DIY CVT repair 01j

In detail: do-it-yourself repair of the 01j variator from a real master for the site my.housecope.com.

At the beginning of the 2000s, Audi was actively developing a continuously variable variator, which was supposed to become an alternative to traditional automatic transmissions. CVT 01J CVT appeared in the proposal of the Audi company in 2002. This CVT was offered for all-wheel drive modifications of A4, A6, A8 cars. The maximum engine capacity was 3 liters. That is why this gearbox was not installed on top-end modifications with powerful power units.

These CVT models were one of the first series-produced transmissions to be installed on Audi vehicles. Note that this gearbox has proven itself from the best side and is capable of running more than 200,000 kilometers without overhaul. Due to its design features, the automatic variator 01J CVT it has a compact size, which makes it easy to install it on small-sized Audi A4 models.

Weak point automatic transmission 01j is the control unit. This element does not have the proper resistance to temperature extremes and can fail in summer heat and in subzero temperatures. We also note the fact that regular oil change using high-quality spare parts is the key to trouble-free operation of the variator. To carry out a complete oil change, you will need 7.5 liters of original gear oil. In some cases, there may be problems with the tightness of oil seals and gaskets. All this leads to loss of oil and insufficient pressure in the system. This variator is extremely critical to the quality of the lubricant mixture and the oil pressure in the system. At the first signs of a breakdown, messages appear on the center panel of the vehicle. When such a message appears, the car owner should contact the service center as soon as possible, where they will carry out the necessary repair work.

Video (click to play).

A common failure is a problem with the clutches, which must be replaced if damaged. The problem is that clutches are sold exclusively as a set and they need to be completely replaced, which somewhat increases the cost of repairs.

Repair of any automatic transmission from 1 day

CVTs, DSG, torque converters, new and remanufactured automatic transmissions, spare parts

Well, here it is clear what the conversation is about.

# 1 Post nikola34akp 09-03-09, 02:42

# 2 Post arsas Wed Dec 03, 2014 12:03 am

# 3 Post nikola34akp Wed Dec 03, 2014 9:58 am

# 4 Post nikola34akp 09-03-08, 09:37

# 5 Post vil64 09-03-08, 09:16

# 6 Post Rav 06 Jun 2016 7:26 am

# 7 Post unforgivable503 »Fri May 06, 2016 8:20 am

# 8 Post unforgivable503 Fri May 06, 2016 8:23 am

Secondary through a reducer.
Primary so. If the secondary is diluted, then the circuit in the primary will come out indiscriminately.
It seems that I have not confused anything.
What are your goals?

# 9 Post Rav Sat May 07, 2016 10:36 pm

# 10 Post unforgivable503 09-03-07, 08:20

# 11 Message Rav 09-03-07, 03:36

# 12 Message unforgivable503 09-03-07, 03:16

Your question is not clear to me.
When they tear a badly going box, then they leave. It is always necessary to disassemble and look, she does not forgive dumb experiments.

# 13 Message Rav Wed May 11, 2016 9:08 pm

# 14 Message Rav Wed May 11, 2016 9:09 pm

Users browsing this forum: no registered users and 8 guests

AGGREGATKA is a federal network of technical centers, the main specialization of which is the repair and maintenance of automatic transmissions of all types, including robotic transmissions with double clutch, CVT transmissions and classic hydromechanical automatic transmissions

Dear forum users, we really need help, there should be specialists among you who repair or refurbish the jf011e 4WD variator. The problem is when disassembling the valve body, metal balls fell out of it, I don’t know where to put them now. I really need your help. And tell me the addresses in St. Petersburg where at the stand they can check the valve body for me. I thank everyone who will respond to help. Photo of the plate in the attachment

I want to replace the claw, it is also the position sensor of the leading cone))
Protruding parts do not interfere, presumably, the cover guide does not allow you to remove, is it possible?
how much can you pry on and jam the flange? or will the sealant close everything?

update: Removed. Sits very tightly on the guide pins, in my case - on one.
What is the best way to clean the inside? just wipe it with a lint-free cloth? attacked while shooting some trash.

Well, the expected question is how to collect? ))
Apply sealant to the flange according to the instructions, align the triangles on both shafts with temporary longer screws, insert the parking pin into the “very middle” and put my “foot”. Tighten with what moment?

Novel!
You are a sadomasochist

- kroilovo leads to a hitalov.
I would have removed the checkpoint and did it on the removed one.
Here and here look at the pictures on the repair reports

Thanks for the compliment ))
I started this because there is no money, there is nowhere to take it.
I read a lot of forums, I realized that I can.
I do it on the street in the yard under the trees))

Hard. On the street and without a hole
Military field conditions

The last time I did this was in the 90s - I also threw off the checkpoint without a pit

PS I invited the Partner to the topic, we are waiting for his answer, maybe they will tell you what

I didn’t throw off the box, it’s too much for me, I just took off the lid.
I will collect on the weekend, while there is no time.
if you have any advice - I will only be glad.

Wait - so judging by the photo, the cover on the drive side?
and according to other photos you have already opened the box.
What happened to the plug? How did you determine what exactly it needs to be changed?

Here in the photo you can see that in the main body there are some guides or rods from forks or something else

Read also: DIY radiator repair

Audi made many names for different sub-modifications for each variant of the car and engine, modeled on the names of Honda's automatic transmissions, but these are all Multitronic variators with different letters of the FSA type. JFJ from 2000 to 2007 (below is a table) have the same design for hardware and electronics and are repaired with the same Repair Kits.

Pick up repair kits - press the button on the left.

Typical diseases of the 01J variator:

The main reason for coming to repair this fairly reliable variator in the early years is the oil change (G 052 180 A2).

A partial oil change requires approx. 4.5 liters. Complete replacement - by double partial replacement - 7.5 l. It is sensitive to the level and quality of the oil, the oil is checked against the overflow plug - at a temperature of +35 .. + 45 ° C, oil should start to flow. Change is recommended in 40-60 tkm, but the older the variator, the more often it needs to be checked and changed. Opaque oil is a marker for urgent oil change or overhaul.

Filters are available with 130010 tube (Original) and without 130010A tube (non-original). There are two types of the filter itself - with a rib (130010A - 01J-301-519N) and without rib (130010B - 01J-301-519L ). Interchangeable. The filter is inside the box and changes only when the variator is overhauled.

The design of the 01J variator is especially demanding on the purity of the oil and operation with a borderline state of oil and with a clogged filter kills the variator units with every kilometer of run.

A typical overhaul order for this variator is Gaskets and Seals Repair Kit # 130002. More often they order budgetary Overol ATOK-130002A less often - Prescription.

Rings, seals and seals are changing, aging rapidly from high temperatures.

In some repair kits, there are no Reluctors - speed indicators. They (Regulators, on the right in the diagram - yellow) sold separately - No. 130079, when the craftsmen find it necessary to replace them as well.

Also, clutches are often ordered in one Set - No. 130003.

Kits differ in the thickness of the Forward clutches. 2.7 mm (unified with 0AW) or 2.05 mm.

Winter driving with a cold transmission kills the friction clutches especially quickly. More details - here.

Also, only in a set (Forward and Reverse) order a set of steel discs. - No. 130004.

The kit also changes the piston Reverse 130966 during the bulkhead.

The next typical CVT consumable 01J : Ejection pump (No. 130501).

The ejection pump is made of plastic and works according to the principle of "atomizer", when one stream of liquid entrains (the other) a stream of air. Only in this variator, instead of air, another stream of the same oil is carried away by oil. And of course, like all atomizers, such a system is demanding on the cleanliness of the channels and the oil temperature. It is quickly clogged with suspension, the channels wear out, ceases to work normally and, together with the rest of the “consumables”, must be replaced.

Problems with this pump lead to problems with the cooling and lubrication of the clutches. He really does not like working with cold oil.

Another consumable is the oil pipe (No. 130992).

All three solenoids-electric regulator are changed after the resource is exhausted (normal resistance is 4.7 Ohm).

Solenoids are the same: 130420A - no spout, there are three solenoids on the plate: N88 - cooling and emergency shutdown solenoid, N215 - pressure regulator in clutch packs, N216 - pulley gear ratio control solenoid (see diagram on the left)

This variator uses a pull chain. From tensile loads and friction, such a chain develops its resource quite early (Drive chain variator - No. 130700), is replaced practically at every overhaul of the variator after runs over 100 tkm, since even a slight wear will lead to a noticeable disruption in the sliding of the chain along the cones, which immediately reduces the transmitted torque and quickly "ages" the cones themselves.

Empirically, a regularity was established that up to 2 liters it is reasonable to use a pushing chain, and over 2.5 liters - a pulling chain. But for powerful cars, the variator turns out to be even less reliable than preselective boxes, and in modern stepped automatic transmissions, the gearshifts have become no less smooth than in variators, with a significant superiority in reliability.Therefore, the direction of development of variators in the direction of the "pulling" chain can be considered unpromising.

Together with the chain, tension bars are often changed - 130701 and 130702.

The design of the variator does not allow the vehicle to be towed, which leads to fatal consequences for the cones and, as a result, for the transmission itself. The cone is the CVT unit that determines the resource and the bottleneck in the design.

The sore spot of an electrician is familiar to all variators and 6-mortars of the first generations: ECU - CVT control unit Multitronic VL-300 ... For repair press No. 130446A.

The reason for the early failure: the unit floats completely in oil, which heats up in these transmissions over 110 degrees. The material of the case and sensor components, especially of the first years of production, could not withstand prolonged overheating.

Therefore, for these variators, there is a recommendation after 3-5 years of operation - to install an additional oil cooling radiator. Or every summer to clean the existing cooling system inside and outside and change the oil more often than at a “young” age.

In 2003, the manufacturer refined the design of the control unit, using materials that are more resistant to temperatures and the VL300-7 Multitronics began to come for repairs later and less often.

The problem is usually expressed in the fact that the display "PRND" lights up and the computer generates various kinds of errors. And depending on these DTCs, the Multitronics are successfully repaired. (Suggestion from below).

- There is another serious (but more rare) problem - Differential.

During the overhaul, you should pay attention to the condition of the differential. If there are problems with him, then the box is not a tenant. Differential replacement 01J it is almost impossible work in a service environment.

Fighting Oil Leaks - Replacing Oil Seals:

- cuff (oil seal) of the pump (130070),

- cuff of the left and right axle shaft (130073, 130076).

The opinion of the masters on Multitronics is here and here. 01J device - here.

In general, on new cars this super-complicated and finely adjusted transmission works fine in German, but after 150-200 tkm driving with it is like playing “Russian roulette”.

Refurbished Multitronic VL-300 on ZF variator 01J.

Two variants of Multitronic are known to be repaired:

- Square connector (on right 130446 B).

- With K round connector (left 130446A).

Although the investment in a proprietary European CVT project was astronomical amounts, this pull-belt CVT design could not compete with DSG and push-belt CVTs. Many designers and financiers consider such a design a dead-end branch of automatic transmission development and an unsuccessful investment of Audi.

The cost and availability of the items you need can be checked in the online store by clicking the number on an orange background to search for a part.

CVTs are gaining more and more popularity among the varieties of gearboxes. So the carmaker Audi did not stand aside and installed variator gearboxes on the new A6 C6 models.

Each of the above listed elements can fail at any time. In today's article, we will analyze with you the main malfunctions of the Audi A6 variator, their causes of failure and methods of self-repair.

Earlier I already told you about how to replace the fuel filter Audi A6 with your own hands, so anyone interested can read this article by clicking on the link.

Most of the malfunctions in a CVT gearbox arise from improper operation, which I would refer to:

Violation of the frequency of replacement of the working fluid
Violation of the frequency of filter replacement
Using poor quality fluid
Aggressive driving style

In addition, there are other malfunctions that are determined using computer diagnostics. Each malfunction has its own diagnostic code. The codes determine:

malfunctions of input sensors (working fluid temperature sensor, speed sensors of the driving and driven pulleys, pressure sensors in the main line, pressure in the driving and driven pulleys);
malfunctions of the electronic control unit;
malfunctions of actuators (stepper motor, solenoid valves of pressure in the main line and pressure in the driven pulley, lock-up valves of the torque converter and control of the planetary gearbox).

The most common cause of variator malfunction begins with wear on the bearings of the cones, while a characteristic hum becomes audible. Bearing noise occurs due to the ingress of wear products on their working surfaces, as a result of which they become unusable. Special oil filters retain metal suspension for the time being.

The next reason that can cause problems with the variator is jerking and jerking of the vehicle, which occurs due to the seizure of the oil pump pressure relief valve. The same harmful wear products interfere with the normal operation of this unit, disrupting the stable pressure in the system.

Timely contacting a specialized workshop will help to avoid higher repair costs. Minor damage to tapered pulleys is removed by grinding, while the belt will most likely have to be replaced.

The rather rare malfunctions that precede the breakdown of the variator include the failure of the torque converter, as well as failures in the electronics caused by breakdowns of some elements of the control unit. However, this kind of malfunction occurs quite rarely and is not a regularity, but rather a factor of bad luck.

As I already noticed earlier, the most common variator failure is considered to be worn out bearings for cones. A sign of this problem is a prolonged hum, which manifests itself already when driving 50 thousand km. To change all bearings and their parts, the motorist will have to pay over 34,000 rubles. Such a malfunction most often occurs in Audi A6 C5 cars.

Loud noise of bearings, and then their slow destruction occur for the following reasons. First, the destruction of the working surfaces is facilitated by the ingress of various foreign metal bodies, such as wear products, on them.

The installed oil filter and magnet collecting metal powder cannot block access to the working surfaces of the variator for heavy foreign bodies. In this case, the bearing life will extend the reduction of the engine oil change time to 25 thousand km.

But that doesn't always help. There are cases when some CVTs work quietly for 100 thousand km, while others, under the same operating conditions, buzz even when driving 50 thousand km. High bearing noise is often caused by poor quality bearings, low accuracy and low load ratings.

When it comes to shortening oil change intervals, not all manufacturers share the same point of view. For example. During the warranty period (100 thousand km), Renault advises only to carry out periodic checks of the oil level and condition. At the Audi concern, the oil change must be done once every 75 thousand km.

In addition to the usual machine oil, it makes sense to fill the variators with special oils marked “CVT”, original NS-2 or ELFMATIC CVT fluids. For Audi cars, DiaQueen type CVT-J1 can be used. It is not recommended to pour the oil used in the hydromechanical automatic into the variator, although some little-known manufacturers have adapted their variators for these substances.

Often, when the vehicle is moving, jerks and twitching appear. Reason - the pressure relief valve in the oil pump does not work.

Wear products falling on the contact surface wedge it in an intermediate state.As a result, the pressure level deviates from the norm, which impedes the operation of both pulleys and causes the belt to slip. In this situation, you need to make a visit to the service center as soon as possible.

With timely treatment, repair work will be cheaper: small defects in tapered surfaces are eliminated by grinding.

During diagnostics, specialists often consider problems with the front wheel bearings to be the cause of the noise of the variators, which are immediately replaced with new ones. Replacing these bearings can be costly, since on some machines it is one piece together with the hub, which costs between $ 300 and $ 400.

Many motorists who pull out a stalled vehicle by jogging by quickly moving the lever from position D to R and vice versa, are faced with the following situation - jerks when moving the lever from the parking position to R and D. with friction wheel. The wear of the splines is explained by the absence of a pause when moving from D to R and vice versa (you need to wait for the vehicle to stop). As a result, the gears of the planetary gear must be replaced.

Some drivers, when this problem occurs, immediately begin to check the valve body for malfunctions, which is actually reliable and problems with it rarely happen.

A lot of attention in a stepless unit is paid to the temperature regime. Often, problems in the operation of variators arise from an increase in temperature. In modern cars, a self-diagnosis device is provided, which includes special sensors. When the temperature value rises, they turn on the indicator on the dashboard indicating a malfunction, and the variator is put into emergency stop mode.

To maintain the normal temperature of oils in modern cars, in addition to a heat exchanger, another radiator is installed in the engine compartment near the climate system. Various dirt gets into the bumper through the air duct.

The first sign of a dirty radiator is overheating when the vehicle is moving at high speed. Therefore, once every 3 years (or more often) it is necessary to thoroughly flush the radiator. It would also be nice to install a special mesh in the air duct to protect the radiator from various objects flying out from under the wheels of the car in front.

Despite the mistrust of domestic motorists towards CVTs, Western motorists install this type of transmission with a greater degree of optimism. According to statistics, they break down much less often compared to hydromechanical gearboxes. That is why many car manufacturers, who initially doubted the durability of CVTs, are now being installed more and more every year.

For example, the manufacturer Audi installs variators on a new generation of crossovers with a two-liter engine. Subaru has CVTs for XV, Forester cars. By the way, most of the users of these cars cannot be classified as calm motorists.

These machines are used for high speed cross-country travel. But before, many thought that the variators in such conditions would immediately fail. This means they have become better quality.

A variator is a gearbox without steps (i.e. without the usual gear shifting by means of gear engagement). In fact, there is no gear shifting in the variator at all, the torque is transmitted and changed smoothly, without jerks, and it is limited by the specified parameters. Therefore, a car with such a box is suitable for those who drive without sudden accelerations and stops and want to save a lot on fuel. Instead of the usual gear pairs, this type of transmission has two pulleys connected together by a belt or chain.CVT repair will be associated with them, or with its electronic control.

The variator is quite reliable and rarely needs repair, but there are things that it does not like. This is a fast driving style, constant use of the maximum power of the gearbox and hard braking. The second destructive moment is the working fluid, if it is of poor quality or does not change to a new one according to the regulations. All of the above, individually and in combination, leads to overheating and increased wear of parts and leads to a malfunction of the variator. Separately, it is worth noting the filter element. You should know that every time you change the fluid in the variator, the filter must be replaced with a new one.

Symptoms of a malfunctioning variator in an electrician will be seen immediately. A light on the instrument panel will tell you about this. "Service required"... You can find out in more detail what kind of malfunction is taking place using the variator diagnostics.

The most common malfunction is jerking when driving, as they say "the variator jerks."

These may be malfunctions of the variator control unit, electronic actuators and various sensors, which are abundant in this type of transmission.
Signs of a variator breakdown in its mechanical part are shocks when shifting gears, the inability to manually switch, the gearbox speed does not change, its movement in neutral gear, slippage, or no movement at all.

If you need to get to a car service, then remember that if it is impossible to change speeds, towing a vehicle is impossible in other ways, except on a tow truck. It is also not recommended to tow on a flexible or rigid hitch in the event of other malfunctions, but there is such a possibility if a certain sequence of gear changes is observed, without sudden movements, very slowly and not far.

To repair the variator with your own hands, you will need a lot of knowledge and skills. Not every service takes care of these boxes. The main reason for this is the large number of electrical devices. To check the variator properly, you need to have a whole arsenal of diagnostic equipment, which, by the way, will also see mechanical breakdowns. But if you still decide to fix the problem yourself, then this is possible.

How to identify a malfunction of the variator?

For diagnostics, it is necessary to dismantle the variator and disassemble, before that, carefully disconnecting all the wiring and remembering the sequence of actions. Just like with any other box, this is the only way to determine exactly what is out of order and fix it. Without disassembling the boxes, it is impossible to say unequivocally what kind of problem is taking place. In this case, the cost of repairing the variator will be much cheaper and consist only of purchasing the necessary spare parts.

CVT repair in service

This begs the question - how much does it cost to repair a variator in a car service?

It is quite expensive to repair a CVT transmission, so many car owners prefer buying contract or new boxes to repair.

It is impossible to answer it unequivocally. First, it depends on the make of the car (and the price difference is huge). Secondly, from the type of breakdown. In the best case, it will be flushing the valve body valves with an oil change - approximately 6-8 thousand rubles, replacing these valves - 10-13, replacing the entire valve body - 20-25, complete restoration of all elements - 40-45 thousand rubles (Such calculations are applicable to models Peugeot, Honda). Consider also the price of diagnostic services. Thirdly, the cost of repairing the variator depends on the region in which you live.

This is the selection of the optimal speed range for the engine speed. As already mentioned at the beginning, the variator does not have a gear change in our usual understanding, it moves smoothly within the given framework.

Calibration is setting the desired speed range.

The variator is calibrated either in the process of movement or in the parking lot. Before and after the repair of the variator gearbox, calibration must be carried out.

The CVT gearbox is gaining more and more these days, and there is a fairly simple explanation for this. First of all, it is the simplicity of the design. But, nevertheless, the service and repair of the variator requires certain knowledge and skills. The gearbox consists of various components and systems, which, if used incorrectly, can malfunction and it will be difficult to repair them.

Many variator malfunctions are the result of non-observance of the basic rules of operation and maintenance:

non-compliance with the terms of fluid replacement;
failure to comply with the deadlines for replacing filters;
the use of low quality lubricants;
driving errors;
driving at top speed;
frequent sharp braking;
driving on bad roads.

To avoid many troubles with the variator box and then not to repair, adhere to the following simple maintenance rules:

every thirty thousand km. mileage change the oil;
change the filter elements in time;
after seventy thousand km. mileage change the stepper motor and shaft sensors.

Disassembled variator gearbox

Do not forget that diagnostics of the variator is much cheaper than repairing it with your own hands, even at a service station.

In the event of a malfunction concerning the electronic part, the message - Service required will light up on the display located on the dashboard.

Electronic problems

If the temperature of the liquid rises above the norm, it will light up - Slow down.

In order to accurately establish the breakdown and fix it yourself, you need special diagnostics carried out using special equipment. For many breakdowns, a special code is provided by which they are installed:

sensor malfunctions (temperature, pulley speed, pressure, line, pulley pressure);
ECU malfunctions;
malfunctions of a stepper motor, valves, mains;
decrease or increase in pressure in the pulley.

When carrying out diagnostics, do not forget that a probable prerequisite for a malfunction may not only be a breakdown of some unit. Often, the wiring can be damaged or a defect in a connector. Also, the problem may lie in the failure of the transmission control unit.

In some situations, upon detection of malfunctions, the control system of the variator transmission can be automatically transferred to a special mode. This mode differs from the usual one in a special fixed gear ratio.

It will not be possible to establish malfunctions of the mechanical part of the boxes only with the help of electronic diagnostics. In this situation, there is a need to carry out a whole range of measures:

it is necessary to check the condition of the working fluid;
identify all the symptoms of a malfunction;
analysis of all ECU data;
testing on the road.

In the operation of variator boxes, failures and breakdowns of a different plan sometimes occur. Very often there are noises and squeaks of various types. In this case, the transmission may need to be disassembled. This process is not so complicated and with a detailed study of the material, you can handle it yourself.

Before proceeding with disassembly, it is worthwhile to prepare in advance special containers for the parts to be removed. To make it easier to assemble later, arrange the containers in the order of disassembly. If you are doing this work for the first time and are not sure that you can remember the order of disassembly, then the whole process can be captured on the camera. Parts can also be labeled.

It is better to repair in a well-lit and ventilated area.

The first step is to unscrew the bolts that secure the cover.
We remove it.
We remove the shaft together with a part of the body.
We unscrew the remaining bolts.
Remove the second part of the cover.
We remove the gears.
We unscrew the screws that secure the pump casing.
We remove the gear.
Remove the pump chain.
Remove the oil pump cover.
We remove the shaft.
We turn over the gearbox.
Using a screwdriver, remove another cover.
The belt must be tightened with clamps.
We remove the pulleys and belt.
We release the pulleys from the belt.

Removed and disassembled gearbox

Now that the variator is disassembled, it is necessary to check all its components and systems. Pay special attention to the condition of the bearings, pay attention to whether the backlash is increased. Look at the condition of the belt and if its tension is loose. Inspect gears, hydraulic block and other parts for possible defects. The most common problem resulting in noise in the CVT box is high bearing wear. In this case, nothing will help, except for a replacement, you can do it yourself.

It is very important to identify the malfunction in the variator box in time and eliminate it. This will allow you to avoid more serious damage, which will be quite difficult to repair, and it costs much less.

In this video, the auto repairman will tell you in detail and show how you can repair variator gearboxes with your own hands. It costs much less than contacting a service station.

Self-flushing of the automatic transmission valve body
We do the repair of the machine box ourselves
Compare the tiptronic gearbox and the automatic

In fact, everything is written very correctly. In any case, I try to solve such problems in car services at inexpensive prices, they do their job efficiently.

Hello
I have a problem with the box
honda fit 2002 release
mileage 157000
the oil in the box changed 140,000
the problem is that the car does not go forward when starting after a night of inactivity
goes back without problems, but does not go forward until it warms up well for about 15 minutes
and even when it is turned on for a long time on D during warm-up, then D starts flashing
if you turn off the engine and then start it, it no longer blinks and starts to slowly get under way.
during the day there are no problems, everything works fine.

Video (click to play).

Hello!
Honda fit aria stopped driving forward and backward rides perfectly

Rate the article:

Grade 3.2 who voted: 85