Audi TT 2007 User Manual
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
Workshop Manual
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic)
Edition 09.2010
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
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 D3E8031CB49
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 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, gearbox allocation, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Calculating ratio „i“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 When working on the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 When working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 When using test equipment while road-testing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Notes on dual clutch gearbox 0BH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Safety functions of gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Notes on tow-starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Exploded view - dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 There is currently no provision for repairs to the clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Exploded view - selector lever handle, selector lever display illumination bulb L101 . . . . 20
2.1 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Detaching selector lever boot from selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Moving interlock button on selector lever handle into installation position . . . . . . . . . . . . . . 24
3 Removing and installing selector lever display illumination bulb L101 . . . . . . . . . . . . . . . . 26
4 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Operating manual release of selector mechanism from position „P“ . . . . . . . . . . . . . . . . . . 28
4.2 Checking selector mechanism and ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Adjusting and checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5 Removing and installing selector lever sensors control unit J587 with selector lever E313 ,
tiptronic switch F189 and selector lever locked in position P switch F319 . . . . . . . . . . . . 34
4.6 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 35
4.7 Checking connectors on selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Transporting dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7 Securing gearbox to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.2 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.1 Checking gear oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10 Removing and installing gear oil cooler and gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Contents i
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
10.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.1 Removing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11.2 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1 Exploded view - oil pan, mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . 85
1.1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . 89
1.3 Removing and installing gearbox input speed sender G182 / oil temperature sender for multi-
plate clutch G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1 Renewing oil seals with dual clutch gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.1 Renewing oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.2 Renewing stub shaft oil seal (right-side) with bevel box installed . . . . . . . . . . . . . . . . . . . . 96
1.3 Renewing oil seal between dual clutch gearbox and bevel box with gearbox installed . . . . 99
2 Exploded view - oil seals in bevel box and stub shaft bearings in bevel box . . . . . . . . . . . . 102
2.1 Renewing oil seals for stub shaft (right-side) with bevel box removed . . . . . . . . . . . . . . . . 103
2.2 Renewing needle bearing (polygon bearing) on stub shaft of bevel box . . . . . . . . . . . . . . 106
2.3 Renewing oil seal between bevel box and dual clutch gearbox (on bevel box) . . . . . . . . . . 108
2.4 Renewing output flange oil seal on bevel box (bevel box removed) . . . . . . . . . . . . . . . . . . 110
3 Gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.1 Overview of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.2 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.3 Topping up gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.4 Draining gear oil and filling up after repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5 Rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ii Contents
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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.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
00 – Technical data
1 Gearbox identification
The „7-speed dual clutch gearbox 0BH (S tronic)“ is installed in
the Audi TT 2007 ►. Allocation ⇒ page 2 .
Audi TT 2007 ➤
The gearbox code letters are located on the top of the gearbox
near the starter and on the gearbox flange -arrow-.
Example:
♦ MLA = gearbox code
♦ 05.10.09 = date of production: 5 October 2009.
♦ The other figures are production-related.
Note
The gearbox code letters are also given on the vehicle data stick‐
ers.
1. Gearbox identification 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
2 Code letters, gearbox allocation, ratios, equipment
Dual clutch gearbox 0BH four-wheel drive
Gearbox Code letters MLA MYD
Allocation Model
Ratios Final drive I
Z2 : Z
1
Overall ratio
i
in top gear
ov.
Allocation: rear
final drive
Manufac‐
tured
Engine
for 1st, 4th, 5th and
reverse gears
Final drive II
for 2nd, 3rd, 6th
and 7th gears
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
7th gear
Reverse
gear
Designation Rear final drive 0BY
fro
m
to
09.10 09.10
Audi TT 2007 ► Audi TT 2007 ►
2.5 ltr. - 250 kW
5-cyl. TFSI
69 : 17 = 4.059 69 : 17 = 4.059
69 : 20 = 3.450 69 : 20 = 3.450
57 : 16 = 3.562 57 : 16 = 3.562
48 : 19 = 2.526 48 : 19 = 2.526
47 : 28 = 1.678 47 : 28 = 1.678
47 : 46 = 1.022 47 : 46 = 1.022
41 : 52 = 0.788 41 : 52 = 0.788
35 : 46 = 0.761 35 : 46 = 0.761
33 : 52 = 0.635 33 : 52 = 0.635
48 : 19 x 53 : 48 =
2.789
2.191 2.191
2.5 ltr. - 250 kW
5-cyl. TFSI
48 : 19 x 53 : 48 =
2.789
2.1 Calculating ratio „i“
Example:
Drive gear ZG1 = 52 ZA1 = 20
Driven gear ZG2 = 33 ZA2 = 69
i = Z2 : Z1 (Z1 = number of teeth on drive gear, Z2 = number of
teeth on driven gear)
iG = gear ratio = ZG2 : ZG1 = 33 : 52 = 0.635
iA = axle ratio = ZA2 : ZA1 = 69 : 20 = 3.450
i
= overall ratio = iG x iA = 0.635 x 3.450 = 2.191
ov.
7th gear Final drive
2 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
3 Capacities
Gearbox capacity
Capacities Dual clutch gearbox 0BH, four-wheel
drive
Initial filling 7.0 ltr. + 0.1 ltr.
Oil change approx. 5.5 ltr.
Change interval ⇒ Maintenance tables
Lubricant Gear oil for dual clutch gearbox ⇒
Electronic parts catalogue
Note
Use only the correct type of gear oil for dual clutch gearbox 0BH
(available as a replacement part). Other types of lubricant cause
malfunctions and/or failure of the gearbox.
– Checking gear oil level and topping up ⇒ page 63
– Filling up with gear oil after repair ⇒ page 69
Bevel box capacity
Audi TT 2007 ➤
Capacities Bevel box
Initial filling 0.9 ltr.
Oil change Filled for life, no change
Lubricant Gear oil ⇒ Electronic parts catalogue
Note
Use only the correct type of gear oil (available as a replacement
part) for the bevel box. Other types of oil cause malfunctions and/
or failure of the bevel box.
– Checking gear oil level and topping up ⇒ page 115
– Filling up with gear oil after repair ⇒ page 119
3. Capacities 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
4 Safety precautions
4.1 When working on the vehicle
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.
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.
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.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 .
4.2 When working on vehicles with start/ stop system
Please note the following when working on vehicles with start/stop
system:
WARNING
Risk of injury due to automatic engine start on vehicles with
start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
4 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
4.3 When using test equipment while roadtesting the vehicle
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 be caused if the passenger's airbag is triggered 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 diagnostic 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 2007 ➤
4. Safety precautions 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
5 Notes on dual clutch gearbox 0BH
5.1 General notes
Gearbox
The layout of the dual clutch gearbox 0BH „S tronic“ is basically
similar to that of a 7-speed manual gearbox. The engine torque
is transferred to the gearbox via the dual-mass flywheel. The two
multi-plate clutches are controlled hydraulically and actuated al‐
ternately so that the gearbox is operated like an automatic gear‐
box, in other words the gears are engaged automatically (but can
also be selected manually via the tiptronic function). There is no
clutch pedal. For further information please refer to ⇒ Self-study
programme No. 454 ; 7-speed dual clutch gearbox 0BT .
Selector mechanism
In selector lever position „P“ the selector lever cable is used to
engage the parking lock mechanically. All other gearshift com‐
mands and selector lever positions are transmitted via the CAN
data bus from the selector lever -J743- (selector mechanism) to
the mechatronic unit for dual clutch gearbox -E313- .
Gear oil (gearbox and bevel box)
The dual clutch gearbox „0BH“ has a common oil system.
This oil system lubricates the gears and shafts, the final drive, the
clutches and the mechatronic unit for dual clutch gearbox -J743- .
Note
Use only the correct type of gear oil for dual clutch gearbox
„0BH“ (available as a replacement part). Other types of oil will
cause malfunctions and/or failure of the gearbox; for part number
refer to ⇒ Electronic parts catalogue .
The bevel box has a separate oil filling ⇒ page 115 .
Note
Use only the correct type of gear oil (available as a replacement
part) for the bevel box. Other types of oil will cause malfunctions
and/or failure of the bevel box; for part number refer to ⇒ Elec‐
tronic parts catalogue .
When does the gear oil filter have to be changed?
Note
The gear oil filter does not always require replacement.
Do not change the filter if:
♦ The gear oil cooler or its O-rings have been renewed and no
coolant has entered the oil system.
♦ Oil seals or O-rings have been renewed in the gearbox.
♦ The oil pan or mechatronic unit have been renewed.
♦ The maintenance interval has been reached.
6 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
The filter must be changed if:
♦ Metal particles are found in the oil.
♦ The clutch is burnt out or mechanically defective.
Disposal regulations for oils
Drained oil must be disposed of properly.
♦ Improper disposal of used oil endangers the environment.
♦ It must not be mixed with solvents, brake fluid, coolant or sim‐
ilar.
♦ 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
Audi TT 2007 ➤
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 selector lever posi‐
tion display in the instrument cluster will continue to show the
selector 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 selector lever position display in the
instrument 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 the selector lever
is in position „R“ and the vehicle is still rolling backwards. In
this case, selector lever position „D“ will start to flash on the
selector lever position display 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 en‐
gaged once the vehicle has come to a standstill.
♦ 3) The complete selector lever position display in the instru‐
ment cluster is lit up and flashing. The current selector lever
position is indicated in the instrument cluster (e.g. „D“ is high‐
lighted). This is an indication that the gearbox has been over‐
loaded or the maximum temperature in the gearbox has been
exceeded (overheating), e.g. towing a load that was too heavy.
♦ 4) If the complete selector lever position display in the instru‐
ment cluster is lit up and flashing, this means that a serious
fault in the gearbox has been identified. The display in the in‐
5. Notes on dual clutch gearbox 0BH 7
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
strument 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 indi‐
cator that he should immediately contact an Audi Service
Partner.
8 Rep. gr.00 - Technical data
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with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
6 Notes on tow-starting and towing
Caution
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, as the
gearbox would otherwise be seriously damaged.
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 2007 ➤
6. Notes on tow-starting and towing 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 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
7 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.
A number of generally applicable instructions for the various re‐
pair procedures are summarised here. They apply to the work
described in this Manual.
Guided Fault Finding, vehicle self-diagnosis and testing system
♦ Before servicing the gearbox, the cause of the fault should be
identified as exactly as possible using the vehicle diagnostic
tester via Guided Fault Finding , Vehicle Self-diagno-
sis and Test Instruments.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ "Workshop equipment and special tools" .
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 installing a replacement gearbox, the gear oil level must
be checked and topped up if necessary ⇒ page 63 . For ca‐
pacities refer to ⇒ page 3 , for specifications refer to ⇒
Electronic parts catalogue .
♦ When installing gearbox, ensure that dowel sleeves are fitted
correctly.
10 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
O-rings, oil seals and gaskets
♦ 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.
♦ Renew gaskets: completely remove the old gasket and clean
the sealing surfaces thoroughly.
♦ Lightly lubricate O-rings with gear oil before installation to pre‐
vent them being trapped and damaged during assembly.
♦ Lightly oil the outer circumference of oil seals and fill the space
between the sealing lips -arrow- about half full with sealing
grease -G 052 128 A1- .
♦ Do not use any other lubricants where gear oil is specified.
Otherwise, there is a risk of problems occurring in the gearbox
hydraulics.
♦ The open side of the oil seal should face the side containing
the fluid.
♦ Observe rules for cleanliness ⇒ page 12 .
♦ After installing, check the gear oil level ⇒ page 63 or
⇒ page 115 and rectify as necessary.
Locking elements
♦ 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.
Nuts, bolts
♦ Slacken 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 install bolts with locking fluid; for
locking fluid refer to ⇒ Electronic parts catalogue .
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Where instructions specify a torque setting plus an additional
angle, these bolts must be tightened to the specified torque
and then turned through the specified angle, e.g. 40 Nm + 90°
(90° = a quarter turn).
Audi TT 2007 ➤
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 .
7. Repair instructions 11
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
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 Rules for cleanliness
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Use cleaning fluid -D 009 401 04- to clean the gearbox and its
components.
♦ Use lint-free cloths for cleaning, such as the „WYPALL X70 /
WORKHORSE“ cloth from Kimberly-Clark Professional.
♦ Seal off open lines and connections immediately with clean
plugs or sealing caps from engine bung set -VAS 6122- im‐
mediately.
♦ 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.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
12 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
8 Exploded view - dual clutch gearbox
1 - Circlip
❑ For cover for multiple
clutch
❑ Renew
2 - Cover for multiple clutch
❑ There is currently no
provision for repairs to
the clutch
3 - Circlip
❑ Renew
4 - Shim
❑ There is currently no
provision for repairs to
the clutch
5 - Tapered ring
❑ There is currently no
provision for repairs to
the clutch
6 - Multiple clutch
❑ There is currently no
provision for repairs to
the clutch
7 - Oil seal
❑ Installed in dual clutch
gearbox (right-side),
facing bevel box
❑ Removing and installing
⇒ page 99
8 - Breather pipe
❑ Pressed into gearbox
❑ Must be renewed if re‐
moved
9 - Breather cap
❑ Fitted onto breather pipe
10 - Screw plug
11 - O-ring
❑ Always renew
12 - Gear oil cooler
❑ Removing and installing ⇒ page 73
13 - Bolt
❑ 20 Nm and then turn 45° further
14 - Filter housing
❑ 20 Nm
15 - O-ring
❑ Always renew
Audi TT 2007 ➤
8. Exploded view - dual clutch gearbox 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
16 - Heat shield
17 - Gear oil filter
❑ Notes on oil filling and filter change ⇒ page 6
❑ Removing and installing ⇒ page 75
18 - Bolt
❑ 10 Nm and then turn 45° further
19 - Cable support bracket
❑ Secures selector lever cable to gearbox
20 - Gearbox selector lever
21 - Bolt
❑ 10 Nm and then turn 90° further
22 - Gearbox
23 - Oil seal
❑ For drive shaft (left-side)
❑ Removing and installing ⇒ page 95
24 - Seal
❑ Always renew
25 - Oil drain plug
❑ 10 Nm and then turn 30° further
❑ For mechatronic unit
26 - Overflow pipe
❑ 3 Nm
Caution
♦Keep exactly to specified
torque.
♦The overflow pipe can
break between the
thread and the collar.
Note
❑ Draining and filling oil ⇒ page 69
27 - Seal
❑ Always renew
28 - Oil drain plug
❑ 45 Nm
❑ For gearbox
29 - Bolt
❑ Tightening torque ⇒ Item 29 (page 85)
30 - Gearbox input speed sender -G182- / clutch temperature sender -G509-
❑ The two senders are combined in one component and can only be renewed together
❑ Removing and installing ⇒ page 93
31 - Mechatronic unit for dual clutch gearbox -J743-
❑ Removing and installing ⇒ page 89
32 - Bolt
❑ Tightening torque ⇒ Item 32 (page 85)
14 Rep. gr.00 - Technical data
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with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Always renew
33 - Oil pan
❑ With gasket
❑ Removing and installing ⇒ page 86
❑ Always renew
34 - Bolt
❑ Tightening torque ⇒ Item 34 (page 85)
❑ Always renew
35 - Securing clip
❑ Always renew
36 - O-ring
❑ Always renew
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
8. Exploded view - dual clutch gearbox 15
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
30 – Clutch
1 There is currently no provision for re‐
pairs to the clutch.
16 Rep. gr.30 - Clutch
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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.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
34 – Controls, housing
1 Electrical/electronic components and fit‐
ting locations
Diagnostic connection
Fitting location: The diagnostic connection is located below the
knee padding to the left of the steering wheel.
The components listed below can be tested with the Guided
Fault Finding function in the vehicle diagnostic tester .
Audi TT 2007 ➤
Selector lever lock solenoid -N110-
Fitting location: The selector lever lock solenoid -N110- is a com‐
ponent part of the shift unit.
The selector lever lock solenoid -N110- cannot be renewed sep‐
arately. The shift unit must be renewed in the event of a fault
⇒ page 31 .
Mechatronic unit for dual clutch gearbox -J743-
Fitting location: The mechatronic unit for dual clutch gearbox J743- -1- is bolted to the front of the gearbox housing -arrowsand covered by the gearbox oil pan.
The control unit is an integrated component of the mechatronic
unit for dual clutch gearbox -J743- .
Removing and installing mechatronic unit for dual clutch gearbox
-J743- ⇒ page 89
1. 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
Gearbox input speed sender -G182- / clutch temperature sender
-G509-
Fitting location: The gearbox input speed sender -G182- / clutch
temperature sender -G509- -1- is secured to the gearbox housing
with bolt -2-.
Removing and installing gearbox input speed sender -G182- / oil
temperature sender for multi-plate clutch -G509- ⇒ page 93 .
Selector lever sensors control unit -J587- with selector lever E313- , tiptronic switch -F189- , selector lever locked in position
P switch -F319-
Fitting location: The components are integrated in the printed cir‐
cuit of the shift unit; they cannot be renewed separately.
The shift unit must be renewed if one of the components is de‐
fective ⇒ page 31 .
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 lights up, please
refer to safety functions of gearbox control unit ⇒ page 7 .
Removing and installing instrument cluster ⇒ Electrical system;
Rep. gr. 90
Selector lever display illumination bulb -L101-
Fitting location: in trim for selector lever boot -1-.
Removing and installing selector lever display illumination bulb L101- ⇒ page 26
18 Rep. gr.34 - Controls, housing
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
Brake light switch -F-
Fitting location: The brake light switch -2- is located on the brake
master cylinder.
Removing and installing brake light switch ⇒ Brake system; Rep.
gr. 45 .
Kick-down switch -F8-
An adapted value from accelerator position sender -G79- / accel‐
erator position sender 2 -G185- (integrated in accelerator pedal
module) is stored in the engine control unit as the kickdown signal.
♦ Signal is transmitted from engine control unit to gearbox con‐
trol unit via CAN bus.
Removing and installing accelerator pedal module ⇒ Fuel supply
system, petrol engines; Rep. gr. 20 .
Audi TT 2007 ➤
1. 19
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
2 Exploded view - selector lever handle, selector lever display illumina‐
tion bulb -L101-
1 - Bolt
❑ 1 Nm
2 - Trim for selector lever boot
with selector lever display illu‐
mination bulb -L101-
❑ Removing and installing
⇒ page 26
3 - Guide
4 - Selector lever boot
❑ Detaching selector lever
boot from selector lever
handle ⇒ page 22
5 - Selector lever handle
❑ ⇒ „2.1 Removing and in‐
stalling selector lever
handle“, page 20
❑ ⇒ „2.3 Moving interlock
button on selector lever
handle into installation
position“, page 24
2.1 Removing and installing selector lever handle
Special tools and workshop equipment required
♦ Removal wedge -3409-
20 Rep. gr.34 - Controls, housing
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
Removing
Note
The selector lever handle is removed together with the selector
lever boot.
– Apply handbrake.
– Shift selector lever into position „N“.
– Unclip selector lever boot on both sides using removal wedge
-3409- and lift it off -arrows-.
– Turn selector lever boot -2- inside out over selector lever han‐
dle -3-.
– Turn locking ring in direction of -arrow- as far as stop.
• Raised lug -b- on locking ring is moved away from lug -a-.
Caution
Audi TT 2007 ➤
Risk of damage to the selector mechanism.
Do not touch the interlock button -1- on the selector lever han‐
dle when pulling off the handle.
Otherwise the selector lever handle or the pull rod of the se‐
lector mechanism will be damaged when the handle is pulled
off.
– Pull off selector lever handle together with selector lever boot
upwards -arrow-, taking care not to touch interlock button -1-.
Installing
Installation is carried out in reverse sequence; note the following:
– Turn locking ring in direction of -arrow- as far as stop.
• Raised lug -b- on locking ring is moved away from lug -a-.
• Interlock button faces direction of travel.
Caution
Risk of damage to the selector mechanism.
The interlock button -1- must protrude from the selector lever
handle during installation. If the interlock button was pressed
in by mistake when the handle was removed, the interlock but‐
ton must be moved back to its installation position
⇒ page 24 .
If the interlock button has been pressed in and the handle is
installed with the interlock button in this position, the handle
and the pull rod of the selector mechanism -3- will be damaged
irreparably.
– Carefully press selector lever handle fully into selector lever,
taking care not to touch interlock button -1-.
• The handle must engage in the annular groove on the selector
lever.
2. Exploded view - selector lever handle, selector lever display illumination bulb L101 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
– Turn locking ring in direction of -arrow- as far as stop.
• It must be possible to turn the locking ring; press handle if
necessary.
• Lug -a- must align with raised lug -b- on locking ring.
Note
♦
The handle is not locked until the locking ring has been turned.
Only then can you press the interlock button on the handle.
♦
There may be increased resistance when you press the inter‐
lock button for the first time after installation.
– Press interlock button -1- on selector lever handle.
– Fold selector lever boot down and clip it in.
– Check selector mechanism ⇒ page 30 .
2.2 Detaching selector lever boot from se‐
lector lever handle
Procedure:
– Remove selector lever handle ⇒ page 20 .
– Pull guide -1- off in direction of -arrow-.
22 Rep. gr.34 - Controls, housing
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
• Do not touch interlock button -A- when selector lever handle
has been removed.
– Hold upper end of selector lever boot -arrow 1-.
– Turn selector lever handle in direction of -arrow 2- and pull it
off -arrow 3-.
Installing selector lever boot with selector lever handle:
• Do not touch interlock button -A- when selector lever handle
has been removed.
– Insert selector lever handle in selector lever boot -arrow 1-
(with interlock button turned 90° out of position towards left).
– Hold upper end of selector lever boot -arrow 2-.
– Turn selector lever handle in direction of -arrow 3-.
Audi TT 2007 ➤
– Clip guide -1- upwards into handle in opposite direction of
-arrow-.
– Install selector lever handle ⇒ page 20 .
2. Exploded view - selector lever handle, selector lever display illumination bulb L101 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
2.3 Moving interlock button on selector lever handle into installation position
Special tools and workshop equipment required
♦ Release tool -T40203-
Selector lever handle with interlock button:
• Installation position: the interlock button -1- must protrude
from the selector lever handle.
If the interlock button has been pressed in, it must be moved back
into its installation position so that the selector lever handle can
be installed.
– Carefully insert release tool -T40203- into selector lever han‐
dle -1- as far as stop.
Note
For illustration purposes, the handle is shown without selector
lever boot.
• Recess on release tool -T40203- should face interlock button,
hook should point towards left.
24 Rep. gr.34 - Controls, housing
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
– Hold selector lever handle -A- and turn release tool -T40203-
180° in direction of -arrow 1-.
– Hold handle and carefully pull out release tool -T40203-
-arrow 2-.
• When pulling out release tool -T40203- , interlock button -Aon selector lever handle is pressed out and locked in position.
• Do not touch interlock button on selector lever handle before
installing handle so that interlock button is not pressed in
again.
Audi TT 2007 ➤
2. Exploded view - selector lever handle, selector lever display illumination bulb L101 25
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
7-speed dual clutch gearbox 0BH (S tronic) - Edition 09.2010
3 Removing and installing selector lev‐
er display illumination bulb -L101-
Special tools and workshop equipment required
♦ Removal wedge -3409-
Removing
– Apply handbrake.
– Shift selector lever into position „N“.
– Switch off ignition.
– Unclip selector lever boot on both sides using removal wedge
-3409- and lift it off -arrows-.
– Pull selector lever boot up and over handle.
– Using removal wedge -3409- , pry trim panel for centre console
out of centre console -arrows-.
– Unplug electrical connectors and remove trim panel for centre
console.
26 Rep. gr.34 - Controls, housing
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