A351207 2028085-

Technical Service Bulletin
35 0B5 7 Speed S-tronic, leaks from transmission
35 12 07 2028085/2 December 21, 2012. Supersedes Technical Service Bulletin Group 34 number 11-07 dated
November 30, 2011 for reasons listed below.
Model(s)
Year
S4
2010-12
S5 Cab
2010-12
VIN Range
Vehicle-Specific Equipment
All
0B5 S-Tronic transmission
Condition
REVISION HISTORY
Revision
Date
Purpose
2
-
Revised Service (Added case leak repair procedure)
Revised Warranty (Added labor for case leak repair)
Revised Required Parts and Tools (Added parts for case leak repair)
1
11/30/2011
Original publication
Customer may report: Oil leaking under vehicle.
Technical Background
Before the repair can be performed the source of the leak must be located.
Possible points include:
Page 1 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Technical Service Bulletin
 Leaking from the oil pan seal.
Figure 1. Leak on the oil pan seal (red arrows).
 Crack in the oil pan.
Figure 2. Crack in the oil pan.
 Leak between gearbox housing
and intermediate housing
Note:
Can be confused with O-ring of
drain plug.
Figure 3. Leak between gearbox housing and
intermediate housing.
Page 2 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Technical Service Bulletin
Production Solution
Not applicable.
Service
Locate leak:
1. Thoroughly clean the
stained area.
2. Dry.
3. Apply talcum spray, or
similar, (Figure 4) to
the area that was
stained with oil.
4. Warm up the vehicle
Figure 4. Leak located with Talcum spray.
(test drive) and
recheck for leaks.
5. If the leak is around the oil pan, remove the oil pan and check the gasket for imperfections
or damage (Figure 1). If the oil pan is undamaged, only replace the oil pan seal.
6. If the oil pan is damaged as in Figure 2 or 6, check the mechatronics for loose bolts (Figure
5). Replace any loose bolts (Figure 5) and torque according to the repair manual
instructions. Also, replace the pan and seal.
Page 3 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Technical Service Bulletin
7. If pan is cracked as in
Figure 2, and no loose
bolts on the
mechatronics unit are
found, replace oil pan
and seal.
Figure 5. Loose bolts in the Mechatronics.
Figure 6. Damaged oil sump because of loose bolts.
8. If there is a leak between gearbox housing and intermediate housing as in Figure 3, reseal
the case by following instructions in ELSA >> Repair manual >>Transmission >>S Tronic
Transmission Internal Components >>35 Gears, Shafts >>Removal and Installation >>
Sensor Module with Transmission Input Speed Sensor -G612-,-G632-, -G676- and Circuit
Board 3..
Page 4 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Technical Service Bulletin
Note: These instructions require transmission case disassembly. Audi Academy
course # 950224 is required viewing before attempting repair service. Complete the course
and the assessment #950224B before attempting repair or warranty claim may be denied.
This can be found on the Audi Academy CRC site.
Tip: Use caution
when lifting or
lowering intermediate
housing to avoid
damage to
components (Figure
7).
Figure 7. Caution points: Drip tray Sensor module connector.
9. Assemble according to the repair manual and check/correct the oil level.
Warranty
Claim Type:
Use applicable claim type. If vehicle is outside any warranty, this Technical
Service Bulletin is informational only.
Service Number:
3435
Damage Code:
0050
Labor Operations:
Leaking around pan:
Inspect pan and gasket
3460 1999
10 TU
for damage
Page 5 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Technical Service Bulletin
Pan gasket faulty no pan damage:
Remove and install oil
3460 1900
160 TU
3511 1999
30 TU
3460 1900
160 TU
3435 19xx
See ELSA for appropriate
pan replace gasket.
Pan damaged:
Check Mechatronics
bolts, replace bolts and
re-torque if needed.
Remove and replace oil
pan with new gasket
Case leaking:
Remove and install
gearbox
TUs.
Reseal transmission case 3512 1950
570 TU
leak
Diagnostic Time:
Clean off oil and
3435 9999
90 TU
0150 0000
Time stated
determine leak origin,
includes one test drive.
GFF to perform basic
setting and adaptation
on diagnostic
after sensor replacement
protocol (Max
only
100 TU)
Road test prior to service
No allowance
0 TU
0121 0004
10 TU
procedure
Road test after service
procedure
Technical diagnosis at dealer’ s discretion
(Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance details)
Page 6 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Technical Service Bulletin
Claim Comment:
As per TSB 2028085/2
All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures
Manual. Claims are subject to review or audit by Audi Warranty.
This damage is due to outside influence and is not covered by any Audi warranty.
Required Parts and Tools
Part Number
Part Description
Quantity
0B5321361C
Transmission pan (only if cracked/damaged)
1
0B5321371E
Gasket for transmission pan
1
N 10405702
Bolts for Mechatronics unit
6
G052529A2
Dual clutch gearbox oil (ATF)
Up to 7.5 Liters
Parts needed for case leak reseal ( in addition to above)
G052513A2
Final Drive oil (MTF)
5.0 Liters
0B5927321F
Module
1
0B5321391A
Harness
1
AMV18800102
Sealing paste
1
0B5301515H
Pump with seals
1
WHT001955
Bolt
1
WHT002459
Bolt
28
WHT001958B
Bolt
2
0B5301227C
Seal kit
1
0B5323525B
O-ring
1
Page 7 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Technical Service Bulletin
0B5311113F
Seal
1
0B5315105TC
Oil pipe with seals
1
0B5315105TA
Oil pipe with seals
1
0B5325571
Sleeve with seals
1
0B5311944B
Seal
4
0B5321473
Oil pipe
1
WHT003380
Seal
1
WHT003379
Seal
1
0B5301311E
Oil drip tray (Replace if broken)
1
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with
your Parts Department and service manuals for the latest information.
Page 8 of 8
© 2012 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights
of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.