Audi TT 14 User Manual
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Service
Workshop Manual
Audi TT 1999 ➤
Automatic gearbox 09G
Edition 12.2007
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
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
39 - Final drive - front 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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A0057007320
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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Notes on the automatic 6-speed gearbox 09G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Code letters, gearbox allocation, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Capacities in planetary gearbox and final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Notes on tow-starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Rules for cleanliness when working on the automatic gearbox . . . . . . . . . . . . . . . . . . . . . . 11
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Exploded view - torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Renewing oil seal for torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Checking torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Electrical/electronic components and fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Removing and installing automatic gearbox control unit J217 . . . . . . . . . . . . . . . . . . . . . . 23
2 Exploded view - shift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.1 Checking selector mechanism and ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Removing and installing shift unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Removing and installing printed circuit with tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . 32
3.2 Removing and installing sliding cover for selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.5 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6 Removing and installing locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Adjusting locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 Transporting the automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Securing gearbox to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Exploded view - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.2 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8 Overview - ATF in gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.1 Checking and correcting ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.2 Filling up with ATF - vehicles with ATF filler hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.3 Filling up with ATF - vehicles without ATF filler hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.4 Draining ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.5 Filling up with ATF following repair work - vehicles with ATF filler hole . . . . . . . . . . . . . . . . 75
8.6 Filling up with ATF following repair work - vehicles without ATF filler hole . . . . . . . . . . . . 78
9 Exploded view - ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.1 Removing and installing ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Contents i
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1 Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses . . . . 82
1.1 Removing and installing ATF oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.3 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.4 Removing and installing wiring harness with 14-pin connector . . . . . . . . . . . . . . . . . . . . . . 94
1.5 Removing and installing wiring harness with 8-pin connector and gearbox oil temperature
sender G93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.6 Removing and installing gearbox input speed sender G182 . . . . . . . . . . . . . . . . . . . . . . . . 96
1.7 Removing and installing gearbox output speed sender G195 . . . . . . . . . . . . . . . . . . . . . . 97
2 Overview - multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Removing and installing multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.2 Adjusting multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1 Flange shaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.1 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.2 Renewing flange shaft oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
ii Contents
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Automatic gearbox 09G - Edition 12.2007
00 – Technical data
1 Gearbox identification
The “Automatic 6-speed gearbox 09G” is installed in the Audi TT
1999 ▸. Allocation ⇒ page 3 .
Location on gearbox
Code letters -arrow-
Audi TT 1999 ➤
Gearbox details
-Arrow 1-:
GGZ = gearbox code letters
02E2T00006 = manufacturer's serial number
♦ 02: year of manufacture 2002
♦ E: month of manufacture May; A = January up to M = Decem‐
ber
♦ 2T: type designation = 09G
♦ 00006: serial number in production month, here: 6th gearbox
in month
-Arrow 2-:
09G 300 036 H = part number of gearbox
Note
♦
Additional data are production-related.
♦
The code letters for the gearbox are also given on the vehicle
data stickers.
1. Gearbox 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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
2 Notes on the automatic 6-speed
gearbox 09G
Gearbox
The automatic gearbox 09G is equipped with 6 hydraulically ac‐
tivated forward gears. When the lock-up clutch is closed, the 2nd,
3rd, 4th, 5th and 6th gears become mechanically driven gears by
cutting out the torque converter slip.
Torque converter
The torque converter is equipped with a lock-up clutch. The lockup clutch is closed dependent on load and speed. The 2nd, 3rd,
4th, 5th and 6th gears can be driven mechanically (no slip).
ATF
The ATF is filled for life. The ATF need not be changed as part of
a service.
Planetary gearbox and final drive have a shared ATF filling.
Checking and filling ⇒ page 65 .
Note
Only the ATF available as a replacement part may be used in the
automatic gearbox 09G. Other types of oil will cause malfunctions
and/or failure of the gearbox; for ATF refer to ⇒ Electronic parts
catalogue .
Self-diagnosis
Before performing repairs to the automatic gearbox, determine
the cause of the fault as precisely as possible using “Guided Fault
Finding” ⇒ Vehicle diagnosis, testing and information system VAS
5051.
Variation of gear-change points for gradients
An additional gear change map automatically selects gear
changes for gradients depending on accelerator pedal position
and driving speed.
♦ Gear change map for extreme uphill gradients is matched to
engine output
♦ Gear change map for extreme downhill gradients is matched
to the braking effect of the engine
♦ Increased engine braking effect can also be obtained by di‐
rectly selecting a specific gear via the tiptronic function, e.g.
when towing a trailer on downhill gradients.
2 Rep. Gr.00 - 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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
3 Code letters, gearbox allocation, ratios, equipment
Automatic gearbox 09G
Gearbox Code letters FXA HFY HFY
Manufac‐
tured
Torque convert‐erCode letters QBAA QBAA QBAA
from
to
09.02 08.04 09.05
Allocation Model
Engine
Ratios 1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
1.8 ltr. - 132 kW 1.8 ltr. - 132 kW 1.8 ltr. - 140 kW
4.044 4.044 4.044
2.370 2.370 2.370
1.556 1.556 1.556
1.159 1.159 1.159
0.852 0.852 0.852
0.672 0.672 0.672
3.193 3.193 3.193
gear
Intermediate
drive
No. of teeth Driving gear 49 49 49
Output gear 52 52 52
Ratio 1.061 1.061 1.061
Final drive No. of teeth Pinion shaft 15 15 15
Final drive gear 61 61 61
Ratio 4.067 4.067 4.067
3. Code letters, gearbox allocation, ratios, equipment 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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
4 Capacities in planetary gearbox and
final drive
Capacities Automatic gearbox 09G
Initial filling 5.9 ltr.
Changing Life filling; change only after re‐
pair, if oil pan is removed.
Lubricant ATF ⇒ Electronic parts catalogue
Caution
Risk of malfunction or gearbox failure.
♦ Only the ATF available as a replacement part for the au‐
tomatic gearbox 09G may be used in the planetary gear‐
box and final drive ⇒ Electronic parts catalogue .
Planetary gearbox and final drive have a shared ATF filling.
Checking and correcting ATF level ⇒ page 65 .
4 Rep. Gr.00 - 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.
Automatic gearbox 09G - Edition 12.2007
5 Safety precautions
Observe the following precautions to avoid possible injury and/or
damage to the vehicle:
WARNING
Accidents and injury can be caused if a gear is inadvertently
engaged while the engine is running.
♦ Before working on the vehicle while the engine is running,
shift the selector lever into position “P” and apply the
handbrake.
Danger from toxic exhaust gases when engine is running.
♦ When the engine is running, the exhaust system must al‐
ways be connected to an exhaust gas extractor unit.
Observe the following precautions to avoid possible injury and/or
irreparable damage to electrical and electronic components:
♦ Switch off ignition before disconnecting and connecting test
equipment.
Audi TT 1999 ➤
Caution
When disconnecting the battery there is a risk of serious dam‐
age to electronic components:
♦ Observe the correct procedure for disconnecting the bat‐
tery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnecting battery ⇒ Rep. Gr. 27 .
5. Safety precautions 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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
Observe the following precautions if test equipment has to be
used when road-testing the vehicle.
WARNING
Accidents can be caused if the driver is distracted by test
equipment or if test equipment is not secured.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
TT Coupé:
Always secure testing equipment to the rear seat with a strap
and have them operated from there by a second person.
TT Roadster:
♦ Move the passenger's seat to the rearmost position.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052 A- or diagnosis system -VAS 5053- .
♦ Test equipment may only be operated by the passenger;
the tester -1- must be placed flat on the passenger's lap
as illustrated.
6 Rep. Gr.00 - 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.
Automatic gearbox 09G - Edition 12.2007
6 Notes on tow-starting and towing
Caution
Risk of irreparable damage to gearbox.
♦ When the vehicle is towed, the selector lever must be set
to position “N” and the vehicle must not be towed for a
distance of more than 50 km or at a speed in excess of
50 km/h.
Note
It is not possible to start the engine by means of tow-starting, for
instance in the case of insufficient battery charge or if the starter
is not working.
Audi TT 1999 ➤
6. Notes on tow-starting and towing 7
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
7 Repair instructions
7.1 Contact corrosion!
Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
7.2 General repair instructions
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. The usual basic safety
precautions also naturally apply when carrying out repair work.
To avoid repetition, a number of generally applicable instructions
for the various repair procedures are summarised here. They ap‐
ply to the work described in this Manual.
8 Rep. Gr.00 - 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.
Automatic gearbox 09G - Edition 12.2007
Guided fault finding, vehicle self-diagnosis and testing system
♦ Before servicing the automatic gearbox, the exact cause of the
malfunction must be determined as precisely as possible via
the vehicle diagnostic, testing and information system -VAS
5051B- in the modes “Guided Fault Finding”, “Vehicle SelfDiagnosis” and “Test Instruments”.
Environmental and waste disposal regulations for oil
♦ ATF, gear oil and any other type of oil must be handled with
care.
♦ Dispose of drained oil properly.
♦ Always adhere to statutory environmental and waste disposal
regulations.
♦ Observe the information shown on the packaging of the oil.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ "Workshop equipment and special tools" .
Gearbox
♦ Rules for cleanliness when working on the automatic gearbox
⇒ page 11 .
♦ Do not run engine or tow vehicle with ATF oil pan removed or
when there is no ATF in the gearbox.
♦ If gearbox has been removed from vehicle, secure torque con‐
verter to prevent it from falling out.
♦ Check position of torque converter before installing gearbox
⇒ page 16 .
♦ When installing gearbox ensure dowel sleeves are correctly
seated.
♦ After installing, check ATF level and top up if necessary: plan‐
etary gearbox and final drive ⇒ page 65 . Capacities and
specifications ⇒ page 4
O-rings, oil seals and gaskets
♦ Always renew O-rings, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ The open side of the oil seal should face the side containing
the fluid.
♦ Before installing, lightly lubricate outer circumference and
sealing lips of oil seals with ATF or gear oil, depending on fit‐
ting location.
♦ Lightly lubricate O-rings with ATF before installation to prevent
them getting crushed during assembly.
Audi TT 1999 ➤
♦ Use only ATF for parts running in ATF. Other lubricants will
cause malfunction of the gearbox hydraulics.
♦ When installing a new oil seal, position the seal such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
♦ After installing, check ATF level and top up if necessary: plan‐
etary gearbox and final drive ⇒ page 65 . Capacities and
specifications ⇒ page 4
7. Repair instructions 9
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
Nuts, bolts
♦ Loosen bolts in reverse sequence to the specified tightening
sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Parts which are particularly sensitive to distortion (e.g. valve
body) must be kept straight when removing and installing;
loosen or tighten diagonally in stages.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Renew self-locking nuts and bolts.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then apply locking fluid -AMV 185 101
A1- to bolts again before fitting.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
♦ Renew bolts which are tightened by turning through a speci‐
fied angle.
Circlips, snap rings
♦ Do not over-stretch circlips.
♦ Renew circlips which have been damaged or over-tensioned.
♦ Circlips must be properly seated in the base of the groove.
10 Rep. Gr.00 - Technical data
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Automatic gearbox 09G - Edition 12.2007
8 Rules for cleanliness when working
on the automatic gearbox
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ Use cleaning fluid -D 009 401 04- to clean the gearbox and its
components.
♦ Use lint-free cloths for cleaning; Audi recommends the “WY‐
PALL X70 / WORKHORSE” cloth from Kimberly-Clark Pro‐
fessional.
♦ Seal off open lines and connections with clean plugs or sealing
caps immediately.
♦ Place removed parts on a clean surface and cover them over.
Use sheeting and paper. Use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
completed immediately.
♦ Only install clean components: do not remove replacement
parts from packaging until just before installation.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
Audi TT 1999 ➤
8. Rules for cleanliness when working on the automatic gearbox 11
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
32 – Torque converter
1 Exploded view - torque converter
Note
♦
General repair instructions ⇒ page 8 .
♦
Rules for cleanliness when working on the automatic gearbox
⇒ page 11 .
1 - Torque converter
❑ Secure to prevent it fall‐
ing out when gearbox is
removed ⇒ page 13
❑ Code letters ⇒ page 3
❑ Identification
⇒ page 13
❑ Installing ⇒ page 15
❑ Installation depth
⇒ page 16
2 - Oil seal
❑ Renewing ⇒ page 13
12 Rep. Gr.32 - Torque converter
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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.
Automatic gearbox 09G - Edition 12.2007
Secure the torque converter to prevent it from falling out
– Secure torque converter using support bridge -30 - 211 A- to
prevent it from falling out, as shown in illustration.
1.1 Identification of torque converter
There are various types of torque converter. They are marked with
code letters -arrow- (for example SIM).
Torque converter/gearbox allocation ⇒ page 3 .
Audi TT 1999 ➤
The code letters -arrow- of the torque converter can be read off
with the gearbox installed.
Note
Turn torque converter further until code letters appear in opening
(QEAA in this example).
1.2 Renewing oil seal for torque converter
Special tools and workshop equipment required
♦ Extractor lever -VW 681-
1. Exploded view - torque converter 13
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
♦ Thrust piece -T10175-
Procedure
• Gearbox removed ⇒ page 44 .
– Remove oil seal for torque converter using oil seal extractor
lever -VW 681- .
– Lightly lubricate outer circumference and sealing lips of new
oil seal with ATF.
• Installation position: open side of oil seal points towards gear‐
box.
– Drive oil seal for torque converter in flush with thrust piece -
T10175- .
1.3 Draining torque converter
Special tools and workshop equipment required
♦ Used oil collection and extraction unit -V.A.G 1782-
14 Rep. Gr.32 - Torque converter
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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.
Automatic gearbox 09G - Edition 12.2007
Procedure
Drain the torque converter as follows if the torque converter has
become obstructed by abrasion or when performing a major over‐
haul of the gearbox:
– Extract ATF from torque converter with used oil collection and
extraction unit -V.A.G 1782- and oil extractor probe.
1.4 Checking torque converter
Procedure
– Check torque converter hub -arrow- for scoring.
Note
The torque converter must be renewed as a complete unit if it is
damaged or defective.
Audi TT 1999 ➤
1.5 Installing torque converter
Special tools and workshop equipment required
♦ Depth gauge -VAS 6082-
Procedure
– Push the torque converter hub through the oil seal onto the
gearbox shaft as far as the first stop.
– Push torque converter into torque converter bellhousing by
hand, turning it so that torque converter hub engages in slots
of internal gear of ATF pump. You should feel the torque con‐
verter slide into place.
1. Exploded view - torque converter 15
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
Installation depth
Caution
If the torque converter is not fitted correctly, the drive lugs on
the torque converter or the ATF pump will be seriously dam‐
aged when the gearbox is joined to the engine.
• If the torque converter is fitted correctly, the distance -a- be‐
tween the flange on gearbox housing and the contact surface
of the torque converter stud is at least 19.5 mm.
– It is important to ensure that the distance -a- remains un‐
changed during the subsequent assembly work. The torque
converter must not slip out of the gearbox.
16 Rep. Gr.32 - Torque converter
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
37 – Controls, housing
1 Electrical/electronic components and fitting locations
1 - Control unit for automatic
gearbox -J217-
❑ Fitting location; remov‐
ing and installing
⇒ page 23
❑ Unplugging multi-pin
connector ⇒ page 23
❑ Checked via self-diag‐
nosis
2 - 16-pin connector -T16- (di‐
agnostic connector)
❑ Fitting location
⇒ page 19
3 - Selector lever lock solenoid
-N110❑ Fitting location
⇒ page 19
❑ Checked via self-diag‐
nosis
❑ Removing and installing
⇒ page 35
4 - Valve body
❑ Fitting location
⇒ page 20
❑ Removing and installing
⇒ page 88
❑ Identification of solenoid
valves ⇒ page 20
5 - Wiring harness with 8-pin
connector
❑ For senders
❑ With integrated gearbox
oil temperature sender -
G93❑ Fitting location ⇒ page 21
❑ Gearbox oil temperature sender -G93- is checked by self-diagnosis
❑ Removing and installing ⇒ page 95
6 - Wiring harness with 14-pin connector
❑ For solenoid valves
❑ Fitting location ⇒ page 22
❑ Designation of solenoid valves and routing of wiring harness ⇒ page 20
❑ Removing and installing ⇒ page 94
7 - Multi-function switch -F125-
❑ Fitting location ⇒ page 19
❑ Checked via self-diagnosis
❑ ⇒ “2.1 Removing and installing multi-function switch F125 ”, page 99
❑ ⇒ “2.2 Adjusting multi-function switch F125 ”, page 100
1. Electrical/electronic components and fitting locations 17
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
8 - Selector mechanism cover
❑ Tiptronic switch -F189- is integrated in printed circuit underneath selector mechanism cover; fitting lo‐
cation ⇒ page 19
❑ Illustration does not correspond to version in vehicle
❑ Removing and installing printed circuit ⇒ page 32
9 - Starter inhibitor relay -J207-
❑ Fitting location ⇒ page 20
10 - Gearbox input speed sender -G182-
❑ Fitting location ⇒ page 21
❑ Checked via self-diagnosis
❑ Removing and installing ⇒ page 96
11 - Gearbox output speed sender -G195-
❑ Registers gearbox output speed
❑ Fitting location ⇒ page 21
❑ Checked via self-diagnosis
❑ Removing and installing ⇒ page 97
12 - Selector lever position display -Y6-
❑ Fitting location ⇒ page 22
❑ If selector lever position display does not light up, this indicates that gearbox is in emergency running
mode with gearbox control unit inactive.
❑ If all segments of selector lever position display light up together, this indicates that gearbox is in emer‐
gency running mode with gearbox control unit active.
13 - Kick-down switch -F8-
❑ Not fitted as a separate component; this function is performed by accelerator position sender -G79- and
accelerator position sender 2 -G185- ; both senders are integrated in accelerator pedal module
⇒ page 22
❑ Signal recognition in engine control unit
❑ Signal transmission from engine control unit to gearbox control unit via CAN bus
❑ Checked via self-diagnosis
14 - Brake light switch -F-
❑ Fitting location ⇒ page 22
❑ Signal recognition in engine control unit
❑ Signal transmission from engine control unit to gearbox control unit via CAN bus
❑ Checked via self-diagnosis
18 Rep. Gr.37 - Controls, housing
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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.
Automatic gearbox 09G - Edition 12.2007
Diagnostic connector
♦ Fitting location: The diagnostic connector is located below the
knee padding on the left side of the steering wheel.
Selector lever lock solenoid -N110-
♦ Fitting location: The selector lever lock solenoid -N110-
-arrow- is located in the selector mechanism.
Audi TT 1999 ➤
Multi-function switch -F125-
♦ Fitting location: The multi-function switch -F125- is located at
the top of the gearbox.
tiptronic switch -F189-
♦ Fitting location: The tiptronic switch -F189- is integrated in the
printed circuit underneath the selector mechanism cover.
1. Electrical/electronic components and fitting locations 19
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
Starter inhibitor relay -J207-
♦ Fitting location: On 13-position relay carrier ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
Valve body
♦ Fitting location: The valve body is bolted to the underside of
the gearbox housing and covered by the ATF oil pan on the
gearbox.
Solenoid valves
1 - Solenoid valve 1 -N88-
2 - Solenoid valve 2 -N89-
3 - Solenoid valve 4 -N91-
4 - Solenoid valve 6 -N93-
5 - Solenoid valve 5 -N92-
6 - Solenoid valve 9 -N282-
7 - Solenoid valve 10 -N283-
8 - Solenoid valve 3 -N90-
A - 14-pin connector
B - Wiring harness leading to 14-pin connector
20 Rep. Gr.37 - Controls, housing
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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.
Automatic gearbox 09G - Edition 12.2007
Gearbox output speed sender -G195- and gearbox input speed
sender -G182-
♦ Fitting location: The senders are fixed to the gearbox housing
behind the valve body.
1 - Gearbox input speed sender -G182-
2 - Gearbox output speed sender -G195-
Automatic gearbox hydraulic pressure sender 1 -G193- and au‐
tomatic gearbox hydraulic pressure sender 2 -G194-
♦ Fitting location: The senders are attached to the valve body.
1 - Hydraulic pressure sender 1 for automatic gearbox -G193-
2 - Hydraulic pressure sender 2 for automatic gearbox -G194-
Audi TT 1999 ➤
Wiring harness with 8-pin connector
♦ With integrated gearbox oil temperature sender -G93-
-arrow-.
♦ Fitting location: The wiring harness with 8-pin connector is at‐
tached to the valve body and gearbox.
1. Electrical/electronic components and fitting locations 21
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
Wiring harness with 14-pin connector
♦ Fitting location: The wiring harness with 14-pin connector is
attached to the valve body and gearbox.
Selector lever position display -Y6-
♦ Fitting location: The selector lever position display -Y6- is in‐
tegrated in the instrument cluster.
Note
If the selector lever position display -Y6- is defective, renew the
instrument cluster ⇒ Rep. Gr. 90 .
Kick-down switch -F8-
♦ Fitting location: integrated in accelerator pedal module
-arrow-
Note
♦
Accelerator position sender -G79- and accelerator position
sender 2 -G185- perform the function of the kickdown switch
-F8- .
♦
Renew accelerator pedal module if accelerator position send‐
er is defective ⇒ Rep. Gr. 20 .
Brake light switch -F-
♦ Fitting location: The brake light switch -F- -arrow- is located on
the pedal cluster.
Note
♦
To ensure a secure fit, the switch may only be fitted once.
♦
Removing and installing brake light switch -F- ⇒ Rep. Gr. 46 .
22 Rep. Gr.37 - Controls, housing
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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.
Automatic gearbox 09G - Edition 12.2007
1.1 Removing and installing automatic gear‐
box control unit -J217-
♦ Fitting location: The gearbox control unit is located in the ple‐
num chamber (centre) next to the engine control unit.
Removing
– Remove wiper motor ⇒ Rep. Gr. 92 .
Note
Only unplug or plug in the connector for the gearbox control unit
30 seconds after the ignition has been switched off.
– Release connector in direction of -arrow- and unplug it from
gearbox control unit.
Note
♦
When the connectors for the gearbox control unit are discon‐
nected, this resets the adaption values in the gearbox control
unit. When it is put back into operation, the control unit has to
relearn these adaption values. During this “learning process”
the gear change quality may not be as good as usual.
♦
Use adhesive tape to prevent scratches on wing and plenum
chamber panel.
Audi TT 1999 ➤
– Unscrew four nuts and take out gearbox control unit.
Note
If necessary, turn gearbox control unit slightly.
Installing
• Tightening torque:
Component Nm
Gearbox control unit to bracket 10
Installation is carried out in reverse sequence; note the following:
– Perform basic setting ⇒ Vehicle diagnosis, testing and infor‐
mation system VAS 5051.
1. Electrical/electronic components and fitting locations 23
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
2 Exploded view - shift unit
WARNING
Accidents and injury can be caused if a gear is inadvertently
engaged while the engine is running.
♦ Before working on the vehicle while the engine is running,
shift the selector lever into position “P” and apply the
handbrake.
1 - Selector lever handle
❑ Removing and installing
⇒ page 27
2 - Sleeve
❑ Clips into selector lever
handle
❑ Prevents selector lever
handle from being
pulled off
3 - Centre console (rear)
4 - Cover
❑ With retaining ring, prin‐
ted circuit and frame
5 - Bolt
❑ For adjusting locking ca‐
❑ 10 Nm
6 - Locking cable
7 - Nuts
❑ Selector mechanism to
❑ 23 Nm
8 - Floor plate
9 - Shift unit
❑ Removing and installing
10 - Bolts
❑ Tightening torque and
11 - Bolt
❑ For adjusting selector lever cable
❑ 13 Nm
12 - Lever
❑ For selector shaft
13 - Support bracket
❑ For selector lever cable
14 - Bolt
❑ For support bracket
❑ 2x
ble
floor plate
⇒ page 27
sequence ⇒ page 25
24 Rep. Gr.37 - Controls, housing
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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.
Automatic gearbox 09G - Edition 12.2007
❑ 23 Nm
15 - Nut
❑ For securing bracket -item 16- to gearbox
❑ 13 Nm
16 - Bracket
❑ With clip for selector lever cable
Cover (bottom) for selector mechanism: tightening torque and
sequence
– Renew nuts -arrows A-.
– Hand-tighten bottom cover (with glued-on seal) to selector
mechanism, making sure that seal is seated correctly.
– Tighten nuts and bolts in 2 stages as follows:
1. Tighten nuts -arrows A- to 10 Nm.
2. Tighten bolts -arrows B- to 23 Nm.
Audi TT 1999 ➤
2.1 Checking selector mechanism and igni‐
tion key removal lock
Proceed as follows:
♦ It should not be possible to operate the starter while the se‐
lector lever is in position “S”, “D” or “R” or in the tiptronic
position.
♦ On right-hand drive vehicles the starter should not operate in
selector lever positions “P” and “N” when the locking button in
the selector lever handle is pressed.
♦ If the selector lever is moved into position “N” while the vehicle
is rolling at a speed above 5 km/h, the solenoid for the selector
lever lock must not engage and block the selector lever. The
selector lever can be shifted into a driving gear.
♦ If the selector lever is moved into position “N” while the vehicle
is rolling at a speed below 5 km/h (almost at a standstill), the
solenoid for the selector lever lock should only engage after a
delay of approx. one second. The selector lever cannot be
shifted out of position “N” until brake pedal is depressed.
Selector lever in position “P” and ignition switched off:
The ignition key can be removed.
Selector lever in any position other than “P” and ignition switched
off:
The ignition key cannot be removed.
Selector lever in position “P”, button on selector lever pressed in
and ignition switched on:
• Brake pedal not depressed:
The selector lever is locked with the button pressed in, and cannot
be shifted out of position “P”. The solenoid for selector lever lock
blocks the selector lever.
• Brake pedal depressed:
The solenoid for selector lever lock releases the selector lever
and a gear can be engaged. Shift the selector lever slowly from
position “P” through “R, N, D and S” and check whether the dis‐
2. Exploded view - shift unit 25
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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.
Audi TT 1999 ➤
Automatic gearbox 09G - Edition 12.2007
play in the instrument cluster shows the correct selector lever
position in each case.
Selector lever in position “N”, button on selector lever pressed in
and ignition switched on:
• Brake pedal not depressed:
The selector lever is locked and cannot be shifted out of position
“N”. The solenoid for selector lever lock blocks the selector lever.
• Brake pedal depressed:
The solenoid for selector lever lock releases the selector lever
and a gear can be engaged.
Note
♦
If you depress the brake pedal you can shift from “N” to “D”
without pressing the button on the selector lever.
♦
However, to shift from “N” to “R” you do have to additionally
press the button on the selector lever.
Selector lever in position “D”, ignition switched on:
The selector lever is locked and cannot be shifted from “D” to “S”.
• Press button on selector lever:
The selector lever is released and can be shifted from “D” to “S”.
Selector lever in position “D”, ignition and lights switched on:
• Shift selector lever into tiptronic gate:
The illuminated “D” symbol in the selector lever position display
should go out and the “+” and “–” symbols should light up.
The selector lever position display in the instrument cluster should
switch from “PRNDS” to “654321” when the selector lever is
moved into the tiptronic gate.
• Move the selector lever in the tiptronic gate to “+” and “–”.
When you move the selector lever to “+” or “–”, the display
“654321” in the instrument cluster should move one gear up or
down accordingly.
– If the selector mechanism or the ignition key removal lock does
not operate as described, connect vehicle diagnostic, testing
and information system -VAS 5051B- .
– “Interrogate fault memory - all fault menus”, trace and elimi‐
nate any faults displayed via “Guided Fault Finding”.
26 Rep. Gr.37 - Controls, housing
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