Audi TT 20 User Manual

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Workshop Manual
Audi TT 1999 ➤
Direct shift gearbox 02E, four-wheel drive
Edition 12.2006
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.
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.
Copyright © 2010 Audi AG, Ingolstadt A0057108920
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
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, gearbox allocation, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Notes on the direct shift gearbox 02E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Safety functions of gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Notes on tow-starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Rules for cleanliness when working on the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Servicing multiple clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Multiple clutch - exploded view of components (replacement parts) . . . . . . . . . . . . . . . . . . 13
1.2 Removing and installing multiple clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Servicing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Adjusting selector lever cable - vehicles with vehicle ID No. to 8N 41013847 . . . . . . . . . . 30
2.4 Adjusting selector lever cable - vehicles with vehicle ID No. from 8N 41013848 . . . . . . . . 31
2.5 Checking adjustment of selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Checking function of ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.7 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.8 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.9 Removing and installing selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.10 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.11 Removing and installing tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.12 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 40
2.13 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.14 Removing and installing locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.15 Adjusting locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.16 Checking connectors on selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.5 Transporting the direct shift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 Gear oil in direct shift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1 Checking and topping up gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2 Checking and topping up gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Changing gear oil or filling up after performing repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Contents i
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Audi TT 1999 ➤ Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
4.5 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6 Checking and topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1 Draining oil in bevel box and filling up after repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Oil pan, mechatronic unit and gear oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Oil pan, mechatronic unit and gear oil pump - exploded view of components . . . . . . . . . . 97
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.3 Removing and installing mechatronic unit for direct shift gearbox J743 . . . . . . . . . . . . . . 102
1.4 Removing and installing gearbox input speed sender G182 / oil temperature sender for multi-
plate clutch G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.5 Removing and installing gear oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1 Flange shaft and oil seals on gearbox - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.1 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.2 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.3 Renewing oil seal between bevel box and gearbox (on gearbox) . . . . . . . . . . . . . . . . . . . . 112
1.4 Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2 Flange shafts and oil seals on bevel box - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.2 Renewing flange shaft oil seal (right-side) at bevel box (outer) . . . . . . . . . . . . . . . . . . . . . . 119
2.3 Renewing needle bearings (polygon bearings) for flange shaft (right-side) . . . . . . . . . . . . 121
2.4 Renewing oil seal between gearbox and bevel box (on bevel box) . . . . . . . . . . . . . . . . . . 122
2.5 Renewing oil seal for bevel box output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4 Rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ii Contents
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006

00 – Technical data

1 Gearbox 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

2 Code letters, gearbox allocation, ratios, equipment

Direct shift gearbox 02E four-wheel drive
Gearbox Code letters GVF GVG GYU
Allocation Model
Ratios Final drive I
Z2 : Z
1
Overall ratio i
Allocation: rear final drive Designation: 02D
Manufac‐ tured
fro m
03.03 03.03 07.03
to
Engine
Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
3.2 ltr. - 184 kW 6 cylinders
3.2 ltr. - 184 kW 6 cylinders
3.2 ltr. - 184 kW 6 cylinders
69 : 17 = 4.059 69 : 17 = 4.059 69 : 17 = 4.059
for 1st to 4th gear Final drive II
69 : 22 = 3.136 69 : 22 = 3.136 69 : 22 = 3.136 for 5th/6th gear and reverse gear
1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse
gear in top gear 2.889 2.889 2.889
ov.
45 : 13 = 3.462 45 : 13 = 3.462 45 : 13 = 3.462
45 : 22 = 2.045 45 : 22 = 2.045 45 : 22 = 2.045
45 : 31 = 1.452 45 : 31 = 1.452 45 : 31 = 1.452
41 : 38 = 1.079 41 : 38 = 1.079 41 : 38 = 1.079
39 : 35 = 1.114 39 : 35 = 1.114 39 : 35 = 1.114
35 : 38 = 0.921 35 : 38 = 0.921 35 : 38 = 0.921
22 : 14 x 33 : 13 =
3.989
22 : 14 x 33 : 13 =
3.989
22 : 14 x 33 : 13 =
05.04
3.989
Direct shift gearbox 02E four-wheel drive
Gearbox Code letters GYV GYW HAH
Manufac‐ tured
fro m
03.03 07.03
03.04
06.04
10.05
to
Allocation Model
Engine
Ratios Final drive I
Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
3.2 ltr. - 184 kW 6 cylinders
3.2 ltr. - 184 kW 6 cylinders
3.2 ltr. - 184 kW 6 cylinders
69 : 17 = 4.059 69 : 17 = 4.059 69 : 17 = 4.059
for 1st to 4th gear
Z2 : Z
1
Final drive II
69 : 22 = 3.136 69 : 22 = 3.136 69 : 22 = 3.136
for 5th/6th gear
Overall ratio i
and reverse gear 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse
gear in top gear 2.889 2.889 2.889
ov.
45 : 13 = 3.462 45 : 13 = 3.462 45 : 13 = 3.462 45 : 22 = 2.045 45 : 22 = 2.045 45 : 22 = 2.045 45 : 31 = 1.452 45 : 31 = 1.452 41 : 28 = 1.464 41 : 38 = 1.079 41 : 38 = 1.079 41 : 38 = 1.079 39 : 35 = 1.114 39 : 35 = 1.114 35 : 32 = 1.094 35 : 38 = 0.921 35 : 38 = 0.921 35 : 38 = 0.921
22 : 14 x 33 : 13 =
3.989
22 : 14 x 33 : 13 =
3.989
22 : 14 x 33 : 13 =
3.989
Allocation: rear final drive Designation: 02D
2 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006
Direct shift gearbox 02E four-wheel drive
Gearbox Code letters HQB
Manufac‐ tured
fro m
11.05
to
Allocation Model
Engine
Audi TT 1999 ▸
3.2 ltr. - 184 kW 6 cylinders
Ratios Final drive I
69 : 17 = 4.059
for 1st to 4th gear
Z2 : Z
1
Final drive II
69 : 22 = 3.136 for 5th/6th gear and reverse gear
Overall ratio i
1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse
gear
in top gear 2.889
ov.
45 : 13 = 3.462
45 : 22 = 2.045
41 : 28 = 1.464
41 : 38 = 1.079
35 : 32 = 1.094
35 : 38 = 0.921
22 : 14 x 33 : 13 =
3.989
Allocation: rear final drive Designation: 02D
Audi TT 1999 ➤

2.1 Calculating ratio “i”

Example:
Drive gear ZG1 = 38 ZA1 = 22
Driven gear ZG2 = 35 ZA2 = 69
i = Z2 : Z1 (Z1 = number of teeth on drive gear, Z2 = number of teeth on driven gear)
iG = gear ratio = ZG2 : ZG1 = 35 : 38 = 0.92
iA = axle ratio = ZA2 : ZA1 = 69 : 22 = 3.136
iov = overall ratio = iG x iA = 0.92 x 3.136 = 2.89
6th gear Final drive
2. Code letters, gearbox allocation, ratios, equipment 3
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Audi TT 1999 ➤ Direct shift gearbox 02E, four-wheel drive - Edition 12.2006

3 Capacities

Gearbox capacity
Capacities Direct shift gearbox 02E
Initial filling 6.9 ltr. Oil change approx. 5.5 ltr. Change interval ⇒ Maintenance tables Lubricant, specification Gear 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
⇒ page 86 .
Checking gear oil level and changing gear oil ⇒ page 74 .
Bevel box capacity
Capacities Bevel box
Initial filling 0.9 ltr. Oil change Filled for life, no change Lubricant For 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
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

4 Safety 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

5 Notes on the direct shift gearbox 02E

5.1 General 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

5.2 Safety 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

6 Notes 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

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 ⇒ 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 ➤

7.2 General 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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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
8 Rules 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

1 Servicing 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.

1.1 Multiple 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

1.2 Removing 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
– Bolt universal dial gauge bracket -VW 387- onto gearbox
flange.
– 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 mm 2.3 mm
2.24 mm 2.2 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
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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
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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
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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
Component Nm
Drain plug to gearbox, M24 45 Oil filter housing to gearbox 20
24 Rep. Gr.30 - Clutch
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Direct shift gearbox 02E, four-wheel drive - Edition 12.2006

34 – Controls, housing

1 Electrical/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
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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
+ 104 hidden pages