Audi TT 14 User Manual

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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 with respect to the correctness of information in this document. Copyright by AUDI AG.

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.

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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Automatic gearbox 09G - Edition 12.2007

2.2 Removing and installing selector lever handle

Removing

– Shift selector lever to position “D”.

– Slide sleeve -1- downwards.

– Use a wire clip -4- to secure interlock button -2- in pulled-out

position -arrow-, as shown in illustration.

Note

Under no circumstances pull button out further, as selector lever handle -3- would then become damaged.

– Pull selector lever handle off upwards.

Installing

Installation is carried out in reverse sequence; note the following:

Audi TT 1999 ➤

Note

♦

To install the selector lever handle -3-, the interlock button

-2- must be pulled out as far as it will go and secured with either a wire clip -4- or with the assembly aid supplied with the new handle.

♦

If the interlock button was not secured, do not attempt to pull it out of the selector lever handle using mechanical tools. In‐ stead, apply a compressed air gun to the bottom of the handle, blow out the interlock button and secure it in this position.

– Push selector lever handle fully onto selector lever.

• The interlock button faces the driver.

• The handle must engage in the annular groove on the selector

lever.

– Remove cable tie or assembly aid.

• The interlock button mechanism should engage in the vertical

groove on the selector lever. If not, press the interlock button into the selector lever handle.

– Pull sleeve -1- upwards and engage by turning in clockwise

direction.

2.3 Removing and installing shift unit

Removing

– Shift selector lever to position “D”.

– Switch off ignition and take out ignition key.

– Remove selector lever handle ⇒ page 27 .

– Remove rear centre console ⇒ Rep. Gr. 68 .

– Unplug electrical connector -1- for printed circuit.

– Pull electrical connector out through hole -arrow- in bracket

-2-.

2. Exploded view - shift unit 27

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Unplug electrical connector -arrow- for selector lever lock sol‐

enoid -N110- .

– Carefully release frame by bending the four hooks outwards

-arrows- with a screwdriver. Then remove together with re‐ taining ring, printed circuit and cover -A-.

– Shift selector lever into position “P”.

– Disconnect locking cable -1- from selector mechanism locking

lever ⇒ page 40 .

– Unscrew two nuts (front) -arrows- for selector mechanism.

– Detach air hose -1- leading to secondary air pump from air

cleaner housing.

– Release hose clip -2- and detach air hose from air mass meter

-G70- .

– Unplug electrical connector for air mass meter -G70-

-Item 3-.

– Remove bolts -4- and -5- and detach air cleaner housing.

28 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Use an open-end spanner (10 mm) -item 2- or similar to lever

selector lever cable -1- off selector shaft lever -3-.

– Press retainers on support bracket for selector lever cable to‐

gether -arrows- and pull selector lever cable out of support bracket on gearbox.

– Unhook selector lever cable -1- from clip -arrow- on gearbox.

Note

Do not bend or kink the selector lever cable.

Audi TT 1999 ➤

– Disconnect exhaust system at connection -A- of front exhaust

pipe ⇒ Rep. Gr. 26 .

– Remove tunnel cross-piece -B- below exhaust system.

– Remove heat shields -C- and -D-.

2. Exploded view - shift unit 29

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Unscrew bolts -arrows B-.

Note

-Arrows A- can be disregarded.

– Remove selector mechanism with selector lever cable down‐

wards.

Installing

• Tightening torque ⇒ page 24 , ⇒ page 31 , ⇒ page 25

Installation is carried out in reverse sequence; note the following:

– Insert selector lever cable in support bracket on gearbox and

carefully push onto selector shaft lever. Take care not to bend selector shaft lever, otherwise precise adjustment of selector mechanism will no longer be possible.

Note

Do not bend or kink the selector lever cable.

– Hook selector lever cable -1- into clip -arrow- on gearbox.

• When routing selector lever cable, ensure a clearance of at least 5 mm from ATF cooler.

– Install exhaust system and perform stress-free alignment ⇒

Rep. Gr. 26 .

– Adjust locking cable ⇒ page 42 .

– Install rear centre console ⇒ Rep. Gr. 68 .

– Install selector lever handle ⇒ page 27 .

– Adjust selector lever cable ⇒ page 39 .

– Check selector mechanism and ignition key removal lock

⇒ page 25 .

30 Rep. Gr.37 - Controls, housing

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Audi TT 1999 ➤

Automatic gearbox 09G - Edition 12.2007

3 Exploded view - selector mechanism

Note

Lubricate all bearings and moving surfaces with polycarbamide grease ⇒ Electronic parts catalogue .

1 - Selector lever handle

❑ Removing and installing

⇒ page 27

2 - Sleeve

3 - Bolt

❑ 8x ❑ 4 Nm

4 - Retaining ring

5 - Upper cover

❑ Includes symbol insert ❑ Clipped onto frame

-item 8-

6 - Side cover

❑ Clipped onto frame

-item 8-

7 - Printed circuit

❑ With integrated tiptronic

switch -F189-

❑ Can be checked in “Gui‐

ded fault finding” using ⇒ Vehicle diagnosis, testing and information system VAS 5051

❑ Removing and installing

⇒ page 32

8 - Frame

❑ With sliding cover ❑ Removing and installing

⇒ “3.1 Removing and in‐ stalling printed circuit with tiptronic switch F189 ”, page 32

9 - Selector lever cable

❑ Do not bend or kink ❑ Renew selector lever cable if sleeve is damaged ❑ Checking and adjusting ⇒ page 39 ❑ Removing and installing ⇒ page 36 ❑ Do not lubricate cable eye and ball socket

10 - Locking plate

❑ Renew

11 - Nut

❑ 4x ❑ Self-locking ❑ Renew

3. Exploded view - selector mechanism 31

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

❑ Tightening torque and sequence ⇒ page 25

12 - Cover (bottom)

❑ For selector mechanism ❑ With glued-on gasket

13 - Bolt

14 - Securing clip

❑ For pivot pin -item 16- of pawl -item 15-

15 - Pawl

❑ For selector lever lock ❑ Engages in cable lever of shift unit

16 - Pivot pin

❑ For pawl

17 - Selector lever lock solenoid -N110-

❑ Can be checked in “Guided fault finding” using ⇒ Vehicle diagnosis, testing and information system VAS

5051

❑ Removing and installing ⇒ page 35

18 - Locking cable

❑ For ignition key removal lock ❑ Do not kink ❑ Removing and installing ⇒ page 40 ❑ Adjusting ⇒ page 42 ❑ Checking operation of the ignition key withdrawal lock ⇒ page 25 .

19 - Shift unit

❑ Removing and installing ⇒ page 27

20 - Steering lock

21 - Clip

❑ Fit from above ❑ Fitting location: angled ends pointing to steering lock

3.1 Removing and installing printed circuit

with tiptronic switch -F189-

Removing

– Shift selector lever to position “D”.

– Switch off ignition and take out ignition key.

– Remove selector lever handle ⇒ page 27 .

– Remove rear centre console ⇒ Rep. Gr. 68 .

– Unplug electrical connector -1-.

– Pull connector out through hole -arrow- in bracket -2-.

32 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Carefully release frame by bending the four hooks outwards

-arrows- with a screwdriver. Then remove together with re‐ taining ring, printed circuit and cover -A-.

– Remove bolts -arrows-.

– Remove retaining ring from frame together with top cover and

side cover.

Audi TT 1999 ➤

– Unclip electrical wiring harness -A-.

– Pull printed circuit with tiptronic switch -F189- off frame

-arrows-.

– Check that magnet -arrow- is securely seated on transverse

slide of sliding cover; if magnet is loose, renew sliding cover

⇒ page 34 .

3. Exploded view - selector mechanism 33

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

Installing

• Tightening torque ⇒ page 31 .

Installation is carried out in reverse sequence; note the following:

– Fit printed circuit onto frame with holes -arrows- over guides

of frame.

– Clip wiring harness -A- into frame.

• Make sure printed circuit is not deformed.

– Install rear centre console ⇒ Rep. Gr. 68 .

– Install selector lever handle ⇒ page 27 .

3.2 Removing and installing sliding cover for

selector lever

Removing

– Remove printed circuit ⇒ page 32 .

– Carefully lever out retaining tabs -arrows-, one after the other.

Note

If retaining tabs are damaged, bottom part of frame must be re‐ newed.

– Take out top part of frame -1- and sliding cover -2-.

Installing

Installation is carried out in reverse sequence; note the following:

– Place sliding cover -2- in bottom part of frame -3-.

• Magnets -arrow A- and -arrow B- must be securely attached to sliding cover.

Note

♦

If magnets are loose, sliding cover must be renewed.

♦

If magnet -arrow A- is missing, tiptronic switch -F189- will not work.

– Carefully clip top part of frame -1- into bottom part of frame

-3-.

– Install printed circuit ⇒ page 32 .

34 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

3.3 Removing and installing selector lever lock solenoid -N110-

Removing

– Shift selector lever into position “R”.

– Switch off ignition and take out ignition key.

– Slightly open cover of storage compartment -4-.

– Lift out switch console -1- and unplug electrical connectors

-2-.

– Carefully press retaining tabs -3- forwards and lift out storage

compartment.

Audi TT 1999 ➤

– Unplug electrical connector -arrow- at selector lever lock sol‐

enoid -N110- .

Note

For illustration purposes, the selector mechanism is shown with the centre console removed.

– Shift selector lever into position “P”.

– Disconnect exhaust system at connection -A- of front exhaust

pipe ⇒ Rep. Gr. 26 .

– Remove tunnel cross-piece -B- below exhaust system.

– Remove heat shields -C- and -D-.

3. Exploded view - selector mechanism 35

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– First, unscrew nuts -arrows A-, and then remove bolts

-arrows B-.

– Carefully push selector mechanism cover (bottom) including

protective sleeve forwards over selector lever cable.

Note

Take care not to damage protective sleeve.

– Unclip selector lever lock solenoid -N110- -arrows A-, pull out

of pawl -arrow B- and detach.

Installing

Installation is carried out in reverse sequence; note the following:

– Engage selector lever lock solenoid -N110- in pawl -arrow B-

and clip into retainers -arrows A-.

– Install selector mechanism cover (bottom) ⇒ page 25 .

– Install exhaust system and perform stress-free alignment ⇒

Rep. Gr. 26 .

– Observe correct procedure after connecting battery ⇒ Rep.

Gr. 27 .

– Check selector mechanism ⇒ page 25 .

3.4 Removing and installing selector lever cable

Removing

– Shift selector lever to position “D”.

– Switch off ignition and take out ignition key.

– Detach air hose -1- leading to secondary air pump from air

cleaner housing.

– Release hose clip -2- and detach air hose from air mass meter

-G70- .

– Unplug electrical connector for air mass meter -G70-

-Item 3-.

– Remove bolts -4- and -5- and detach air cleaner housing.

36 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Use an open-end spanner (10 mm) -item 2- or similar to lever

selector lever cable -1- off selector shaft lever -3-.

– Press retainers on support bracket for selector lever cable to‐

gether -arrows- and pull selector lever cable out of support bracket on gearbox.

– Unhook selector lever cable -1- from clip -arrow- on gearbox.

Audi TT 1999 ➤

– Disconnect exhaust system at connection -A- of front exhaust

pipe ⇒ Rep. Gr. 26 .

– Remove tunnel cross-piece -B- below exhaust system.

– Remove heat shields -C- and -D-.

– First, unscrew nuts -arrows A-, and then remove bolts

-arrows B-.

– Carefully push cover (bottom) with protective sleeve forwards

over selector lever cable.

Note

Take care not to damage protective sleeve.

3. Exploded view - selector mechanism 37

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Shift selector lever -3- into tiptronic gate -arrow A-.

– Lever selector lever cable -2- off selector lever -3- with a

screwdriver.

– Pull down locking plate -1- for selector lever cable and remove.

– Carefully pull selector lever cable out of shift unit.

Installing

• Tightening torques ⇒ page 24 , ⇒ page 31

Installation is carried out in reverse sequence; note the following:

Note

♦

Renew locking plate for selector lever cable.

♦

Check the protective sleeve for damage; the protective sleeve can only be renewed together with the selector lever cable.

♦

Check that the protective sleeve is not twisted and is fitted correctly.

♦

Do not bend or kink the selector lever cable.

• Selector lever -3- is in tiptronic gate -arrow A-.

– Guide selector lever cable -2- into selector mechanism and

press onto selector lever -3- using a screwdriver -4-.

– Fit new locking plate -1- for selector lever cable.

• Angled end of locking plate must point towards end of selector

lever cable.

– Move selector lever from “P” to “S”.

• Selector mechanism and selector lever cable must move free‐

ly; if necessary renew selector lever cable or service selector mechanism.

– Shift selector lever into position “P”.

– Install selector mechanism cover (bottom) ⇒ page 25 .

– Insert protective sleeve on selector lever cable in cover.

38 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Move selector shaft lever -3- on gearbox to “P” by pushing it

all the way back (opposite to direction of travel).

• Detent lever must engage in parking lock gear; it should no longer be possible to turn both front wheels in the same di‐ rection.

– Loosen nut -2- at front ball socket of selector lever cable -1-.

– Insert selector lever cable in support bracket on gearbox and

carefully push onto selector shaft lever. Take care not to bend selector shaft lever, otherwise precise adjustment of selector mechanism will no longer be possible.

– Tighten nut -2-.

– Hook selector lever cable -1- into clip -arrow- on gearbox.

• When routing selector lever cable, ensure a clearance of at least 5 mm from ATF cooler.

– Install exhaust system and perform stress-free alignment ⇒

Rep. Gr. 26 .

– Check selector mechanism ⇒ page 25 .

Audi TT 1999 ➤

3.5 Checking and adjusting selector lever

cable

Checking

– Shift selector lever into position “P”.

– Detach air hose -1- leading to secondary air pump from air

cleaner housing.

– Release hose clip -2- and detach air hose from air mass meter

-G70- .

– Unplug electrical connector for air mass meter -G70-

-Item 3-.

– Remove bolts -4- and -5- and detach air cleaner housing.

3. Exploded view - selector mechanism 39

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

– Use an open-end spanner (10 mm) -item 2- or similar to lever

selector lever cable -1- off selector shaft lever -3-.

– Press retainers on support bracket for selector lever cable to‐

gether -arrows- and pull selector lever cable out of support bracket on gearbox.

– Place down selector lever cable in such a way that end of cable

can move freely.

Note

Do not bend or kink the selector lever cable.

– Move selector lever from “P” to “S”.

– Check front protective sleeve on selector lever cable for dam‐

age; if necessary renew selector lever cable.

– Shift selector lever into position “P”.

• Selector mechanism and selector lever cable must move free‐ ly; if necessary renew selector lever cable ⇒ page 36 or service selector mechanism.

– Insert selector lever cable in support bracket on gearbox and

carefully push onto selector shaft lever. Take care not to bend selector shaft lever, otherwise precise adjustment of selector mechanism will no longer be possible.

Adjusting

• Tightening torque ⇒ page 24 .

– Shift selector lever into position “P”.

– Loosen nut -2- at front ball socket of selector lever cable -1-.

– While it is in position “P” move selector lever slightly forwards

and backwards, but do NOT shift from “P” into another gear.

– Move selector shaft lever -3- on gearbox to “P” by pushing it

all the way back (opposite to direction of travel).

• Detent lever must engage in parking lock gear; it should no longer be possible to turn both front wheels in the same di‐ rection.

– Tighten nut -2-.

– Check selector mechanism ⇒ page 25 .

3.6 Removing and installing locking cable

Removing

– Switch off ignition and take out ignition key.

– Remove airbag unit and steering wheel ⇒ Rep. Gr. 69 .

– Remove storage compartment (driver's side) ⇒ Rep. Gr. 68 .

– Unscrew bolts -1- and remove handle -5- for steering column

adjustment.

– Remove bolts -2, 3, 4-.

– Detach top and bottom sections of steering column trim.

40 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Shift selector lever into position “P”.

– Turn ignition key to “ignition on” position.

– Then lift clip -1- slightly and pull locking cable -2- out of ignition

lock housing.

– Remove selector lever handle ⇒ page 27 .

– Remove rear centre console ⇒ Rep. Gr. 68 .

– Loosen bolt on support bracket -arrow A- of locking cable.

– Carefully remove locking cable from selector mechanism

-arrow B- and disengage from locking lever -arrow C-.

– Pull locking cable out of dash panel.

Audi TT 1999 ➤

Installing

Note

Do not kink the locking cable.

– Route locking cable -arrow- from steering lock to selector

mechanism as follows:

1 - Behind wiring harness

2 - Underneath footwell vent

3 - Underneath carpet

– Shift selector lever into position “P”.

– Pull locking cable slightly out of cable sleeve and engage in

locking lever -arrow C-.

– Engage support bracket for locking cable in selector mecha‐

nism -arrow B-.

3. Exploded view - selector mechanism 41

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Turn ignition key to “ignition on” position.

– Guide locking cable -2- into ignition lock housing until it en‐

gages audibly.

• Clip -1- must make full contact with ignition lock housing.

• Installation position: Angled ends of clip must point towards ignition lock housing.

– Adjust locking cable ⇒ page 42 .

– Check operation of ignition key withdrawal lock ⇒ page 25 .

– Install rear centre console ⇒ Rep. Gr. 68 .

– Install selector lever handle ⇒ page 27 .

– Install steering column trim ⇒ Rep. Gr. 94 .

– Install storage compartment (driver's side) ⇒ Rep. Gr. 68 .

– Install airbag unit and steering wheel ⇒ Rep. Gr. 69 .

3.7 Adjusting locking cable

Special tools and workshop equipment required

♦ Locking cable adjustment gauge -3352 A-

Procedure

• Tightening torque ⇒ page 24 .

• Locking cable must be in installation position.

• Rear centre console has been removed.

• Selector lever is in position “P”

• Ignition key is in removal position.

• Steering column is in “lowest/rearmost” position.

Caution

To adjust the locking cable always proceed as described in the following.

42 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Loosen bolt at support bracket.

– Fit locking cable adjustment gauge -3352 A- between locking

lever -1- and locking cable eye -2-.

– To compensate for play, pull support bracket as far as stop in

direction of -arrow-.

• When adjusted correctly, it must be possible to take out and insert locking cable adjustment gauge -3352 A- easily.

– Tighten bolt at support bracket.

– Remove locking cable adjustment gauge -3352 A- .

– Check operation of ignition key withdrawal lock ⇒ page 25 .

Audi TT 1999 ➤

3. Exploded view - selector mechanism 43

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

4 Removing and installing gearbox

Special tools and workshop equipment required

♦ Support bracket -10 - 222

A-

♦ Rack -10 - 222 A /1-

♦ Engine and gearbox jack -

V.A.G 1383 A-

♦ Gearbox support -3282-

♦ Shackle -10 - 222 A /12-

♦ Hose clamps, up to Ø 25

mm -3094-

♦ Support bridge -30 - 211 A-

44 Rep. Gr.37 - Controls, housing

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♦ Hooks -3004-

♦ Adjustment plate -3282/36-

Audi TT 1999 ➤

Automatic gearbox 09G - Edition 12.2007

Removing

Note

All cable ties which are released or cut open during removal must be fitted in the same position when installing.

– Shift selector lever to position “N”.

– Remove engine cover panel -1- -top arrows-.

– Remove cover panel (front left) -arrows-.

4. Removing and installing gearbox 45

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

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.

– With ignition switched off, disconnect earth wire -arrow- at

battery.

– Detach air hose -1- leading to secondary air pump from air

cleaner housing.

– Release hose clip -2- and detach air hose from air mass meter

-G70- .

– Unplug electrical connector for air mass meter -G70-

-Item 3-.

– Remove bolts -4- and -5- and detach air cleaner housing.

– Remove battery ⇒ Rep. Gr. 27 .

– Remove battery tray -arrows-.

– Use an open-end spanner (10 mm) -item 2- or similar to lever

selector lever cable -1- off selector shaft lever -3-.

– Press retainers on support bracket for selector lever cable to‐

gether -arrows- and pull selector lever cable out of support bracket on gearbox.

46 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Unhook selector lever cable -1- from clip -arrow- on gearbox

and tie up.

Note

Do not bend or kink the selector lever cable.

– Unplug electrical connector at multi-function switch -F125- .

– Remove electrical connections from starter.

– Remove starter -C- ⇒ Rep. Gr. 27 .

Audi TT 1999 ➤

– Mark coolant hoses at ATF cooler for reinstallation.

Note

Depending on the version, the vehicle may be fitted with a small plastic tube in the supply line to the ATF cooler. This tube has to be re-fitted as part of installation.

– Clamp off coolant hoses with hose clamps -3094- and detach

hoses from ATF cooler.

Note

Seal off ATF cooler with clean plugs or sealing caps to prevent dirt from entering.

– Set up support bracket -10 - 222 A- with rack -10 - 222 A /1-

on body flanges -arrows-, as shown in illustration.

– Engage hook of spindle with shackle -10 - 222 A /12- in engine

lifting eye.

– Partly take up weight of engine/gearbox assembly via spindle.

4. Removing and installing gearbox 47

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Unscrew earth connection -arrow-.

– Remove all engine/gearbox securing bolts which are accessi‐

ble from above.

– Remove both front wheels.

– Remove centre noise insulation (loosen fasteners -arrows-).

– Completely remove drive shaft (left-side) using wedge -

T10161- ⇒ Rep. Gr. 40 .

Note

The gearbox has no separate flange shaft; the drive shaft is fitted into the gearbox.

– If fitted, unscrew nuts -arrows- and tie up bracket for front left

vehicle level sender -G78- to one side.

48 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Remove noise insulation (left-side) -arrows-.

Vehicles with power-steering pressure pipe on tubular cross member:

– Detach power-steering pressure pipe from tubular cross mem‐

ber -arrows-.

Audi TT 1999 ➤

Vehicles with power-steering pressure pipe on gearbox:

– Unbolt power-steering pressure pipe from gearbox -arrows-

and detach speed nut from gearbox.

Continued for all vehicles:

– If fitted, remove tubular cross member -arrows-.

4. Removing and installing gearbox 49

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– If fitted, remove cross piece from subframe -arrows-.

– First unscrew bolts -A- and then bolts -B- and remove pendu‐

lum support.

– Press swivel joint (right-side) out of wheel bearing housing ⇒

Rep. Gr. 40 .

Note

♦

This work step is necessary so that the drive shaft (right-side) need not be separated from the wheel bearing (wheel hub).

♦

The drive shaft (right-side) only has to be separated from the gearbox.

– Remove bolts -B- and detach heat shield -A-.

– Press drive shaft (right-side) -C- off gearbox -arrow- using

wedge -T10161- ⇒ Rep. Gr. 40 .

Note

The gearbox has no separate flange shaft; the drive shaft is fitted into the gearbox.

50 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Lift drive shaft (right-side) -A- up and secure with wire.

– Unclip cap -C-

– Remove 6 nuts -arrow- for torque converter (turn crankshaft

60° in direction of engine rotation each time).

Note

♦

If the six nuts have not all been removed from the torque con‐ verter, the torque converter will be pulled out when you remove the gearbox from the engine.

♦

To loosen the torque converter nuts, counterhold at bolt for vibration damper.

Audi TT 1999 ➤

Caution

The flexible joints in the front exhaust pipe can be damaged.

♦ The flexible joints in the front exhaust pipe must not be

bent further than 10°.

– Loosen nuts -arrows- and move clamp towards rear.

– Tie up exhaust system using a chain. To do so, engage hooks

-3004- in openings on underbody (if necessary remove plugs).

4. Removing and installing gearbox 51

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Unplug electrical connectors -A- and -B-.

Note

If electrical connectors -A- or -B- (bolted onto gearbox) are dam‐ aged, corresponding wiring harness must be renewed

⇒ “1.4 Removing and installing wiring harness with 14-pin con‐ nector”, page 94 and ⇒ “1.5 Removing and installing wiring harness with 8-pin connec‐ tor and gearbox oil temperature sender G93 ”, page 95 .

– Unscrew bolts -1- and -2- and detach gearbox support -A-.

– Lower engine/gearbox assembly via spindle (approx. 50 mm).

– Set up gearbox support -3282- on engine and gearbox jack -

V.A.G 1383 A- .

– Place adjustment plate -3282/36- on gearbox support -3282-

(adjustment plate only fits in one position).

– Align arms of gearbox support according to holes in adjust‐

ment plate.

– Secure support elements as illustrated on adjustment plate.

– Place engine and gearbox jack -V.A.G 1383 A- with gearbox

support -3282- underneath gearbox and support gearbox.

– Secure gearbox to gearbox support -3282- with bolt -1-.

52 Rep. Gr.37 - Controls, housing

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– Remove rear bolt -B- securing gearbox to engine.

– Remove remaining engine/gearbox securing bolts.

Audi TT 1999 ➤

Automatic gearbox 09G - Edition 12.2007

– Push gearbox off engine and at the same time press torque

converter out of drive plate.

– Press torque converter against ATF pump -arrow-.

– Carefully pivot gearbox towards subframe.

– Carefully lower gearbox and guide downwards past subframe.

– When lowering gearbox, change position of gearbox as re‐

quired using spindle on gearbox support -3282- .

– Secure torque converter in gearbox using support bridge -30

- 211 A- to prevent it from falling out.

Installing

Note

♦

Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.

♦

Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant.

♦

Do not use parts which have been degreased.

♦

Tolerance for tightening torques ±15%.

4. Removing and installing gearbox 53

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

• Tightening torques ⇒ page 60

• Engine/gearbox securing bolts:

Item Bolt Nm

1, 2

3 2), 4

1)

2)

M12x55 80

M12x165 80

5 M10x65 45

6, 7 M10x55 45

8 M12x70 80 A Dowel sleeves for centralising

1)

•

Bolt with stud M8.

2)

•

Bolt also secures starter to gearbox.

• Additional tightening torques .

Nm

Bolts/nuts M6 10

Torque converter to drive plate

1)

•

Renew nuts.

M8 20 M10 45 M12 65

1)

57

Installation is carried out in reverse sequence; note the following:

Note

♦

Before fitting a replacement gearbox, always clean the ATF cooler.

♦

Renew bolts which are tightened by turning through a speci‐ fied angle.

♦

Renew nuts for torque converter.

♦

Renew self-locking nuts and bolts, and seals, O-rings and gaskets.

♦

Hose connections and hoses for charge air system must be free from oil and grease before fitting.

♦

Secure all hose connections with the correct hose clips (as original equipment); refer to ⇒ Electronic parts catalogue .

♦

To ensure that the charge air hoses can be connected se‐ curely, you must spray the screws on used screw-type clips with rust remover prior to installation.

– Push the torque converter hub through the oil seal onto the

gearbox shaft as far as the first stop.

54 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– 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.

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 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 forwards.

– Before installing, ensure that the dowel sleeves are correctly

located.

– Secure gearbox to engine.

– Use genuine nuts for attaching torque converter to drive plate

⇒ Electronic parts catalogue .

Audi TT 1999 ➤

4. Removing and installing gearbox 55

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Secure torque converter to drive plate, turning crankshaft

60° further each time -arrow-.

– Install gearbox mounting ⇒ page 61 .

– Install pendulum support ⇒ page 63 .

– Fit drive shafts to gearbox ⇒ Rep. Gr. 40 .

– Install starter ⇒ Rep. Gr. 27 .

– Connect coolant hoses to ATF cooler according to markings

made during removal.

Note

Depending on the version, the vehicle may be fitted with a small plastic tube in the supply line to the ATF cooler. This tube has to be re-fitted as part of installation.

– Install battery ⇒ Rep. Gr. 27 .

– Observe correct procedure after connecting battery ⇒ Rep.

Gr. 27 .

– Move selector lever to position “P” and install selector lever

cable ⇒ page 36 .

– Check adjustment of selector lever cable and adjust if neces‐

sary ⇒ page 39 .

– Align exhaust system so it is free of stress ⇒ Rep. Gr. 26 .

– Perform basic setting ⇒ Vehicle diagnosis, testing and infor‐

mation system VAS 5051.

– Check and top up ATF level ⇒ page 65 .

– Install noise insulation ⇒ Rep. Gr. 50 .

– Check coolant level ⇒ Rep. Gr. 19 .

– If rumbling noises occur when driving, adjust assembly mount‐

ings ⇒ Rep. Gr. 10 .

56 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

5 Transporting the automatic gearbox

Special tools and workshop equipment required

♦ Shackle -10 - 222 A /12-

♦ Workshop hoist -VAS 6100-

Audi TT 1999 ➤

Procedure

Shackle -10 - 222 A /12- can be used to transport automatic gear‐ box and also when setting up gearbox support -3282- .

– Secure shackle -10 - 222 A /12- to top of gearbox housing.

– Engage hook of workshop hoist -VAS 6100- in shackle, as

shown in illustration.

– Lift gearbox with workshop hoist -VAS 6100- and shackle -10

- 222 A /12- .

5. Transporting the automatic gearbox 57

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

6 Securing gearbox to engine and

gearbox support

Special tools and workshop equipment required

♦ Support clamp -VW 313-

♦ Engine and gearbox support -VW 540-

♦ Engine and gearbox support -VAS 6095-

58 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

Procedure

• ATF drained ⇒ page 73 .

– Secure gearbox to engine and gearbox support -VW 540-

-arrows-.

– Using workshop hoist -VAS 6100- , insert gearbox into support

clamp -VW 313- or engine and gearbox support -VAS 6095- .

WARNING

The centre of gravity of the gearbox is outside the pivot centre of the support clamp. A second mechanic has to hold the gear‐ box housing when it is being turned in the support clamp VW 313- to prevent it from swinging round.

Audi TT 1999 ➤

6. Securing gearbox to engine and gearbox support 59

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

7 Exploded view - subframe

1 - Engine mounting

❑ Adjusting ⇒ Rep. Gr. 10

2 - Bolt

❑ Tightening torque ⇒

Rep. Gr. 10

3 - Connecting bracket

4 - Bolt

❑ Tightening torque ⇒

Rep. Gr. 10

5 - Bolt

❑ Tightening torque ⇒

Rep. Gr. 10

6 - Bolt

❑ Tightening torque ⇒

Rep. Gr. 10

7 - Centre hex stud

❑ Renew ❑ 50 Nm + 90°

8 - Gearbox mounting

❑ Removing and installing

⇒ page 61

❑ Adjusting ⇒ Rep. Gr. 10

9 - Bolt

❑ 25 Nm

10 - Bolt

❑ Renew ❑ 40 Nm + 90°

11 - Bolt

❑ Renew ❑ 50 Nm + 90°

12 - Gearbox support

13 - Bolt

❑ Renew ❑ 50 Nm + 90°

14 - Pendulum support

❑ Removing and installing ⇒ page 63

15 - Bolt

❑ Renew ❑ 20 Nm + 90°

16 - Bolt

❑ Renew ❑ 50 Nm + 90°

60 Rep. Gr.37 - Controls, housing

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.

7.1 Removing and installing gearbox

mounting

Special tools and workshop equipment required

♦ Support bracket -10-222 A-

♦ Shackle -10 - 222 A /12-

Audi TT 1999 ➤

Automatic gearbox 09G - Edition 12.2007

Removing

– Remove engine cover panel -1- -top arrows-.

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.

– With the ignition switched off, disconnect battery earth cable

⇒ Rep. Gr. 27 .

– Detach air hose -1- leading to secondary air pump from air

cleaner housing.

– Release hose clip -2- and detach air hose from air mass meter

-G70- .

– Unplug electrical connector for air mass meter -G70-

-Item 3-.

– Remove bolts -4- and -5- and detach air cleaner housing.

7. Exploded view - subframe 61

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Remove battery ⇒ Rep. Gr. 27 .

– Remove battery tray -arrows-.

– Open wiring duct on left in engine compartment -arrows-.

– Unclip wiring duct and push to side.

– Set up support bracket -10 - 222 A- with rack -10 - 222 A /1-

on body flanges -arrows-, as shown in illustration.

– Engage hook of spindle with shackle -10 - 222 A /12- in engine

lifting eye.

– Partly take up weight of engine/gearbox assembly via spindle.

– Remove bolts -arrows-.

62 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Remove bolts -1- and -2- and detach gearbox mounting -A-.

Installing

• Tightening torques ⇒ page 60

Note

Renew bolts which are tightened by turning through a specified angle.

– Secure gearbox mounting to body.

– Hand-tighten bolts -arrows- securing gearbox mounting to

gearbox support initially.

Caution

The threads in the gearbox support can be damaged if the bolts are not inserted straight.

♦ Before fitting the bolts -2-, the gearbox support and the

support arm of the gearbox mounting must be aligned ab‐ solutely parallel. If necessary, push the gearbox up at the rear with a trolley jack.

Audi TT 1999 ➤

– Pull gearbox up with spindle on support bracket until gearbox

support contacts support arm of gearbox mounting.

– Adjust assembly mountings ⇒ Rep. Gr. 10 .

– Secure support arm of gearbox mounting to gearbox support.

– Detach support bracket -10 - 222 A- from engine.

7.2 Removing and installing pendulum sup‐

port

Removing

– Remove centre noise insulation (loosen fasteners -arrows-).

7. Exploded view - subframe 63

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– First unscrew bolts -A- and then bolts -B- and remove pendu‐

lum support.

Installing

• Tightening torques ⇒ page 60

Installation is carried out in reverse sequence; note the following:

Note

Renew bolts which are tightened by turning through a specified angle.

– First secure pendulum support to gearbox -arrows B-, then on

subframe -arrows A-.

– Install noise insulation ⇒ Rep. Gr. 50 .

64 Rep. Gr.37 - Controls, housing

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8 Overview - ATF in gearbox

ATF inspection hole

A - Plug for ATF inspection hole

• Tightening torque: 27 Nm.

B - Seal - renew

C - Overflow pipe

• Tightening torque: 1 Nm.

ATF drain plug -B-

• Tightening torque: 39 Nm.

Audi TT 1999 ➤

Automatic gearbox 09G - Edition 12.2007

Plug -arrow- for ATF filler hole

Note

Renew seal.

• Tightening torque: 39.5 Nm.

8.1 Checking and correcting ATF level

Special tools and workshop equipment required

♦ Vehicle diagnostic, testing and information system -VAS

5051B-

8. Overview - ATF in gearbox 65

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

♦ Used oil collection and extraction unit -V.A.G 1782-

♦ Safety goggles

Procedure

• Gearbox must not be in emergency running (backup) mode.

• Drive vehicle onto lifting platform or inspection pit to make sure it is placed absolutely horizontal.

• Selector lever at position “P”.

• Exhaust hose(s) of an exhaust gas extractor (switched on) must be connected.

• Engine idling.

• The air-conditioner and heating system must be switched off.

• Vehicle diagnostic, testing and information system -VAS 5051B- connected up; Vehicle self-diagnosis and vehi‐

cle system 02 - Gearbox electronics

selected.

• The ATF temperature at the beginning of the test must not be higher than 30 °C. If necessary, first allow the gearbox to cool down.

Note

♦

The ATF level will vary according to the ATF temperature.

♦

If the ATF level is checked when the ATF temperature is too low, this will result in overfilling.

♦

If the level is checked when the ATF temperature is too high, this will result in underfilling.

♦

Both overfilling and underfilling will impair the function of the gearbox.

♦

The ATF temperature is taken from the reading on the vehicle diagnostic, testing and information system -VAS 5051B- .

66 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

ATF temperature reading

Display on -VAS 5051B- :

– From menu -1-, select function “Measured values” and ad‐

vance by pressing → button.

Display on -VAS 5051B- : – Using keypad -1- press button 6 for “Display group 006” and

confirm entry by pressing Q

button.

Audi TT 1999 ➤

Display on -VAS 5051B- :

– Read off ATF temperature in display zone -1-.

Checking and correcting ATF level

• Tightening torque ⇒ page 65 .

Note

♦

The ATF level is checked at the ATF inspection hole.

♦

The ATF level is correct if a small amount of fluid comes out at the ATF inspection plug when ATF temperature is between 35°C and 45°C, or 50°C in hot climates (the fluid level rises due to expansion as it warms up).

– Place used oil collection and extraction unit -V.A.G 1782- be‐

low gearbox.

WARNING

Wear safety goggles.

8. Overview - ATF in gearbox 67

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– When ATF reaches temperature of 35 °C, unscrew plug -A-

for ATF inspection hole.

– Cut open seal -arrow- for plug and renew.

Note

When the plug is opened, a small amount of ATF will always run out of the overflow pipe -arrow 2-.

If ATF continues to come out through ATF inspection hole via overflow pipe before ATF has reached a temperature of 45 °C, the ATF level is OK.

Note

♦

Plug for ATF inspection hole must be screwed in again at the latest when ATF reaches temperature of 45 °C (countries with hot climates: 50 °C).

♦

If ATF temperature exceeds 45 °C too much fluid will escape as it expands when heated. In this case the quantity of fluid in the gearbox is NOT sufficient!

– Fit new seal on plug -arrow 1- and tighten.

The ATF check is now completed.

– Exit from function “Measured values” by pressing ← button.

– Press “End output”.

– Switch off ignition and unplug diagnostic connector.

If no ATF emerges from ATF inspection hole when ATF has reached 45 °C, top up with ATF

⇒ “8.2 Filling up with ATF - vehicles with ATF filler hole”, page 69 or ⇒ “8.3 Filling up with ATF - vehicles without ATF filler hole”, page 71 .

68 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

8.2 Filling up with ATF - vehicles with ATF filler hole

Note

Depending on version, automatic gearbox 09G has an ATF filler hole -arrow-.

Special tools and workshop equipment required

♦ ATF filling unit -V.A.G 1924-

Audi TT 1999 ➤

♦ Torx bit T55 -VAS 5383-

Procedure

• Tightening torques ⇒ page 65

• Engine keeps running at idle speed.

• Vehicle diagnostic, testing and information system -VAS

5051B- must be connected.

• Used oil collection and extraction unit -V.A.G 1782- placed

underneath.

– Fill ATF filling unit -V.A.G 1924- with the ATF for the automatic

gearbox 09G.

• ATF specifications ⇒ Electronic parts catalogue .

Caution

The ATF filling unit must be clean and the ATF must not be mixed with other types of ATF!

– Secure reservoir for ATF filling unit -V.A.G 1924- as high as

possible on vehicle.

8. Overview - ATF in gearbox 69

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Remove centre noise insulation (loosen fasteners -arrows-).

– Unscrew plug for ATF filler hole -arrow- with Torx bit T55 -VAS

5383- .

– Attach pipe of ATF filling unit -V.A.G 1924- to ATF filler hole

-arrow-.

– Fill with ATF using ATF filling unit -V.A.G 1924- until ATF

comes out of overflow pipe -arrow 2-.

Note

♦

Plug for ATF inspection hole must be screwed in again at the latest when ATF reaches temperature of 45 °C (countries with hot climates: 50 °C).

♦

If ATF temperature exceeds 45 °C too much fluid will escape as it expands when heated. In this case the quantity of fluid in the gearbox is NOT sufficient!

♦

If necessary, switch off engine and allow gearbox to cool down.

70 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Cut open seals -arrow- for plugs for ATF inspection hole and

for ATF filler hole and renew.

– Fit new seal on plug -arrow 1- for ATF inspection hole and

tighten.

Audi TT 1999 ➤

– Fit new seal on plug -arrow- for ATF filler hole and tighten.

– Exit from function “Measured values” by pressing ← button.

– Press “End output”.

– Switch off ignition and unplug diagnostic connector.

– Install noise insulation ⇒ Rep. Gr. 50 .

8.3 Filling up with ATF - vehicles without ATF filler hole

Special tools and workshop equipment required

♦ Adapter for oil filling -VAS 6262-

8. Overview - ATF in gearbox 71

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

♦ Adapter for filling ATF oil -VAS 6262/2-

Procedure

• Tightening torque ⇒ page 65 .

• Engine keeps running at idle speed.

• Vehicle diagnostic, testing and information system -VAS 5051B- must be connected.

• Used oil collection and extraction unit -V.A.G 1782- placed underneath.

– Screw adapter for filling -VAS 6262- onto ATF bottle.

• ATF specifications ⇒ Electronic parts catalogue .

– Screw adapter for filling ATF oil -VAS 6262/2- into ATF in‐

spection hole (hand-tight).

– Pump 1 ltr. of ATF into gearbox.

– Pull adapter for oil filling -VAS 6262- off -VAS 6262/2- at quick-

release coupling.

– Allow ATF to drain off until it drips.

If ATF comes out through ATF inspection hole via overflow pipe before ATF has reached a temperature of 45 °C, ATF level is OK.

Note

♦

Plug for ATF inspection hole must be screwed in again at the latest when ATF reaches temperature of 45 °C (countries with hot climates: 50 °C).

♦

If ATF temperature exceeds 45 °C too much fluid will escape as it expands when heated. In this case the quantity of fluid in the gearbox is NOT sufficient!

♦

If necessary, switch off engine and allow gearbox to cool down.

♦

If no ATF emerges from ATF inspection hole when ATF has reached 45 °C, top up again with 1 ltr. of ATF.

72 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Cut open seal -arrow- for plug for ATF inspection hole and

renew.

– Fit new seal on plug -arrow 1- for ATF inspection hole and

tighten.

– Exit from function “Measured values” by pressing ← button.

– Press “End output”.

– Switch off ignition and unplug diagnostic connector.

Audi TT 1999 ➤

8.4 Draining ATF

Special tools and workshop equipment required

♦ Used oil collection and extraction unit -V.A.G 1782-

♦ Safety goggles

♦ Allen key (5 mm)

Procedure

• Tightening torque ⇒ page 65 .

• Drive vehicle onto lifting platform or inspection pit to make sure it is placed absolutely horizontal.

• Engine not running.

Note

♦

Observe relevant disposal regulations.

♦

The engine must not be started and vehicle must not be towed without ATF in gearbox.

8. Overview - ATF in gearbox 73

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Remove centre noise insulation (loosen fasteners -arrows-).

– Place used oil collection and extraction unit -V.A.G 1782- be‐

low gearbox.

WARNING

Wear safety goggles.

– Remove ATF drain plug -B- and drain off ATF.

– Remove plug -A- for ATF inspection hole.

– Unscrew overflow pipe -C- using Allen key (5 mm) and allow

remaining ATF to drain off.

– Reinstall overflow pipe.

– Cut open seals -arrow- for ATF drain plug and plugs for ATF

inspection hole and for ATF filler hole and renew.

74 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Fit ATF drain plug -B- with new seal and tighten.

– Fill up with ATF

⇒ “8.5 Filling up with ATF following repair work - vehicles with ATF filler hole”, page 75 or ⇒ “8.6 Filling up with ATF following repair work - vehicles with‐ out ATF filler hole”, page 78 .

8.5 Filling up with ATF following repair work

- vehicles with ATF filler hole

Note

Depending on version, automatic gearbox 09G has an ATF filler hole -arrow-.

Audi TT 1999 ➤

Special tools and workshop equipment required

♦ Used oil collection and extraction unit -V.A.G 1782-

♦ ATF filling unit -V.A.G 1924-

♦ Torx bit T55 -VAS 5383-

8. Overview - ATF in gearbox 75

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

Procedure

• Tightening torques ⇒ page 65

– Fill ATF filling unit -V.A.G 1924- with the ATF for the automatic

gearbox 09G.

• ATF specifications ⇒ Electronic parts catalogue .

Caution

The ATF filling unit must be clean and the ATF must not be mixed with other types of ATF!

Note

♦

The engine must not be started and vehicle must not be towed without ATF in gearbox.

♦

Before fitting a replacement gearbox, always clean the ATF cooler.

– Secure reservoir for ATF filling unit -V.A.G 1924- as high as

possible on vehicle.

– Unscrew plug for ATF filler hole -arrow- with Torx bit T55 -VAS

5383- .

– Cut open seal -arrow- for plug for ATF filler hole and renew.

76 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Fit drain plug -B- with new seal and tighten.

– Attach pipe of ATF filling unit -V.A.G 1924- to ATF filler hole

-arrow-.

Audi TT 1999 ➤

– Fill with ATF using ATF filling unit -V.A.G 1924- until ATF

comes out of overflow pipe -arrow 2-.

– Shift selector lever into position “P”.

– Start engine.

– Continue filling with ATF using ATF filling unit -V.A.G 1924-

until ATF comes out of inspection hole again.

– Tighten plug for ATF inspection hole.

– With brake pressed, select all gear positions “P, R, N, D, S”

one after the other at idling speed, maintaining each position for approx. 10 seconds.

– Shift selector lever into position “P”.

– Check and top up ATF level ⇒ page 65 .

Note

Observe all notes and test requirements for “Checking and cor‐ recting ATF level”.

Caution

Both overfilling and underfilling will impair the function of the gearbox.

8. Overview - ATF in gearbox 77

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

8.6 Filling up with ATF following repair work

- vehicles without ATF filler hole

Special tools and workshop equipment required

♦ Adapter for oil filling -VAS 6262-

♦ Adapter for filling ATF oil -VAS 6262/2-

Procedure

• Tightening torque ⇒ page 65 .

• Used oil collection and extraction unit -V.A.G 1782- placed underneath.

– Screw Adapter for oil filling -VAS 6262- onto ATF bottle.

• ATF specifications ⇒ Electronic parts catalogue .

78 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

– Screw adapter for filling ATF oil -VAS 6262/2- into ATF in‐

spection hole (hand-tight).

– Pump 3 ltr. of ATF into gearbox.

– Unscrew adapter for filling ATF oil -VAS 6262/2- and tighten

plug for ATF inspection hole.

– Shift selector lever into position “P”.

– Start engine.

– With brake pressed, select all gear positions “P, R, N, D, S”

one after the other at idling speed, maintaining each position for approx. 10 seconds.

– Shift selector lever into position “P”.

– Check and top up ATF level ⇒ page 65 .

Note

Observe all notes and test requirements for “Checking and cor‐ recting ATF level”.

Audi TT 1999 ➤

Caution

Both overfilling and underfilling will impair the function of the gearbox.

8. Overview - ATF in gearbox 79

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

9 Exploded view - ATF cooler

1 - Gearbox housing

2 - O-ring

❑ Renew

3 - ATF cooler

❑ Removing and installing

⇒ page 80

4 - O-ring

❑ Renew

5 - Washer

6 - Dished spring

❑ Should rest on washer

-item 5-

❑ Installation position:

Raised side must face upwards

7 - Bolt

❑ 36 Nm

9.1 Removing and installing ATF cooler

Special tools and workshop equipment required

♦ Hose clamps, up to Ø 25 mm -3094-

80 Rep. Gr.37 - Controls, housing

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Automatic gearbox 09G - Edition 12.2007

Removing

– Detach air hose -1- leading to secondary air pump from air

cleaner housing.

– Release hose clip -2- and detach air hose from air mass meter

-G70- .

– Unplug electrical connector for air mass meter -G70-

-Item 3-.

– Remove bolts -4- and -5- and detach air cleaner housing.

– Mark coolant hoses at ATF cooler for reinstallation.

Note

Depending on the version, the vehicle may be fitted with a small plastic tube in the supply line to the ATF cooler. This tube has to be re-fitted as part of installation.

Audi TT 1999 ➤

– Clamp off coolant hoses with hose clamps -3094- and detach

hoses from ATF cooler.

– Unscrew bolt -arrow A- and detach ATF cooler -1- with O-ring

from gearbox.

Installing

• Tightening torque ⇒ page 80 .

Installation is carried out in reverse sequence; note the following:

Note

Renew O-rings.

– Install dished spring ⇒ Item 6 (page 80) :

• Should rest on washer ⇒ Item 5 (page 80) .

• Raised side of dished spring must face upwards.

– When installing ATF cooler -1-, insert lug -arrow B- in slot on

gearbox housing.

– Connect coolant hoses according to markings made on ATF

cooler during removal.

Note

Depending on the version, the vehicle may be fitted with a small plastic tube in the supply line to the ATF cooler. This tube has to be re-fitted as part of installation.

– Check coolant level ⇒ Rep. Gr. 19 .

– Check and top up ATF level ⇒ page 65 .

9. Exploded view - ATF cooler 81

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

38 – Gears, control

1 Exploded view - ATF oil pan, ATF

strainer, valve body and internal wir‐ ing harnesses

WARNING

Do not run engine or tow vehicle with ATF oil pan removed or when there is no ATF in the gearbox.

Note

♦

General repair instructions ⇒ page 8 .

♦

Rules for cleanliness when working on the automatic gearbox

⇒ page 11 .

♦

Lubricate O-rings with ATF. Other types of lubricant will cause the gearbox hydraulics to malfunction.

♦

Always renew valve body if it has collected dirt or if it is de‐ fective.

♦

The components shown in the following illustrations can be removed with the gearbox installed.

82 Rep. Gr.38 - Gears, control

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1 - Screw plug

❑ For ATF inspection hole ❑ Tightening torque

⇒ page 65

2 - Seal

❑ Renew

3 - Overflow pipe

❑ Tightening torque

⇒ page 65

4 - ATF oil pan

❑ Removing and installing

⇒ page 86

5 - Bolt

❑ 8x ❑ Tightening torque and

sequence ⇒ page 86

6 - Gasket

❑ Renew

7 - Magnet

❑ 2x ❑ Clean before installing ❑ Insert in recesses in

ATF oil pan

8 - Bolt

❑ 3x ❑ 11 Nm

9 - ATF strainer

❑ Removing and installing

⇒ page 88

10 - Bolt

❑ 12x, different lengths ❑ Renew ❑ Allocation and tightening torque ⇒ page 86

11 - Valve body

❑ Removing and installing ⇒ page 88 ❑ Identification of solenoid valves ⇒ page 20

12 - Bolt

❑ 5.5 Nm

13 - Gearbox input speed sender -G182-

❑ with wiring and 2-pin connector ❑ Removing and installing ⇒ page 96

Audi TT 1999 ➤

Automatic gearbox 09G - Edition 12.2007

14 - Bolt

❑ 5.5 Nm

15 - Gearbox output speed sender -G195-

❑ with wiring and 2-pin connector ❑ Removing and installing ⇒ page 97

1. Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses 83

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

16 - Gearbox housing

17 - ATF breather

18 - ATF cooler

❑ Removing and installing ⇒ page 80

19 - Multi-function switch -F125-

❑ Checked via self-diagnosis ❑ Removing and installing ⇒ page 99 ❑ Adjusting ⇒ page 100

20 - Seal

❑ Renew

21 - ATF drain plug

Tightening torque ⇒ page 65

22 - Selector shaft lever

❑ Inside gearbox, on valve body ❑ Removing and installing ⇒ “1.3 Removing and installing valve body”, page 88

23 - Washer

24 - Nut

❑ Note installation position ⇒ “1.3 Removing and installing valve body”, page 88 ❑ 10 Nm

25 - Large spring

26 - Small spring

27 - Damper piston

❑ Removing and installing ⇒ “1.3 Removing and installing valve body”, page 88

28 - Wiring harness with 8-pin connector and integrated gearbox oil temperature sender -G93-

❑ with O-ring on electrical connector ❑ Renew O-ring ❑ Components ⇒ page 84 ❑ Removing and installing ⇒ page 95

29 - Bolt

❑ 5.5 Nm

30 - Wiring harness with 14-pin connector

❑ with O-ring on electrical connector ❑ Renew O-ring ❑ Components ⇒ page 84 ❑ Removing and installing ⇒ page 94

31 - Bolt

❑ 5.5 Nm

Internal wiring harnesses

84 Rep. Gr.38 - Gears, control

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1 - Connector

❑ For automatic gearbox

hydraulic pressure sender 1 -G193-

2 - Connector

❑ For gearbox input speed

sender -G182-

3 - Wire

❑ Leading to gearbox in‐

put speed sender G182-

4 - Connector

❑ For automatic gearbox

hydraulic pressure sender 2 -G194-

5 - Wire

❑ At gearbox output

speed sender -G195-

6 - Connector

❑ To gearbox output

speed sender -G195-

7 - Bracket

8 - Gearbox oil temperature sender -G93-

A - 14-pin connector

B - Wiring harness

❑ Leading to 14-pin con‐

nector

C - Bracket

D - Bolts

❑ For securing connectors

-item 2- and -item 6-

❑ 7 Nm

E - Bolt

❑ 11 Nm

Audi TT 1999 ➤

Automatic gearbox 09G - Edition 12.2007

1. Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses 85

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

ATF oil pan - tightening torque and sequence

– Tighten bolts for ATF oil pan diagonally in stages to 7 Nm.

Bolts for valve body - allocation and tightening torque

– Renew bolts -arrows- for valve body; note bolt lengths:

♦ -Arrows-: bolts M6x21

♦ -Arrows A-: bolts M6x16

♦ -Arrows B-: bolts M6x28

– Tighten bolts -arrows- in two stages from outside to inside as

follows:

1. Tighten to 8 Nm.

2. Turn 90° further.

1.1 Removing and installing ATF oil pan

Removing

Note

♦

General repair instructions ⇒ page 8 .

♦

Rules for cleanliness when working on the automatic gearbox

⇒ page 11 .

– Drain ATF ⇒ page 73 .

Note

Some ATF always remains in the oil pan.

86 Rep. Gr.38 - Gears, control

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Automatic gearbox 09G - Edition 12.2007

– Loosen bolts -arrows- in diagonal sequence and remove.

– Detach ATF oil pan together with oil pan gasket.

Installing

• Tightening torque ⇒ page 82 .

Installation is carried out in reverse sequence; note the following:

Note

Renew gasket.

– Clean magnets ⇒ Item 7 (page 83) . Ensure that magnets

make full contact with recesses in ATF oil pan.

Note

It is essential that magnets are fitted at specified points in ATF oil pan.

Audi TT 1999 ➤

– Clean sealing surfaces; they must be free from oil and grease.

Note

♦

Make sure gasket for oil pan is fitted correctly.

♦

When fitting ATF oil pan, take care not to trap any wires.

– Fit ATF oil pan and tighten bolts ⇒ page 86 .

– Fill up with ATF after performing repair work

⇒ “8.5 Filling up with ATF following repair work - vehicles with ATF filler hole”, page 75 or ⇒ “8.6 Filling up with ATF following repair work - vehicles with‐ out ATF filler hole”, page 78 .

– Install noise insulation ⇒ Rep. Gr. 50 .

1. Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses 87

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

1.2 Removing and installing ATF strainer

Removing

Note

♦

General repair instructions ⇒ page 8 .

♦

Rules for cleanliness when working on the automatic gearbox

⇒ page 11 .

– Remove ATF oil pan ⇒ page 86 .

– Remove bolts -arrows-.

– Pull ATF strainer -A- off valve body.

Installing

• Tightening torque ⇒ page 82 .

– Apply a thin coating of ATF to seals around suction collar on

back of ATF strainer.

Note

If seals between back of ATF strainer and valve body are defec‐ tive or are no longer properly secured, ATF strainer must be renewed.

– Fit ATF strainer on valve body and tighten bolts -arrows-.

– Install ATF oil pan ⇒ page 86 .

– Fill up with ATF after performing repair work

⇒ “8.5 Filling up with ATF following repair work - vehicles with ATF filler hole”, page 75 or ⇒ “8.6 Filling up with ATF following repair work - vehicles with‐ out ATF filler hole”, page 78 .

1.3 Removing and installing valve body

Removing

Note

♦

General repair instructions ⇒ page 8 .

♦

Rules for cleanliness when working on the automatic gearbox

⇒ page 11 .

♦

Always renew valve body if it has collected dirt or if it is de‐ fective.

– Shift selector lever to position “D”.

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.

88 Rep. Gr.38 - Gears, control

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Automatic gearbox 09G - Edition 12.2007

– With the ignition switched off, disconnect battery earth cable

⇒ Rep. Gr. 27 .

– Remove ATF oil pan ⇒ page 86 .

– Remove ATF strainer ⇒ page 88 .

– To prevent mix-ups and to ensure that all components are re‐

installed in the original installation positions, mark all solenoid valves, connectors, plugs and electrical wires before removing them. If necessary, make sketches or take photographs.

Note

♦

It is important to have these sketches or photographs to en‐ sure that the connectors on the solenoid valves are not inter‐ changed by mistake when the valve body is re-installed.

♦

Interchanging the connectors could under some circumstan‐ ces destroy the gearbox.

– Carefully lever out retaining tabs of connectors on solenoid

valves using a small screwdriver and unplug connectors:

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-

Audi TT 1999 ➤

1. Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses 89

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Remove bolts -D- and -E-.

– Carefully unplug the following connectors:

1 - For automatic gearbox hydraulic pressure sender 1 -G193-

2 - For gearbox input speed sender -G182-

6 - For gearbox output speed sender -G195-

– Carefully pull gearbox oil temperature sender -G93- out of

valve body together with bracket -item 7-.

Note

For reinstallation purposes, note the attachment of the bracket at gearbox oil temperature sender -G93- .

– Disengage wiring harness from bracket -C-.

Note

If connectors are damaged, wiring harness -B- with 8-pin con‐ nector -A- and/or gearbox input speed sender -G182- and/or gearbox output speed sender -G195- must be renewed (depend‐ ing on defective connector).

– Remove selector shaft lever -A-.

Note

♦

In so doing, carefully keep hold of selector shaft lever with universal pliers -B-, so that torque is not transferred to multifunction switch -F125- .

♦

Ensure that spool valve on valve body which selector shaft lever engages in is not damaged.

– Unscrew bolts -arrows- on valve body in diagonal sequence

and carefully remove valve body.

– Detach brackets -1- and -2-.

3 - Identification marking on valve body, here e.g. “A2”

Note

♦

Only remove bolts indicated.

♦

If other bolts are loosened, this may affect the operation of the valve body or the valve body could come apart.

90 Rep. Gr.38 - Gears, control

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Automatic gearbox 09G - Edition 12.2007

Note

When removing the valve body you may need to secure the damper piston -E- so that it cannot fall out or, alternatively, re‐ move it together with the two springs.

Installing

• Tightening torques ⇒ page 82

Note

♦

Renew bolts for valve body; for allocation refer to ⇒ page 86 .

♦

Specified routing of wires must be carefully adhered to so that wires do not get trapped or damaged when fitting valve body.

♦

Any damaged or crushed wires must be renewed.

– Route wiring harness -C- (with 8-pin connector) in recess on

valve body as shown in illustration.

• Wiring harness -C- must not make contact with planetary gear‐ box. Sufficient clearance -a- must be maintained so that, when vehicle is being driven, wiring harness does not chafe against planetary gearbox and become damaged.

– Route wiring harnesses -A-, -B- and -D- across edge of gear‐

box as shown in illustration.

– Make sure that damper piston -E- has been fitted into gearbox

correctly, as shown in illustration.

Audi TT 1999 ➤

Note

♦

If damper piston -E- has been removed you must clean it to‐ gether with the two springs and install it according to

⇒ Item 27 (page 84) , ⇒ Item 26 (page 84) and ⇒ Item 25 (page 84) .

♦

To reinstall, fit the two springs into one another, lubricate the outer wall of the damper piston and the opening in the gearbox with ATF and fit all components into the gearbox.

♦

If necessary, press the damper piston into the gearbox (secure against falling out) until the valve body is fitted.

1. Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses 91

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Fit valve body on gearbox without using any force.

• Wiring harnesses must not be trapped by valve body, crushed wires must always be renewed.

– Secure brackets for wiring harnesses -1- and -2- with correct

bolts (hand-tight).

– Secure remaining bolts -arrows- on valve body (hand-tight).

Note

♦

If wire -3- (leading to gearbox input speed sender -G182- ) is too short to be able to secure connector -2- to valve body at specified location, wiring is routed incorrectly or is trapped by valve body. In that case you must remove valve body once more and route wiring correctly.

♦

Crushed wires have to be renewed.

– Make absolutely sure that no wires have been trapped.

– Then tighten bolts -arrows- on valve body ⇒ page 86 .

92 Rep. Gr.38 - Gears, control

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Automatic gearbox 09G - Edition 12.2007

– Engage wiring harness in bracket -arrow B-.

– Fit lever -2- on selector shaft -5-.

Note

Make sure that pin on selector shaft lever engages in spool valve

-1- -arrow A-. You may have to move the spool valve in or out of the valve body accordingly.

– Fit washer -4- and nut -3- onto selector shaft.

• The centring collar on nut has to point in direction of washer and must fit into washer when it is screwed on.

• Wiring harness must be routed to run below selector shaft lev‐ er.

– Tighten nut.

Note

Audi TT 1999 ➤

♦

In so doing, carefully keep hold of selector shaft lever with universal pliers -B-, so that torque is not transferred to multifunction switch -F125- .

♦

Ensure that spool valve on valve body which selector shaft lever engages in is not damaged.

– Plug in connectors at solenoid valves according to sketches/

photographs taken earlier. Pay particular attention to the col‐ ours of the connectors and wires.

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-

Note

Interchanging the connectors could under some circumstances destroy the gearbox.

– Route wiring harness -B- to 14-pin connector -A-, as shown in

illustration.

1. Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses 93

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– Plug in connectors according to sketches/photographs taken

earlier.

Note

Counterparts of connectors must have same colour as connec‐ tors.

– Plug in connector -2- for gearbox input speed sender -G182-

and connector -6- for gearbox output speed sender -G195- .

– Attach bracket -7- to gearbox oil temperature sender -G93-

-item 8- and insert as a unit into valve body.

– Tighten bolt -E-.

– Plug in connector -1- at automatic gearbox hydraulic pressure

sender 1 -G193- and connector -4- at automatic gearbox hy‐ draulic pressure sender 2 -G194- , keeping connectors straight.

– Tighten bolts -D- for securing connectors -2- and -6-.

Note

♦

If wire -3- (to gearbox input speed sender -G182- ) is too short to be able to secure connector -2- to valve body at specified location, wiring was routed incorrectly or is trapped by valve body. In that case you must remove valve body once more and route wiring correctly.

♦

Crushed wires have to be renewed.

– Engage wiring harness -B- in bracket -C- and route as shown

in illustration.

– Install ATF strainer ⇒ page 88 .

– Install ATF oil pan ⇒ page 86 .

– Observe correct procedure after connecting battery ⇒ Rep.

Gr. 27 .

– Perform basic setting ⇒ Vehicle diagnosis, testing and infor‐

mation system VAS 5051.

– Fill up with ATF after performing repair work

⇒ “8.5 Filling up with ATF following repair work - vehicles with ATF filler hole”, page 75 or ⇒ “8.6 Filling up with ATF following repair work - vehicles with‐ out ATF filler hole”, page 78 .

1.4 Removing and installing wiring harness with 14-pin connector

Removing

Note

♦

General repair instructions ⇒ page 8 .

♦

Rules for cleanliness when working on the automatic gearbox

⇒ page 11 .

– Remove valve body ⇒ page 88 .

94 Rep. Gr.38 - Gears, control

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Automatic gearbox 09G - Edition 12.2007

– With gearbox installed, unplug 14-pin connector -A- at gear‐

box.

– Unscrew bolt for 14-pin connector on outside of gearbox hous‐

ing.

– Pull connector out of gearbox housing and carefully guide wir‐

ing harness -D- out behind.

Installing

• Tightening torque ⇒ page 82 .

Installation is carried out in reverse sequence; note the following:

Audi TT 1999 ➤

Note

Renew O-ring on connector.

– Lubricate O-ring with ATF.

– Press connector with O-ring fitted into gearbox as far as it will

go.

– Install valve body ⇒ page 88 .

1.5 Removing and installing wiring harness with 8-pin connector and gearbox oil temperature sender -G93-

Removing

Note

♦

General repair instructions ⇒ page 8 .

♦

Rules for cleanliness when working on the automatic gearbox

⇒ page 11 .

– Remove valve body ⇒ page 88 .

1. Exploded view - ATF oil pan, ATF strainer, valve body and internal wiring harnesses 95

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Audi TT 1999 ➤ Automatic gearbox 09G - Edition 12.2007

– With gearbox installed, unplug 8-pin connector -B- at gearbox.

– Unscrew bolt for 8-pin connector on outside of gearbox hous‐

ing.

– Pull connector out of gearbox housing and carefully guide wir‐

ing harness -C- out behind.

Installing

• Tightening torque ⇒ page 82 .

Installation is carried out in reverse sequence; note the following:

Note

Renew O-ring on connector.

– Lubricate O-ring with ATF.

– Press connector with O-ring fitted into gearbox as far as it will

go.

– Install valve body ⇒ page 88 .

1.6 Removing and installing gearbox input speed sender -G182-

Removing

Note

♦

General repair instructions ⇒ page 8 .

♦

Rules for cleanliness when working on the automatic gearbox

⇒ page 11 .

– Remove valve body ⇒ page 88 .

96 Rep. Gr.38 - Gears, control