Audi TT 21 User Manual
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Service
Workshop Manual
Audi TT 1999 ➤
5-speed manual gearbox 02J
Edition 10.2007
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - 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 A0057005020
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 ➤
5-speed manual gearbox 02J - Edition 10.2007
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Servicing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Checking hydraulic clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Pedal cluster - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing and installing clutch pedal switch F36 (square housing) . . . . . . . . . . . . . . . . . . 14
1.4 Removing and installing clutch pedal switch F36 (round housing) . . . . . . . . . . . . . . . . . . . . 14
1.5 Removing and installing clutch pedal switch for engine start F194 . . . . . . . . . . . . . . . . . . 15
1.6 Removing and installing over-centre spring (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.8 Exploded view - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.9 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.10 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.11 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Fault-finding on power transmission - complaints regarding defects on the clutch and clutch
3.2 Servicing clutch - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.3 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1 Servicing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.2 Removing and installing gear knob and boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3 Servicing gear lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.4 Removing and installing selector cables - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.6 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4 Removing and installing gearbox bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3 Checking gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3 Removing and installing gearbox housing cover and 5th gear . . . . . . . . . . . . . . . . . . . . . . 85
4.4 Dismantling and assembling gearbox housing and selector mechanism . . . . . . . . . . . . . . 86
4.5 Removing and installing input shaft, output shaft (pinion shaft), differential and selector
forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.6 Dismantling and assembling sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Contents i
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
6 Dismantling and assembling selector mechanism in gearbox . . . . . . . . . . . . . . . . . . . . . . 106
7 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.2 Modified springs for 5th gear synchromesh from gearbox build date 05 11 1 . . . . . . . . . . 122
1.3 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.4 Table of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2 Output shaft (pinion shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.1 Dismantling and assembling output shaft (pinion shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.2 1st gear synchromesh modified as of gearbox build date 02 05 0 . . . . . . . . . . . . . . . . . . . . 140
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1 Renewing flange shaft oil seals (gearbox installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.1 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.2 Renewing flange shaft oil seal (right-side) - separate oil seal and sleeve . . . . . . . . . . . . . . 149
1.3 Renewing flange shaft oil seal (right-side) - combined oil seal and sleeve . . . . . . . . . . . . 152
2 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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.
5-speed manual gearbox 02J - Edition 10.2007
00 – Technical data
1 Gearbox identification
The 5-speed manual gearbox 02J is fitted in conjunction with 4cylinder injection engines in the Audi TT 1999 ▸.
Allocation ⇒ page 1 .
1.1 Location on gearbox
Code letters and date of manufacture -arrow 1-
Manual gearbox 02J -arrow 2-
Audi TT 1999 ➤
Manual gearbox 02J -arrow 2-
Code letters and date of manufacture of gearbox
Example: DZF 15 10 8
Additional data are production-related.
Note
I I I I
I I I I
Code letters Day Month Year -1998- of
manufacture
The gearbox code letters are also given on the vehicle data stick‐
ers.
1.2 Code letters, allocation, transmission ratios, capacities
Manual gearbox 5-speed 02J
Code letters
Manufactured from 06.98 09.00 09.00
Allocation Model Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
to 05.00 06.06 01.01
DZF
EGZ
1)
1. Gearbox identification 1
EVS
1)
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
Manual gearbox 5-speed 02J
Ratios:
Z2 : Z
1
Overall ratio i
in top gear 3.299 3.299 3.084
ov.
Engine 1.8 ltr. - 110 kW
1.8 ltr. - 132 kW
1.8 ltr. - 110 kW
1.8 ltr. - 132 kW
1.8 ltr. - 110 kW
Final drive 63 : 16 = 3.938 63 : 16 = 3.938 70 : 19 = 3.684
1st gear 33 : 10 = 3.300 33 : 10 = 3.300 33 : 10 = 3.300
2nd gear 35 : 18 = 1.944 35 : 18 = 1.944 35 : 18 = 1.944
3rd gear 34 : 26 = 1.308 34 : 26 = 1.308 34 : 26 = 1.308
4th gear 30 : 29 = 1.034 30 : 29 = 1.034 35 : 34 = 1.029
5th gear 31 : 37 = 0.838 31 : 37 = 0.838 36 : 43 = 0.837
6th gear - - Reverse gear 17 : 10 x 36 : 20 = 3.060 17 : 10 x 36 : 20 = 3.060 17 : 10 x 36 : 20 = 3.060
Speedometer 13 : 22 = 0.591 13 : 22 = 0.591 13 : 22 = 0.591
Capacity 2.0 litres
Clutch actuation Hydraulic
Drive shaft flange ∅ 108 mm 108 mm 108 mm
1)
As of 09.00, modified 1st gear synchromesh and modified selector mechanism on gearbox
• The following data can be found in the ⇒ Electronic parts catalogue .
♦ Gear oil specification
♦ Correct type of clutch plate and pressure plate
Manual gearbox 5-speed 02J
Code letters
EWV
1)
Manufactured from 05.00
to 09.00
Allocation Model Audi TT 1999 ▸
Ratios:
Z2 : Z
1
Overall ratio i
in top gear 3.299
ov.
Engine 1.8 ltr. - 132 kW
Final drive 63 : 16 = 3.938
1st gear 33 : 10 = 3.300
2nd gear 35 : 18 = 1.944
3rd gear 34 : 26 = 1.308
4th gear 30 : 29 = 1.034
5th gear 31 : 37 = 0.838
6th gear Reverse gear 17 : 10 x 36 : 20 = 3.060
Speedometer 13 : 22 = 0.591
Capacity 2.0 litres
Clutch actuation Hydraulic
Drive shaft flange ∅ 108 mm
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.
5-speed manual gearbox 02J - Edition 10.2007
Manual gearbox 5-speed 02J
1)
As of 05.00, modified 1st gear synchromesh
• The following data can be found in the ⇒ Electronic parts catalogue .
♦ Gear oil specification
♦ Correct type of clutch plate and pressure plate
Audi TT 1999 ➤
1. Gearbox identification 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
2 Transmission layout
Identification
-Arrows- point in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft / pinion shaft
6 - Differential
Ratio
-Arrows- point in direction of travel
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.
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
2. Transmission layout 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
3 Calculating ratio “i”
Example:
5th gear Final drive
Drive gear ZG1 = 37 ZA1 = 16
Driven gear ZG2 = 31 ZA2 = 63
i = Z2 : Z1
1)
iG = gear ratio = ZG2 : ZG1 = 31 : 37 = 0.838
iA = axle ratio = ZA2 : ZA1 = 63 : 16 = 3.938
iov = overall ratio
iov = iG x iA = 0.838 x 3.938 = 3.299
1) Z1 = No. of teeth on drive gear, Z2 = No. of teeth on driven gear
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.
5-speed manual gearbox 02J - Edition 10.2007
4 General repair instructions
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. The usual basic safety
precautions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ Workshop equipment and special tools catalogue .
Gearbox
♦ When installing, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ When installing a new gearbox, check the oil level and fill up
with oil if necessary ⇒ page 82 .
♦ Capacity ⇒ page 1 .
Audi TT 1999 ➤
Note
♦
If the oil level is topped up with the gearbox installed, check
oil level as follows:
♦
Fill with oil to bottom lip of filler hole and refit screw plug. Start
engine, engage a gear and allow gearbox to turn for approx.
2 minutes. Switch off engine and again top up oil to bottom lip
of filler hole.
Sealants
♦ Thoroughly clean joint surfaces on gearbox housing etc. be‐
fore applying sealant .
♦ Apply sealant -AMV 188 200 03- evenly and not too thickly.
O-rings, oil seals and gaskets
♦ Always renew O-rings, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Thoroughly clean housing joint surfaces before assembling.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrowabout half full with grease -G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ When installing a new oil seal, position the seal in the housing
so that the sealing lip does not contact the shaft in the same
place as the old seal (make use of insertion depth tolerances).
♦ Lightly lubricate O-rings before installation to prevent them
from being trapped and damaged during assembly.
♦ After renewing seals and gaskets, check and, if necessary, top
up oil level in gearbox ⇒ page 82 .
Locking elements
4. General repair instructions 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
♦ Do not over-stretch circlips.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.
Nuts, bolts
♦ Loosen the nuts and 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.
♦ Especially delicate parts, such as clutch pressure plates, must
not be distorted. Loosen and tighten bolts and nuts in stages
in diagonal sequence.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and 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.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
Bearings
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Lubricate all bearings (except new tapered roller bearings)
with gear oil before installing in gearbox.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er and use new bearings from a single manufacturer.
♦ Use inductive heater -VAS 6414- to heat inner races to approx.
100°C before installing. Press home onto stop when installing
so there is no axial clearance.
♦ Do not interchange the outer or inner races of bearings of the
same size (the bearings are paired).
Shims
♦ Measure shims at several points with a micrometer. Tolerance
variations make it possible to obtain the exact shim thickness
required.
♦ Check for burrs and damage.
♦ Install only shims which are in perfect condition.
Synchro-rings
8 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5-speed manual gearbox 02J - Edition 10.2007
♦ Do not interchange. When re-using synchro-rings, always fit
to the same gear wheel.
♦ Check for wear; renew if necessary.
♦ Check the grooves -arrow 1- on synchro-ring -A- and on inner
ring for wear (flattened sections in grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is fitted, check the outer contact
surface -arrow 2- and inner contact surface -arrow 3- of the
intermediate ring for scoring and visible traces of wear.
♦ Check chamfer on selector gear for scoring and visible traces
of wear.
♦ Lubricate synchroniser rings with gear oil before installing.
Gear wheels
♦ Note correct installation position.
♦ Before installing, clean and heat to 100°C (maximum) using
inductive heater -VAS 6414- .
Selector gears
♦ After installing, check 1st to 5th selector gears for minimal axial
play and freedom of movement.
Clutch actuation
♦ When removing gearbox, remove clutch slave cylinder without
disconnecting pipes.
♦ Do not depress the clutch pedal after removing the slave cyl‐
inder if the hydraulic pipe is still connected. Otherwise, the
piston will be pressed out of the slave cylinder and be de‐
stroyed.
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts in a diagonal sequence and in several gradual
stages.
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures
⇒ “1.1 Checking hydraulic clutch mechanism”, page 11 ).
♦ If the clutch has burnt out, thoroughly clean the bell housing,
flywheel and parts of the engine facing the gearbox in order to
prevent odours.
Audi TT 1999 ➤
4. General repair instructions 9
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 ➤
5-speed manual gearbox 02J - Edition 10.2007
30 – Clutch
1 Servicing clutch mechanism
I - Exploded view - pedal clus‐
ter
⇒ “1.1 Checking hydraulic
clutch mechanism”, page 11
⇒ “1.2 Pedal cluster - exploded
view”, page 13
⇒ “1.3 Removing and installing
clutch pedal switch F36
(square housing)”, page 14
⇒ “1.4 Removing and installing
clutch pedal switch F36 (round
housing)”, page 14
⇒ “1.5 Removing and installing
clutch pedal switch for engine
start F194 ”, page 15
⇒ “1.6 Removing and installing
over-centre spring (LHD vehi‐
cles)”, page 16
⇒ “1.7 Removing and installing
clutch pedal”, page 17
II - Exploded view - hydraulic
system
⇒ “1.8 Exploded view - hy‐
draulic system”, page 19
⇒ “1.9 Removing and installing
master cylinder”, page 20
⇒ “1.10 Removing and instal‐
ling slave cylinder”, page 23
⇒ “1.11 Bleeding clutch sys‐
tem”, page 26
10 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.
Note
♦
Before renewing the master or
slave cylinder on the assumption
that it is defective you must first
check the clutch mechanism
⇒ page 11 .
♦
Disconnect battery earth strap.
♦
Note radio coding for vehicles
with coded radio.
♦
Apply polycarbamide grease -G
052 142 A2- to all bearings and
contact surfaces.
♦
Make sure that no brake fluid es‐
capes into the footwell, the ple‐
num chamber or onto the gear‐
box below. If this does happen,
clean the affected area thor‐
oughly.
♦
When performing work in the
footwell, put cloths on the carpet
to protect it from possible brake
fluid spills.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
1.1 Checking hydraulic clutch mechanism
• Make sure the pedal returns to its initial position and is not
obstructed by additional floor mats or mats that have slipped
out of position.
• Bleed the clutch system if necessary.
1. Servicing clutch mechanism 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
– First check brake fluid level in brake fluid reservoir.
Note
♦
The clutch hydraulics are connected to one of the chambers
-arrow 2- of the brake fluid reservoir via the supply hose
-arrow 1-.
♦
If this chamber is empty or contains too little brake fluid, the
system may be leaking.
– Then check the following components of the hydraulic clutch
mechanism for external leaks:
♦ Supply hose between brake fluid reservoir and master cylinder
♦ Master cylinder
♦ Pipe/hose assembly between master cylinder and slave cyl‐
inder
♦ Connections (plug-in connectors and threaded connections),
including hidden connections
♦ Slave cylinder
Note
♦
External leaks can be detected, for instance, by traces of brake
fluid on or below the gearbox as well as on the noise insulation
panel below the gearbox.
♦
Check correct routing of pipe/hose assembly between master
cylinder and slave cylinder. The pipe/hose assembly must not
be kinked or become trapped.
– Then depress clutch pedal carefully; hold pedal in five different
positions for approx. 20 seconds at each position over its full
travel. Have a 2nd person check the components of the hy‐
draulic clutch mechanism ⇒ page 12 for visible leaks. At the
same time the 1st person should check whether the clutch
pedal yields under the foot at any of the held positions.
– Finally, detach slave cylinder from gearbox (do not open pipe
connections) and check sleeve for traces of escaped brake
fluid.
– Detach sleeve from plunger -arrow- to check for leaks.
12 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.
5-speed manual gearbox 02J - Edition 10.2007
1.2 Pedal cluster - exploded view
1 - Bulkhead
❑ With mounting for
mounting bracket and
master cylinder
2 - Gasket
❑ Always renew
3 - Mounting bracket
❑ For mounting clutch
pedal
4 - Bolt
5 - Mounting bracket
❑ For mounting accelera‐
tor pedal and brake ped‐
al
6 - Nut
❑ 25 Nm
❑ Self-locking
❑ Always renew
7 - Connecting plate
8 - Nut
❑ 25 Nm
❑ Self-locking
❑ Always renew
9 - Bearing bush
10 - Pivot pin
11 - Clutch pedal
❑ Removing and installing
⇒ page 17
12 - Retaining clip
❑ Removing and installing ⇒ Item 4 (page 19)
13 - Nut
❑ 25 Nm
❑ Self-locking
❑ Always renew
14 - Master cylinder
❑ Removing and installing ⇒ page 20
15 - Supply hose
16 - Over-centre spring
❑ Removing and installing ⇒ page 16
17 - Over-centre spring mounting
❑ Install in mounting bracket
❑ When renewing, remove and install master cylinder ⇒ page 20
18 - Clutch pedal switch -F36- or clutch pedal switch for engine start -F194-
❑ Clutch pedal switch for engine start -F194- only installed on USA models
❑ ⇒ “1.3 Removing and installing clutch pedal switch F36 (square housing)”, page 14
Audi TT 1999 ➤
1. Servicing clutch mechanism 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
❑ ⇒ “1.4 Removing and installing clutch pedal switch F36 (round housing)”, page 14
❑ ⇒ “1.5 Removing and installing clutch pedal switch for engine start F194 ”, page 15
19 - Stop
❑ For clutch pedal
❑ Installation position ⇒ page 22
20 - Nut
❑ 25 Nm
❑ Self-locking
❑ Always renew
1.3 Removing and installing clutch pedal switch -F36- (square housing)
Note
To ensure a secure fit, the switch may only be fitted once.
Removing
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. Gr. 68 .
– Unplug electrical connector from clutch pedal switch.
– Remove clutch pedal switch -1- by turning 90° anti-clockwise.
Installing
Installation is carried out in reverse sequence; note the following:
– Grease plunger head of clutch pedal switch -F36- with poly‐
carbamide grease -G 052 142 A2- .
– Pull operating rod of clutch pedal switch all the way out.
– Push clutch pedal down by hand.
– Insert switch in mounting hole and secure by turning clockwise
through 90° -arrows-.
– Release clutch pedal
– Attach electrical connector to clutch pedal switch.
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. Gr. 68 .
1.4 Removing and installing clutch pedal switch -F36- (round housing)
Note
Clutch pedal switch may only be fitted once so as to ensure a firm
fit.
14 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.
5-speed manual gearbox 02J - Edition 10.2007
Removing
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. Gr. 68 .
– Unplug electrical connector from clutch pedal switch.
– Remove clutch pedal switch by turning anti-clockwise through
45°.
Installing
Installation is carried out in reverse sequence; note the following:
– Grease plunger head of clutch pedal switch -F36- with poly‐
carbamide grease -G 052 142 A2- .
– Pull out operating rod -arrow- all the way before installing
clutch pedal switch.
– Insert retainer tabs -1- and -2- of switch in recesses provided
in mounting hole and secure by turning clockwise through 45°.
• The clutch pedal should be in the normal position (i.e. not
pressed down).
• Do not press clutch pedal when installing.
• Plunger is adjusted automatically when clutch pedal switch is
installed.
– Attach electrical connector to clutch pedal switch.
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. Gr. 68 .
1.5 Removing and installing clutch pedal
switch for engine start -F194-
Audi TT 1999 ➤
Note
♦
Only fitted on USA models
♦
To ensure a secure fit, the switch may only be fitted once.
Removing
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. Gr. 68 .
1. Servicing clutch mechanism 15
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 ➤
5-speed manual gearbox 02J - Edition 10.2007
– Detach electrical connector -1- on clutch pedal switch.
– Remove clutch pedal switch for engine start -F194- -2- by
turning 90° anti-clockwise in direction of -arrow-.
Installing
Installation is carried out in reverse sequence; note the following:
– Grease plunger head of clutch pedal switch for engine start -
F194- with polycarbamide grease -G 052 142 A2- .
– Pull operating rod of clutch pedal switch all the way out.
– Insert switch in mounting hole and secure by turning clockwise
through 90°.
– Clutch pedal fully depressed.
– Release clutch pedal
– Attach electrical connector to clutch pedal switch.
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. Gr. 68 .
1.6 Removing and installing over-centre spring (LHD vehicles)
Special tools and workshop equipment required
♦ Assembly clip -T10111-
Removing
– Remove driver's storage compartment (bottom) ⇒ Rep. Gr.
68 .
– Fit assembly clip -T10111- from the right onto over-centre
spring.
– Ensure that the assembly clip is correctly seated:
1 - The rear part of assembly clip must be positioned on the overcentre spring so that the claws fit exactly over the rib -1-.
2 - Lightly depress clutch pedal towards bulkhead.
– Engage the lug -2- of the assembly clip into the cut-out on the
over-centre spring.
– Now depress the clutch pedal towards the bulkhead until the
over-centre spring can be removed from below from the
mountings on the mounting bracket and clutch pedal.
– Return clutch pedal to normal position.
16 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.
5-speed manual gearbox 02J - Edition 10.2007
– Turn over-centre spring together with assembly clip -T10111-
in direction of -arrow A- and take out downwards in direction
of -arrow B-.
Installing
– Pull clutch pedal into the passenger compartment.
– Insert over-centre spring together with assembly clip -T10111-
upwards (in direction of -arrow A-) into mounting bracket and
then turn in direction of -arrow B-.
Audi TT 1999 ➤
– Insert over-centre spring into rear mounting first -arrow A-.
– Operate clutch pedal until over-centre spring seats on mount‐
ing lug -arrow B- on clutch pedal.
– Return clutch pedal to normal position and remove assembly
clip.
– Install driver's storage compartment (bottom) ⇒ Rep. Gr. 68 .
1.7 Removing and installing clutch pedal
Special tools and workshop equipment required
♦ Pliers -T10005-
Removing
– If fitted, turn clutch pedal switch -F36- 45° anti-clockwise and
pull out of mounting.
– Remove over-centre spring ⇒ page 16 .
1. Servicing clutch mechanism 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
– Separate clutch pedal from master cylinder ⇒ page 22 and
push operating rod towards engine compartment as far as
stop.
– Remove nut -A-.
– Pull out bolt until clutch pedal can be removed.
Installing
Installation is carried out in reverse sequence; note the following:
– The retaining clip -A- must be fitted to the master cylinder op‐
erating rod -B-.
– Press clutch pedal in -direction of arrow- until it engages. En‐
sure that it is properly locked.
– Install over-centre spring ⇒ page 16 .
– If fitted, insert clutch pedal switch -F36- in mounting hole and
secure by turning 45° clockwise. Clutch pedal must be pressed
down.
18 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.
5-speed manual gearbox 02J - Edition 10.2007
1.8 Exploded view - hydraulic system
1 - Brake fluid reservoir
2 - Supply hose
3 - Master cylinder
❑ Removing and installing
⇒ page 20
4 - Retaining clip
❑ Renew only when mas‐
ter cylinder has been re‐
moved
❑ Removing ⇒ page 20
❑ Pressing on
⇒ page 20
5 - Clutch pedal
❑ Removing and installing
⇒ page 17
6 - Nut
❑ 25 Nm
❑ Self-locking
❑ Always renew
7 - O-ring
❑ Push onto pipe connec‐
tion
❑ Lubricate with brake flu‐
id before installing
8 - Pipe/hose assembly
❑ Disconnecting from
master cylinder and in‐
stalling ⇒ page 21
❑ Disconnecting from
slave cylinder
⇒ page 24
❑ Allocate according to ⇒ Electronic parts catalogue
9 - Retainer
❑ Secured on body
10 - Dust cap
11 - Bleeder valve
❑ Bleeding clutch system ⇒ page 26
12 - Slave cylinder
❑ Removing and installing ⇒ page 23
13 - Bolt
❑ 23 Nm
14 - Gearbox
15 - Retaining clip
❑ Pull out retaining clip to disconnect pipe ⇒ page 21
16 - O-ring
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
Audi TT 1999 ➤
1. Servicing clutch mechanism 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
17 - Support bracket
18 - Retainer
❑ Secure to support bracket for selector cables
19 - Retaining clip
❑ Pull out retaining clip to disconnect pipe ⇒ page 21
Levering retaining clip -A- off in direction of arrow
Pressing master cylinder operating rod into retaining clip -A- (in
direction of arrow).
1.9 Removing and installing master cylinder
Special tools and workshop equipment required
♦ Pliers -T10005-
20 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.
5-speed manual gearbox 02J - Edition 10.2007
Removing
– Release hose clip -4- and detach intake hose and connector
-1- from air mass meter.
– Remove bolts -2- and -3-.
– If fitted, detach secondary air pipe -5- from air cleaner housing.
– Then remove complete air cleaner housing.
– Clamp off supply hose -A- coming from brake fluid reservoir
using hose clamp -3094- .
– Disconnect supply hose -A- at master cylinder.
– Remove retaining clip -B- from master cylinder.
– Pull pipe/hose assembly -C- out of master cylinder and seal
end of pipe.
Audi TT 1999 ➤
Note
In order to take out the master cylinder the entire clutch pedal
assembly must be removed.
– Remove driver's storage compartment (bottom) ⇒ Rep. Gr.
68 .
– If fitted, remove clutch pedal switch -F36-
⇒ “1.3 Removing and installing clutch pedal switch F36
(square housing)”, page 14 or
⇒ “1.4 Removing and installing clutch pedal switch F36 (round
housing)”, page 14 .
– If fitted, remove clutch pedal switch for engine start -F194- or
⇒ “1.5 Removing and installing clutch pedal switch for engine
start F194 ”, page 15 .
– Now remove complete clutch pedal mounting bracket as fol‐
lows:
– First remove connecting plate -arrow A- -arrows 1-.
– Then remove securing nuts -arrows 2- for mounting bracket
-arrow B-.
– Take off mounting bracket.
1. Servicing clutch mechanism 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
– Remove over-centre spring using assembly clip -T10111- as
follows:
1 - The rear part of assembly clip must be positioned on the overcentre spring so that the claws fit exactly over the rib -1-.
2 - Lightly depress clutch pedal towards clutch pedal stop.
– Engage the lug -2- of the assembly clip into the cut-out on the
over-centre spring.
Release master cylinder operating rod from clutch pedal as fol‐
lows:
– Carefully pull clutch pedal towards you. At the same time,
press both sides of retaining clip inwards using pliers -T10005-
-arrows.
– Turn stop -A- for clutch pedal in direction of arrow and remove.
– Then push master cylinder in the direction of -arrow 1- onto
stop.
It must not be covered in upper area by over-centre spring mount‐
ing -arrow 2-.
– Then swing master cylinder in direction of -arrow 3- out of
mounting bracket.
Installing
Installation is carried out in reverse sequence; note the following:
22 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.
5-speed manual gearbox 02J - Edition 10.2007
– Retaining clip -A- must be fitted on operating rod -B- of master
cylinder.
– Press clutch pedal in -direction of arrow- until it engages. En‐
sure that it is properly locked.
– Fit stop -A- for clutch pedal again.
Installation position:
The arm -arrow- points towards master cylinder -B-.
– Install over-centre spring ⇒ page 16 .
– Bleed clutch system after installing master cylinder
⇒ page 26 .
– If fitted, install clutch pedal switch -F36-
⇒ “1.3 Removing and installing clutch pedal switch F36
(square housing)”, page 14 or
⇒ “1.4 Removing and installing clutch pedal switch F36 (round
housing)”, page 14 .
– If fitted, install clutch pedal switch for engine start -F194- or
⇒ “1.5 Removing and installing clutch pedal switch for engine
start F194 ”, page 15 .
– Install complete air cleaner housing ⇒ Rep. Gr. 24 .
Audi TT 1999 ➤
1.10 Removing and installing slave cylinder
Removing
– Release hose clip -4- and detach intake hose and connector
-1- from air mass meter.
– Remove bolts -2- and -3-.
– If fitted, detach secondary air pipe -5- from air cleaner housing.
– Then remove complete air cleaner housing.
– Detach cable support bracket from gearbox -arrows- and un‐
clip pipe/hose assembly.
1. Servicing clutch mechanism 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
Detaching selector mechanism on vehicles up to 06.01
– Remove circlip -arrow- and pull off gate selector cable -A- with
relay lever.
– Remove nut -arrow- and detach gear selector cable -B- with
gearbox selector lever.
– Tie up gear selector cable with gearbox selector lever and gate
selector cable with relay lever.
Detaching selector mechanism on vehicles from 07.01
– Detach circlip -3- for gear selector cable from gearbox selector
lever -1-.
– Detach circlip -4- for gate selector cable from relay lever -2-.
– Pull gate selector cable and gear selector cable off joint pins
-arrows-.
Continued for all vehicles
– Remove bolts -arrows- for slave cylinder.
– Remove slave cylinder.
– Pull out clip -A- and then pull pipe/hose assembly -C- out of
slave cylinder and seal end of pipe.
Installing
Installation is carried out in reverse sequence; note the following:
24 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.
5-speed manual gearbox 02J - Edition 10.2007
– Press retaining clip -A- in as far as it will go.
– Position recess on hose/pipe assembly so that it faces lug on
clutch slave cylinder -arrow B-.
– Insert hose/pipe assembly -C- in slave cylinder, making sure
you hear it engage.
– Lubricate end of operating rod with MoS2 grease.
– Install slave cylinder -arrows-.
– After installing slave cylinder, bleed clutch system
⇒ page 26 .
Attaching selector mechanism on vehicles up to 06.01
Audi TT 1999 ➤
Fit gearbox selector lever as follows:
– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow Bon the selector shaft.
– Fit gear selector cable -B- with gearbox selector lever
-arrow-.
– Fit gate selector cable -A- with relay lever and secure
-arrow-.
Attaching selector mechanism on vehicles from 07.01
Cable end-pieces securing cables to gearbox selector lever and
relay lever have open drillings.
The holes in the cable end-pieces have different diameters.
1. Servicing clutch mechanism 25
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5-speed manual gearbox 02J - Edition 10.2007
Allocation
Cable end-piece for: Distance “a”
Gear selector cable to gearbox selector lever 10 mm
Gate selector cable to relay lever 8 mm
– Spread small amount of polycarbamide grease -G 052 142 A2-
onto pins -arrows- of gearbox selector lever -1- and relay lever
-2-.
– Always renew circlips -3- and -4- after removing.
– Secure gear selector cable with circlip -3- and gate selector
cable with circlip -4-.
Continued for all selector mechanisms:
– Install cable support bracket on gearbox (arrows), if necessary
clip pipe/hose assembly onto cable support bracket.
Adjust selector mechanism ⇒ page 51 .
– Install complete air cleaner housing ⇒ Rep. Gr. 24 .
Tightening torques
Clutch slave cylinder to gearbox 23 Nm
Selector cable support bracket to gearbox 25 Nm
1.11 Bleeding clutch system
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234- or brake fill‐
ing and bleeding equipment -V.A.G 1869-
♦ Brake fluid specification ⇒ Rep. Gr. 47 .
26 Rep. Gr.30 - Clutch
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