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Service
Workshop Manual
Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive
Edition 12.2006
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
00 –Technical data
1Gearbox identification
The “6-speed direct shift gearbox 02E (four-wheel drive)” is in‐
stalled in the Audi TT 1999 ▸. Allocation ⇒ page 2 .
Audi TT 1999 ➤
The gearbox code is located on the top of the gearbox, near the
oil cooler.
Example of a gearbox:
♦ GKF = gearbox code
♦ 10.05.2 = date of production: 10th May 2002
The code letters of the gearbox are also given on the vehicle data
stickers.
1. Gearbox identification 1
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
3Capacities
Gearbox capacity
CapacitiesDirect shift gearbox 02E
Initial filling6.9 ltr.
Oil changeapprox. 5.5 ltr.
Change interval⇒ Maintenance tables
Lubricant, specificationGear oil for direct shift gearbox 02E
Part No.: ⇒ Parts catalogue
Only the gear oil available as a replacement part may be used for
the direct shift gearbox 02E. Other types of oil cause malfunctions
and/or failure of the gearbox.
When changing gear oil always renew the gear oil filter
Initial filling0.9 ltr.
Oil changeFilled for life, no change
LubricantFor gear oil refer to ⇒ Parts cata‐
logue
Only the gear oil available as a replacement part may be used for
the bevel box. Other oils cause faults and/or failure of the bevel
box.
Checking oil level in bevel box ⇒ page 94 .
4 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
4Safety precautions
Observe the following precautions if test and measuring instru‐
ments are required during a test drive:
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.
♦ Move the passenger's seat to the rearmost position.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052- 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.
Audi TT 1999 ➤
Observe the following precautions to avoid possible injury and/or
the destruction of electrical and electronic components:
♦ Switch off ignition before disconnecting and connecting test
equipment.
Caution
♦ Follow steps required when disconnecting battery ⇒ Elec‐
trical system; Rep. Gr. 27 .
♦ Always switch off ignition before disconnecting or con‐
necting the battery to ensure gearbox control unit is not
damaged.
4. Safety precautions 5
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
5Notes on the direct shift gearbox 02E
5.1General notes
Gearbox
The direct shift gearbox 02E is also referred to as a dual-clutch
gearbox. The engine torque is transferred to the gearbox via the
dual-mass flywheel. The layout of the gearbox is basically similar
to that of a 6-speed manual gearbox. The two multi-plate "wet"
clutches are regulated hydraulically and actuated alternately so
that the gearbox is operated like an automatic gearbox, i.e. the
gears are engaged automatically (or manually via the tiptronic
function). There is no clutch pedal. For further information please
refer to ⇒ Self-study programme No. 308 ; Direct shift
gearbox 02E .
Selector mechanism
The selector lever position is no longer transmitted mechanically
via the selector lever cable and multi-function switch (driving
range sensor) as on the automatic gearbox. The selector lever
positions and gear changes are transmitted to the gearbox control
unit by a separate selector mechanism control unit via CAN bus.
This means that gear shifts are effected without a cable. Excep‐
tion: In selector lever position “P” the selector lever cable is used
to mechanically engage the parking lock.
Gear oil
The gear oil level in gearbox and final drive (front) is checked and
topped up together ⇒ page 74 .
♦ Only the oil available as a replacement part may be used in
the direct shift gearbox 02E. Other types of oil will cause mal‐
functions and/or failure of the gearbox; for Part No. refer to
⇒ page 4 .
The oil level in the bevel box is checked and topped up separately
⇒ page 94 .
♦ Only the gear oil available as a replacement part may be used
for the bevel box. Other oils cause faults and/or failure of the
bevel box.
Regulations for the disposal of oil
Make sure that used oil is taken to the appropriate collection cen‐
tre for recycling.
♦ Improper disposal of used oil endangers the environment.
♦ It is forbidden to add solvents, brake fluid, coolant or similar.
♦ Please observe the information shown on the packaging of the
oil.
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.
6 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
5.2Safety functions of gearbox control unit
In the event of a failure of one or more components/sensors, the
gearbox control unit will activate appropriate backup functions.
This ensures that the gearbox will not be damaged, however, the
function and quality of the gear shifts will be impaired.
Faults detected by the gearbox are classified in four different cat‐
egories.
♦ 1) The fault is stored and a backup programme enables the
vehicle to drive on (in some cases with restrictions). The driver
will not be made aware of the problem, as it is not critical to
driving safety or to the gearbox itself. The gear selection indi‐
cator in the instrument cluster will continue to show the selec‐
tor lever position currently engaged in the normal way. If at all,
the driver will only notice the fault if he experiences driveability
problems, and will then automatically contact an Audi Service
Partner to identify the cause.
♦ 2) Certain positions on the gear selection indicator in the in‐
strument cluster start to flash. This is to inform the driver that
this particular selector lever position is currently not available.
Example: position “D” is not available when selector lever is in
position “R” and vehicle is still rolling backwards. In this case,
selector lever position “D” will start to flash on the gear selec‐
tion indicator in the instrument cluster. The gearbox control
unit prevents the 1st gear from being engaged in order to avoid
damage to the gearbox. 1st gear will be engaged once the
vehicle has come to a standstill.
♦ 3) The complete gear selection indicator in the instrument
cluster is lit up and flashing. The current selector lever position
is indicated in the instrument cluster (e.g. “D” is highlighted).
This is an indication that the gearbox has been overloaded or
the maximum temperature in the gearbox has been exceeded
(overheating), e.g. towing a load that was too heavy.
♦ 4) If the complete gear selection indicator in the instrument
cluster is lit up and flashing, this means that a serious fault in
the gearbox has been identified. The display in the instrument
cluster no longer shows the current selector lever position. The
defect is critical with regard to driving safety or the gearbox
itself. It may no longer be possible to use all gears. The driver
is made aware by the flashing gear selection indicator that he
should immediately contact an Audi Service Partner.
Audi TT 1999 ➤
5. Notes on the direct shift gearbox 02E 7
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
6Notes on tow-starting and towing
WARNING
If the vehicle has to be towed, the selector lever must be set to
position N and the vehicle must not to be towed further than
50 km or at a speed in excess of 50 km/h, as the gearbox would
otherwise suffer irreparable damage.
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.
8 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
7Repair instructions
7.1Contact 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 ⇒ 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.
Audi TT 1999 ➤
7.2General notes
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.
7. Repair instructions 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
Guided fault finding, vehicle self-diagnosis and testing system
♦ Before servicing the gearbox, the exact cause of the failure
must be determined using the functions “Guided Fault Find‐
ing”, “Vehicle Self-diagnosis” and “Test Instruments” ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ "Special tools, Workshop equipment"
Gearbox
♦ Do not run the engine or tow the vehicle with the oil pan re‐
moved or when there is no gear oil in the gearbox.
♦ When renewing the gearbox the gear oil ⇒ page 74 must be
checked and topped up, if necessary. Filling quantities and
specification ⇒ page 4 .
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ When installing gearbox, ensure that dowel sleeves are fitted
correctly.
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.
♦ Always replace paper gaskets. Completely remove old gasket
and clean sealing surfaces thoroughly.
♦ Lightly lubricate the outer circumference and sealing lip of oil
seals with gear oil before installing.
♦ Lightly lubricate O-rings with gear oil or vaseline before instal‐
lation to prevent them from getting crushed during assembly.
♦ Do not use any other lubricants where gear oil is used. Oth‐
erwise, there is a risk of problems occurring in the gearbox
hydraulics.
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Observe rules for cleanliness ⇒ page 12 .
♦ After installing, check gear oil level, adjust to correct level if
necessary ⇒ page 74 .
Locking elements
♦ Do not overstretch circlips; renew if necessary.
♦ Circlips must be properly seated in the base of the groove.
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.
♦ Renew self-locking nuts.
♦ 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 bolt threads before installing.
10 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
Audi TT 1999 ➤
7. Repair instructions 11
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
8Rules for cleanliness when working
on the gearbox
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ 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
carried out immediately.
♦ Only install clean components: do not remove replacement
parts from packaging until just before installation.
♦ Always renew O-rings, oil seals and gaskets.
♦ Always replace paper gaskets. Completely remove old gasket
and clean sealing surfaces thoroughly.
♦ 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 bolt threads before installing.
12 Rep. Gr.00 - Technical data
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
30 –Clutch
1Servicing multiple clutch
♦ The clutch in the direct shift gearbox 02E consists of two sets
of plates, and is therefore referred to as a “multiple clutch”. The
larger set of plates (located on the outside) is designated
“K 1” (clutch 1), and controls the torque flow for reverse gear
and gears “1”, “3” and “5”. The smaller set of plates (on the
inside) is designated “K 2” (clutch 2), and controls the torque
flow for gears “2”, “4” and “6”.
♦ Any work performed on the multiple clutch requires extra care:
all the parts are balanced and matched together in production.
If the components are rotated out of their original positions
when repairing, this will cause imbalance and impair the
smoothness of the gearchanges and reduce the service life of
the unit.
1.1Multiple clutch - exploded view of components (replacement parts)
1 - Multiple clutch with circlip
Caution
♦The drive plate (top sec‐
tion of multiple clutch) of
a new clutch is not se‐
cured with the circlip, it is
only a “close fit” in the
clutch.
♦The drive plate must re‐
main engaged between
the splines of the outer
plate carrier.
♦If the drive plate comes
loose, the clutch plates
can slip out of position in‐
side the multiple clutch
unit. If this happens, it
may not be possible to
adjust the multiple clutch
correctly during installa‐
tion.
2 - Circlip
❑ 10 x, with different thick‐
nesses for adjusting
❑ Determine circlip thick‐
ness when installing
clutch ⇒ page 20
3 - Clutch end cover
4 - Circlip for clutch end cover
1. Servicing multiple clutch 13
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
Dismantled multiple clutch - exploded view of components
Caution
♦ This illustration serves only as an overview of compo‐
nents; at the present time the multiple clutch must NOT be
dismantled, as all outer and inner plates are matched and
balanced before installation.
♦ If the drive plate is loosened, the plates can slip out of
position inside the multiple clutch unit. If this happens, it
may not be possible to adjust the multiple clutch correctly
during installation.
1 - Multiple clutch/clutch hous‐
ing
❑ Outer plate carrier
2 - Oil seals
❑ 4x
3 - Inner plate carrier
❑ Do not remove
Caution
DO NOT remove or lift up
the inner plate carrier.
This could cause the
plates to move out of
their original positions.
4 - Outer plates
❑ 4x
5 - Inner plates
❑ 4x
6 - Thrust washer
7 - Circlip
❑ Fit a new circlip of the
same thickness if the
original circlip is re‐
moved in order to re-in‐
stall the clutch plates.
8 - Circlip
❑ Re-determine thickness
when installing a new
clutch ⇒ page 20
9 - Drive plate
10 - Circlip
❑ Renew
1.2Removing and installing multiple clutch
Special tools and workshop equipment required
14 Rep. Gr.30 - Clutch
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♦ Assembly sleeve -T10302-
♦ Retaining pin -T10303-
Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
Note
Assembly sleeve -T10302- must be cleaned before use; do not
use an assembly sleeve if it is scratched.
Removing clutch end cover
– Drain gear oil ⇒ page 80 .
– Remove gearbox ⇒ page 61 .
– Secure gearbox to assembly stand in vertical position
⇒ page 72 .
– Renew gear oil filter ⇒ page 86 .
1. Servicing multiple clutch 15
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
– Using a screwdriver -1-, pry out circlip -2- for clutch end cover
-arrow- and take out circlip.
– Working through opening for starter motor, pry off clutch end
cover -2- using a screwdriver -1- or suitable lever -arrow- and
take off clutch end cover.
Removing multiple clutch
– Pry out circlip -2- using a screwdriver -1- -arrow-.
16 Rep. Gr.30 - Clutch
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
– Remove drive plate -arrows-.
– Use screwdriver or suitable pliers to pry out circlip -arrow-.
Note
This circlip must be replaced with a new circlip of the correct
thickness when re-assembling.
Audi TT 1999 ➤
– Take out multiple clutch.
– After removing multiple clutch, check clutch bellhousing for
damage caused during removal.
– Pull out pump shaft -A-.
Note
The pump shaft is not re-installed until after the new clutch has
been fitted. Keep the shaft in a suitable place until it is required.
1. Servicing multiple clutch 17
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
Installing multiple clutch
Caution
♦ The drive plate of a new clutch is not secured with a circlip;
it is only a “close fit” in the clutch.
♦ While carrying out the following steps you must therefore
hold the drive plate by pressing it into the outer plate car‐
rier with both thumbs.
♦ The drive plate must remain engaged between the splines
of the outer plate carrier.
♦ If the drive plate comes loose, the clutch plates can slip
out of position inside the multiple clutch unit. If this hap‐
pens, it may not be possible to adjust the multiple clutch
correctly during installation.
– Take the circlip out of the packaging.
– Take the clutch for direct shift gearbox out of the packaging,
at the same time pressing the drive plate into the outer plate
carrier with both thumbs.
– Secure drive plate in outer plate carrier with “old” circlip -A-
from removed clutch.
•Do NOT use the new circlip supplied when carrying out this
installation.
•The circlip must be installed so that the lug on the drive plate
-arrow- and the colour-marked splines on the outer plate car‐
rier are located between the two ends of the circlip.
•The circlip must be fully engaged all round.
– Check that the 4 oil seals on the hub on the underside of the
multiple clutch are correctly seated; engage in position if nec‐
essary.
•The joints of the seals should be offset and not aligned one
above the other.
18 Rep. Gr.30 - Clutch
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
– Apply retaining pin -T10303- to seat of clutch end cover as
illustrated.
– Install multiple clutch in clutch bell housing (turn and move up
and down as required); do not allow clutch to drop into place.
While doing this, keep the drive plate pressed into the outer
plate carrier with both thumbs -arrows-.
Audi TT 1999 ➤
•During this procedure the retaining pin -T10303- must be held
in place by a 2nd mechanic.
Note
♦
The retaining pin remains in position until the clutch end cover
is installed.
♦
The multiple clutch must not be turned from this point onwards,
as this would turn the retaining pin -T10303- out of position.
– Check whether the projecting lug -arrow- on the drive plate is
positioned between the colour-marked splines on the outer
plate carrier.
If no markings are provided:
– Mark position of projecting lug in relation to outer rim of outer
plate carrier with waterproof pen as illustrated.
1. Servicing multiple clutch 19
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Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
•When re-assembling, the lug on the drive plate must be loca‐
ted again at this marked position.
•While carrying out the following two steps the retaining pin T10303- must be held in place by a 2nd mechanic.
– Pry out the old circlip -2- using a screwdriver -1- -arrow-.
Caution
DO NOT remove or lift up the inner plate carrier. This could
cause the plates to move out of their original positions.
– After installing clutch, lift out drive plate -arrows-; if necessary
pry drive plate carefully out of splines on outer plate carrier
using a screwdriver.
– Lay drive plate aside.
Determining thickness of circlip for multiple clutch
– Select the 2 mm thick circlip from the circlips supplied with the
clutch and fit this circlip as shown -arrow-.
Note
This circlip is installed provisionally in order to measure the axial
play.
20 Rep. Gr.30 - Clutch
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
– For 1st measurement, apply tip of dial gauge to end of input
shaft as shown in illustration.
– Set dial gauge to “0” with a preload of 2 mm.
– Lift up clutch as far as it will go and note dial gauge reading (=
axial play of input shaft).
– For 2nd measurement, apply tip of dial gauge to hub of inner
plate carrier as shown in illustration.
•The tip of the dial gauge must not contact the circlip.
– Set dial gauge to “0” with a preload of 2 mm.
– Lift up clutch again as far as it will go and note dial gauge
reading.
The thickness of the new circlip is calculated according to the fol‐
lowing formula:
2nd measurement – 1st measurement + 1.85 mm = thickness
of circlip
The thickness of the new circlips -02E 311 321- is graduated in
steps of 0.1 mm. When selecting the required circlip, round up or
down to the nearest 10th of a millimetre as required. In other
words, values up to 0.049 are rounded down and values of 0.05
and above are rounded up.
Audi TT 1999 ➤
Calculated thickness of new cir‐
New circlip
clip
2.27 mm2.3 mm
2.24 mm2.2 mm
– Remove provisionally fitted circlip (2.0 mm) and fit new circlip
with thickness as calculated above.
Note
♦
If the calculated thickness of the new circlip is exactly 2.0 mm,
the circlip fitted previously for taking the measurement does
not have to be removed.
♦
All remaining circlips should be disposed of.
♦
Circlips may not be used more than once.
1. Servicing multiple clutch 21
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
– Insert pump shaft.
Note
When installing, lift the shaft and turn it slightly -arrow- so that it
slides in and engages fully in the splines.
– Install drive plate in multiple clutch.
•The projecting lug on the drive plate must be positioned be‐
tween the colour-marked splines on the outer plate carrier.
Alternatively, align the new markings made earlier in this pro‐
cedure.
– Install new circlip securing drive plate.
•The circlip must be installed so that the lug on the drive plate
and the colour-marked splines on the outer plate carrier are
located between the two ends of the circlip.
•The circlip must be fully engaged all round.
– Use a screwdriver to check that the circlip is properly seated
and fully engaged.
– Take out retaining pin -T10303- between multiple clutch and
housing.
22 Rep. Gr.30 - Clutch
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.
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
Installing clutch end cover
Note
Renew clutch end cover and circlip.
– Thoroughly degrease running surface -arrow- on drive plate
for oil seal of clutch end cover.
Caution
The contact surfaces of the clutch end cover must be cleaned
very thoroughly, otherwise leaks can occur.
– Clean contact surface for outer seal of clutch end cover.
Caution
♦ Do not touch the seal inside the opening in the clutch end
cover. This seal will only seal properly if the running sur‐
face is absolutely free of grease when installed.
Audi TT 1999 ➤
♦ Do not apply hammer blows directly to the clutch end cov‐
er. Any force applied to the inner part of the clutch end
cover will cause malfunctions.
– Take the new clutch end cover out of its packaging. Always
take hold of the outside of the clutch end cover, as illustrated.
DO NOT touch the seal inside the cover.
– Clean end of gearbox shaft if necessary.
Note
♦
Lightly lubricate the outer seal only.
♦
If there are any stickers on the inside or the outside of the end
cover, remove them thoroughly.
1. Servicing multiple clutch 23
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
– Place assembly sleeve -T10302- on a flat surface.
– The seal in the centre of the clutch end cover must be pre-
formed before installation; this is done by guiding the new
clutch end cover with the outside pointing downwards hori‐
zontally and evenly over the entire length of the assembly
sleeve -arrows-.
– Remove assembly sleeve upwards from clutch end cover and
fit assembly sleeve onto end of clutch shaft.
– Guide clutch end cover with the outside pointing upwards hor‐
izontally over sleeve -arrows- and press cover evenly onto its
seat.
– If necessary use a screwdriver to lever the clutch end cover
carefully into its seat, as illustrated, so that the new circlip can
be fitted.
– Install “new” circlip for clutch end cover into gearbox housing.
Note
To make sure circlip remains in groove always counterhold on
opposite side if necessary.
•The circlip must be fully engaged all round and must be prop‐
erly seated in the base of the groove.
– Use a screwdriver to check that the circlip is properly seated
and fully engaged.
– Fill up with gear oil for direct shift gearbox ⇒ page 80 .
– After installing gearbox, perform basic setting of mechatronic
unit for direct shift gearbox -J743- .
Tightening torques
ComponentNm
Drain plug to gearbox, M2445
Oil filter housing to gearbox20
24 Rep. Gr.30 - Clutch
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.
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
34 –Controls, housing
1Electrical/electronic components and fit‐
ting locations
Diagnostic connector
Fitting location: below knee padding on left side of steering wheel.
Audi TT 1999 ➤
Selector lever lock solenoid -N110-
Fitting location: the selector lever lock solenoid -N110- -item A- is
located in the selector mechanism.
♦ Checked via self-diagnosis
Removing and installing selector lever lock solenoid -N110-
⇒ page 40
Mechatronic unit for direct shift gearbox -J743-
Fitting location: the mechatronic unit for direct shift gearbox J743- is bolted to the front of the gearbox housing and covered
by the gearbox oil pan.
The control unit is an integrated component of the mechatronic
unit for direct shift gearbox -J743- .
Removing and installing mechatronic unit for direct shift gearbox
-J743- ⇒ page 102 .
1. 25
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
Gearbox input speed sender -G182- / oil temperature sender for
multi-plate clutch -G509-
Fitting location: the gearbox input speed sender -G182- / oil tem‐
perature sender for multi-plate clutch -G509- -item A- is bolted to
the gearbox housing below the mechatronic unit for direct shift
gearbox -J743- .
♦ Checked via self-diagnosis
Removing and installing gearbox input speed sender -G182- / oil
temperature sender for multi-plate clutch -G509- ⇒ page 106 .
Selector lever -E313- with tiptronic switch -F189-
Fitting location: the selector lever -E313- with tiptronic switch F189- is integrated in the selector mechanism. These compo‐
nents cannot be renewed separately. Several versions available.
For correct allocation refer to ⇒ Parts catalogue .
♦ Checked via self-diagnosis
D - Electrical connector for tiptronic switch -F189-
Remove and install selector lever -E313- with tiptronic switch F189- only together with selector mechanism ⇒ page 38 .
Selector lever position display -Y6-
Fitting location: integrated into instrument cluster
Note
The selector lever position display can only be renewed together
with the instrument cluster.
If the selector lever position display flashes or is illuminated, take
note of the safety functions of the gearbox control unit
⇒ page 7 .
Removing and installing instrument cluster ⇒ Electrical system;
Rep. Gr. 90
26 Rep. Gr.34 - Controls, housing
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