Identification
⇒ “1.1.1 Final Drive Identification, 0BC”, page 1
⇒ “1.1.2 Final Drive Identification, 0BD”, page 2
⇒ “1.1.3 Final Drive Identification, 0BE, 0BF”, page 3
1.1.1 Final Drive Identification, 0BC
The 0BC rear final drive unit is used with the following transmis‐
sions:
♦ 6-Speed Manual Transmission 0B2 All Wheel Drive (AWD)
♦ 6-Speed Manual Transmission 0B4 All Wheel Drive (AWD)
♦ 7-Speed DSG Transmission 0B5 All Wheel Drive (AWD)
♦ Automatic Transmission 0B6 All Wheel Drive (AWD)
♦ 8-Speed Automatic Transmission 0BK All Wheel Drive (AWD)
♦ 8 speed automatic transmission 0BW All Wheel Drive (AWD)
(only Q5 hybrid)
Rear Final Drive Allocation
♦ Refer to ⇒ “2.1 Transmission/Engine Allocation”, page 5
Layout on Rear Final Drive
Final drive 0BC -arrow 1- and 0AR
Engine code and production date -arrow 2-
Final Drive 0BC -arrow- and 0AR
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
1. Identification 1
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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.
Note
♦ The designation “0AR” can always be found on the rear final
drive housing. Changes to the housings is what differentiate
the “0BC” and “0AR” final drives.
♦ Another characteristic is the location of the threaded holes
-arrows- for securing the crossmember on the rear final drive.
♦ The final drive “0BC” has four threaded holes -arrows- for the
crossmember mounting in the final drive housing. There is also
an additional threaded hole for securing the final drive to the
subframe under the flange/driveshaft.
Rear Final Drive Code Letters and Build Date
Example: JKS 15 03 07
I I I I
Codes Day Month Production year
-2007-
Additional data can be ignored.
Note
When installing a new rear final drive unit, the final drive code, the
PR number and the vehicle engine code must be verified in the
Parts Catalog. This is the only to assure the correct allocation.
1.1.2 Final Drive Identification, 0BD
The 0BD rear final drive unit is assigned to the following trans‐
missions:
♦ 6-Speed Manual Transmission 0B2 All Wheel Drive (AWD)
♦ 6-Speed Manual Transmission 0B4 All Wheel Drive (AWD)
♦ 7-Speed DSG Transmission 0B5 All Wheel Drive (AWD)
♦ Automatic Transmission 0B6 All Wheel Drive (AWD)
♦ 8-Speed Automatic Transmission 0BK All Wheel Drive (AWD)
Rear Final Drive Allocation
♦ Refer to ⇒ “2.1 Transmission/Engine Allocation”, page 5
Layout on Rear Final Drive
Final drive 0BD, code letters and manufacture date -arrow-
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
2 Rep. Gr.00 - General, Technical Data
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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.
-Arrow A- Final Drive 0BD with Part Number (example: 0BD 500
043A)
-Arrow B- Code Letters “JTN”
-Arrow C- Rear Final Drive Date of Manufacture
Exam‐
ple:
F 292 3242
I I I
Production
year- 2006-
F = 2006,
G = 2007,
H = 2008, etc.
Production date
-292nd calendar day-
(always given in
three-digit for‐
mat)
day of manufacture
serial number
Additional data can be ignored.
Note
If the rear final drive unit is replaced, not only the rear final drive
code, but also the PR number and the vehicle engine code must
be verified in the Parts Catalog. This is the only to assure the
correct allocation.
1.1.3 Final Drive Identification, 0BE, 0BF
The »Rear Final Drive 0BF« is installed in Audi A4 from MY 2008,
Audi A5 Coup from MY 2008, Audi A5 Cabriolet from 2009, Audi
A6 from MY 2011, Audi A7 from MY 2011, and Audi A8 from My
2010.
Allocation to the following transmissions:
♦ 6-Speed Manual Transmission 0B2 All Wheel Drive (AWD)
♦ 6-Speed Manual Transmission 0B4 All Wheel Drive (AWD)
♦ 7-Speed DSG Transmission 0B5 All Wheel Drive (AWD)
♦ Automatic Transmission 0B6 All Wheel Drive (AWD)
♦ 8-Speed Automatic Transmission 0BK All Wheel Drive (AWD)
The »Rear Final Drive 0BE« is an enhanced version of the »0BF«
and is installed exclusively with the V8 TDI Engine in the Audi A8
from MY 2010.
Allocation to the following transmission:
♦ 8-Speed Automatic Transmission 0BL All Wheel Drive (AWD)
Rear Final Drive Allocation
♦ Refer to ⇒ “2.1 Transmission/Engine Allocation”, page 5
Layout on Rear Final Drive
Clutch classification -arrow 1-.
Engine code and production date -arrow 2-
Note
A characteristic of the rear final drive “0BF and 0BE” is the hy‐
draulic control unit with the side chambers.
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
1. Identification 3
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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.
♦ -Arrow 1- code -LFW-
♦ -Arrow 2- Rear final drive build dates
Exam‐
ple:
08 12 09
I I I
Production year -2008- Month Day
♦ -Arrow 3- Classification (classification of the clutch friction val‐
ues) for the right clutch. Example: -272D-
♦ -Arrow 4- Classification (classification of the clutch friction val‐
ues) for the left clutch. Example: -4A10-
Additional data can be ignored.
Note
When the rear final drive is replaced, not only the final drive code
but also the PR number and the vehicle engine code must be
verified in the Parts Catalog. This is the only to assure the correct
allocation.
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
4 Rep. Gr.00 - General, Technical Data
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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.
2 Technical Data
⇒ “2.1 Transmission/Engine Allocation”, page 5
⇒ “2.2 Capacities”, page 5
2.1 Transmission/Engine Allocation
Refer to the Parts Catalog for the following information.
♦ Codes
♦ Production time period.
♦ Axle ratio
♦ Drive Axle flange allocation
♦ Allocated to the engine, manual transmission and automatic
transmission using the code letters and the PR numbers
2.2 Capacities
⇒ “2.2.1 Capacities, Rear Final Drive 0BC”, page 5
⇒ “2.2.2 Capacities, Rear Final Drive 0BD”, page 5
⇒ “2.2.3 Capacities, Rear Final Drive 0BF”, page 5
⇒ “2.2.4 Capacities, Rear Final Drive 0BE”, page 5
2.2.1 Capacities, Rear Final Drive 0BC
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
– Checking gear oil level. Refer to
⇒ “4.2 Gear Oil, Checking Level”, page 101 .
2.2.2 Capacities, Rear Final Drive 0BD
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
– Checking gear oil level. Refer to
⇒ “4.2 Gear Oil, Checking Level”, page 101 .
2.2.3 Capacities, Rear Final Drive 0BF
Caution
Gear oil and ATF fluid change.
• For some RS models the gear oil as well as the ATF must
be changed.
• Refer to ⇒ Maintenance Intervals; Rep. Gr. 03 for the
change interval.
• For all other vehicles there is no change interval.
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
2.2.4 Capacities, Rear Final Drive 0BE
Note
The rear final drive 0BE is only installed with the V8 TDI engine.
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
2. Technical Data 5
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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.
3 Overview - Transmission
1 - Transmission
2 - Driveshaft
❑ Overview. Refer to
⇒ “1.1 Overview - Drive‐
shaft”, page 18 .
❑ Removing and instal‐
ling. Refer to
⇒ “1.2 Driveshaft, Re‐
moving and Installing”,
page 23 .
3 - Rear Final Drive
❑ Removing and instal‐
ling. Refer to
⇒ “2 Final Drive”,
page 43 .
❑ Disassembling and as‐
sembling. Refer to
⇒ “3 Final Drive, Disas‐
sembling and Assem‐
bling”, page 84 .
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Rear Final Drive 0BC, 0BD, 0BE, 0BF - Edition 03.2020
6 Rep. Gr.00 - General, Technical Data
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Models covered:
- Audi RS7 Sportback 4.0L V8 8AT (560 HP)
This 2016 Audi RS7 Sportback Service & Repair Manual is a comprehensive guide used by Audi technicians and covers your specific model and its variants.
Whether you're a professional mechanic or a DIY enthusiast, this manual provides troubleshooting and replacement procedures recommended by the manufacturer, complete with step-by-step instructions, clear images, and exploded-view illustrations for fixing vehicle problems.
Regular maintenance is essential for the durability of your vehicle. Over time, some parts will wear out and require replacement. This manual equips you with the manufacturer's recommended troubleshooting charts and replacement procedures, helping you save on repairs and increase your vehicle's reliability.
With wiring diagrams, torque specs, and troubleshooting charts, this manual is a valuable resource for rebuilding the engine and replacing every component. It simplifies the process of identifying issues based on specific symptoms, making it beginner-friendly.
This 2016 Audi RS7 Sportback Service & Repair Manual is the ultimate solution for both weekend DIY’ers and professional mechanics working on Audi vehicles, eliminating the need for multiple heavy manuals.
It's a cost-effective investment that will save you thousands on repairs and maintenance, making it worthwhile after the first oil change.
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