Audi TT 23 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 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive
Edition 12.2004
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 A0057006420
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Servicing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Pedal cluster - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing clutch pedal switch F36 (square housing) . . . . . . . . . . . . . . . . . . 13
1.3 Removing and installing clutch pedal switch F36 (round housing) . . . . . . . . . . . . . . . . . . . . 13
1.4 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Hydraulics - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.8 Removing and installing clutch slave cylinder (release bearing with hydraulic actuator) . . 21
1.9 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Clutch release mechanism - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Renewing input shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Servicing conventional clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Conventional clutch - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Removing and installing conventional clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Servicing self-adjusting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 Self-adjusting clutch (Sachs version) - exploded view of components . . . . . . . . . . . . . . . . 30
4.2 Removing and installing self-adjusting clutch (Sachs version) . . . . . . . . . . . . . . . . . . . . . . 33
4.3 Self-adjusting clutch (LuK version) - exploded view of components . . . . . . . . . . . . . . . . . . 36
4.4 Removing and installing clutch (LuK version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1 Servicing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.2 Gear lever knob and boot - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . 42
1.3 Gear lever and selector housing - exploded view of components . . . . . . . . . . . . . . . . . . . . 43
1.4 Selector cables to 06.2001 - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . 45
1.5 Selector cables from 07.2001 - exploded view of components . . . . . . . . . . . . . . . . . . . . . . 47
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Removing gearbox - vehicles with 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Installing gearbox - vehicles with 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Removing gearbox - vehicles with 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.4 Installing gearbox - vehicles with 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.5 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.6 Removing and installing gearbox mounting - vehicles with 4-cylinder engine . . . . . . . . . . 95
2.7 Removing and installing gearbox mounting - vehicles with 6-cylinder engine . . . . . . . . . . 98
2.8 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Contents i
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
3.1 Removing and installing bevel box - vehicles with 4-cylinder engine . . . . . . . . . . . . . . . . . . 103
3.2 Removing and installing bevel box - vehicles with 6-cylinder engine . . . . . . . . . . . . . . . . . . 109
4 Gear oil in manual gearbox with bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.1 Checking gear oil level in manual gearbox with bevel box and filling up. . . . . . . . . . . . . . . 115
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.1 Gearbox - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.2 Gearbox - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.3 Dismantling and assembling gearbox housing and selector mechanism - gearboxes to
approx. 04.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.4 Removing and installing input shaft, output shafts (pinion shafts), differential, bevel box and
selector rods - gearboxes to approx. 04.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.5 Dismantling and assembling gearbox housing, selector mechanism, input shaft, output shafts
(pinion shafts), differential, bevel box and selector rods - gearboxes to approx. 04.2003 . . 122
5.6 Removing and installing gearbox housing and selector mechanism - gearboxes from approx.
04.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.7 Dismantling and assembling input shaft, output shafts (pinion shafts), differential, bevel box
and selector rods - gearboxes from approx. 04.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.8 Dismantling and assembling gearbox housing, selector mechanism, input shaft, output shafts
(pinion shafts), differential, bevel box and selector rods - gearboxes from approx. 04.2003
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6 Servicing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.1 Dismantling and assembling gearbox housing - gearboxes to approx. 04.2003 . . . . . . . . 142
6.2 Servicing gearbox housing - gearboxes from approx. 04.2003 . . . . . . . . . . . . . . . . . . . . . . 147
7 Servicing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.1 Dismantling and assembling clutch housing - gearboxes to approx. 04.2003 . . . . . . . . . . 156
7.2 Servicing clutch housing - gearboxes from approx. 04.2003 . . . . . . . . . . . . . . . . . . . . . . . . 160
8 Servicing selector mechanism in gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.1 Dismantling and assembling selector mechanism in gearbox - gearboxes to approx.
04.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.2 Dismantling and assembling selector mechanism in gearbox - gearboxes from approx.
04.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
9 Servicing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
9.1 Dismantling and assembling selector forks - gearboxes to approx. 04.2003 . . . . . . . . . . . . 170
9.2 Servicing selector forks - gearboxes from approx. 04.2003 . . . . . . . . . . . . . . . . . . . . . . . . 172
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1 Servicing input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.1 Dismantling and assembling input shaft - gearboxes to approx. 04.2003 . . . . . . . . . . . . . . 175
1.2 Adjusting input shaft - gearboxes to approx. 04.2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.3 Dismantling and assembling input shaft - gearboxes from approx. 04.2003 . . . . . . . . . . . . 186
2 Servicing output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.1 Dismantling and assembling output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . 191
2.2 Adjusting output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3 Servicing output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gear . . . . . . . . . . . . . . 208
3.2 Adjusting output shaft for 5th, 6th and reverse gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
1 Renewing oil seals and needle bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
1.1 Renewing flange shaft oil seal (left-side) - vehicles with 4-cylinder engine . . . . . . . . . . . . 226
1.2 Renewing flange shaft oil seal (left-side) - vehicles with 6-cylinder engine . . . . . . . . . . . . 228
1.3 Renewing flange shaft oil seal (right-side) - vehicles with 4-cylinder engine . . . . . . . . . . . . 231
1.4 Renewing flange shaft oil seal (right-side) - vehicles with 6-cylinder engine . . . . . . . . . . . . 235
1.5 Renewing oil seal for bevel box output flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.6 Renewing needle bearings (polygon bearings) for flange shaft (right-side) - vehicles with 4-
cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
ii Contents
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
1.7 Renewing needle bearings (polygon bearings) for flange shaft (right-side) - vehicles with 6-
cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
2 Servicing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.2 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Contents iii
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
iv Contents
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
00 – Technical data
1 Gearbox identification
♦ The manual gearbox 02M/02Y, four-wheel drive is installed in
the Audi TT 1999 ▸ as 5/6-speed gearbox. Allocation
⇒ page 2 .
♦ The components of manual gearbox 02M, four-wheel drive
and 02Y, four-wheel drive are the same.
Location on gearbox
♦ Code letters and date of manufacture of gearbox -arrow 1-
♦ Manual gearbox 02M/O2Y, four-wheel drive -arrow 2-
Audi TT 1999 ➤
Manual gearbox 02M, four-wheel drive -arrow 2-
Code letters and date of manufacture of gearbox -arrow 1-
Example: DQB 15 10 8
Additional data are production-related.
Note
Code letters Day Month Year “1998” of
manufacture
The code letters of the gearbox are also given on the vehicle data
stickers.
1. Gearbox identification 1
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
2 Code letters, allocation, transmission ratios, capacities
Manual gearbox 5/6-speed 02M, four-wheel drive
Gearbox Code letters DQB DXW EFY
Allocation Model Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
Ratios Final drive I
Z2 : Z
1
Capacity 2.6 litres
Specification ⇒ Parts catalogue
Clutch actuation Hydraulic
Clutch plate ∅ 240 mm 240 mm 240 mm
Drive shaft flange ∅ 108 mm 108 mm 108 mm
Overall ratio i
Allocation: rear final drive Designation 02D ⇒ Parts catalogue
Manufac‐
tured
from
to
09.00
02.01
09.0
01.01
09.00
02.01
Engine 1.8 ltr. - 165 kW 1.8 ltr. - 132 kW 1.8 ltr. - 132 kW
63 : 15 = 4.200 63 : 15 = 4.200 63 : 15 = 4.200
for 1st to 4th gear
Final drive II
63 : 19 = 3.316 63 : 19 = 3.316 63 : 19 = 3.316
for 5th/6th gear and
reverse gear
1st gear 41 : 12 = 3.417 42 : 11 = 3.818 41 : 12 = 3.417
2nd gear 40 : 19 = 2.105 40 : 19 = 2.105 40 : 19 = 2.105
3rd gear 40 : 28 = 1.429 39 : 29 = 1.345 40 : 27 = 1.481
4th gear 37 : 34 = 1.088 35 : 36 = 0.972 38 : 33 = 1.152
5th gear 34 : 31 = 1.097 32 : 33 = 0.970 35 : 30 = 1.167
6th gear 31 : 34 = 0.912 – 32 : 33 = 0.970
Reverse gear 30 : 12 x 23 : 14 =
4.108
in top gear 3.023 3.215 3.215
ov.
31 : 11 x 23 : 14 =
4.630
30 : 12 x 23 : 14 =
4.108
Manual gearbox 5/6-speed 02M, four-wheel drive
Gearbox Code letters FHA FHB FHC
Allocation Model Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
Ratios Final drive I
Manufac‐
tured
from
to
02.01
04.02
08.01
04.02
02.01
04.02
Engine 1.8 ltr. - 132 kW 1.8 ltr. - 165 kW 1.8 ltr. - 132 kW
63 : 15 = 4.200 63 : 15 = 4.200 63 : 15 = 4.200
for 1st to 4th gear
Z2 : Z
1
Final drive II
63 : 19 = 3.316 63 : 19 = 3.316 63 : 19 = 3.316
for 5th/6th gear and
reverse gear
1st gear 41 : 12 = 3.417 41 : 12 = 3.417 42 : 11 = 3.818
2nd gear 40 : 19 = 2.105 40 : 19 = 2.105 40 : 19 = 2.105
3rd gear 40 : 27 = 1.481 40 : 28 = 1.429 39 : 29 = 1.345
4th gear 38 : 33 = 1.152 37 : 34 = 1.088 35 : 36 = 0.972
5th gear 35 : 30 = 1.167 34 : 31 = 1.097 32 : 33 = 0.970
6th gear 32 : 33 = 0.970 31 : 34 = 0.912 –
Reverse gear 30 : 12 x 23 : 14 =
4.108
30 : 12 x 23 : 14 =
4.108
31 : 11 x 23 : 14 =
4.630
Capacity 2.6 litres
2 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.
Audi TT 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
Manual gearbox 5/6-speed 02M, four-wheel drive
Specification ⇒ Parts catalogue
Clutch actuation Hydraulic
Clutch plate ∅ 240 mm 240 mm 240 mm
Drive shaft flange ∅ 108 mm 108 mm 108 mm
Overall ratio i
in top gear 3.215 3.023 3.215
ov.
Allocation: rear final drive Designation 02D ⇒ Parts catalogue
Manual gearbox 5/6-speed 02Y, four-wheel drive
Gearbox Code letters FMN FMR FMT
Manufac‐
tured
from
to
09.02
04.03
05.02
08.02
05.02
08.02
Allocation Model Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
Ratios Final drive I
Engine 1.8 ltr. -165 kW 1.8 ltr. - 132 kW 1.8 ltr. - 132 kW
72 : 17 = 4.235 72 : 17 = 4.235 72 : 17 = 4.235
for 1st to 4th gear
Z2 : Z
1
Final drive II
72 : 22 = 3.273 72 : 22 = 3.273 72 : 22 = 3.273
for 5th/6th gear and
reverse gear
1st gear 47 : 14 = 3.357 49 : 13 = 3.769 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469 45 : 34 = 1.324 47 : 32 = 1.469
4th gear 45 : 41 = 1.098 42 : 43 = 0.977 46 : 40 = 1.150
5th gear 41 : 37 = 1.108 39 : 40 = 0.975 43 : 36 = 1.194
6th gear 38 : 41 = 0.927 – 39 : 40 = 0.975
Reverse gear 23 : 14 x 34 : 14 =
3.990
23 : 14 x 36 : 13 =
4.549
23 : 14 x 34 : 14 =
3.990
Capacity 2.6 litres
Specification ⇒ Parts catalogue
Clutch actuation Hydraulic
Clutch plate ∅ 240 mm 240 mm 240 mm
Drive shaft flange ∅ 108 mm 108 mm 108 mm
Overall ratio i
in top gear 3.033 3.191 3.191
ov.
Allocation: rear final drive Designation 02D ⇒ Parts catalogue
Manual gearbox 5/6-speed 02Y, four-wheel drive
Gearbox Code letters FZL FZP GQT
Manufac‐
tured
from
to
04.03 04.03 01.04
Allocation Model Audi TT 1999 ▸ Audi TT 1999 ▸ Audi TT 1999 ▸
Ratios Final drive I
Engine 1.8 ltr. - 165 kW 1.8 ltr. - 132 kW 3.2 ltr. - 184 kW
72 : 17 = 4.235 72 : 17 = 4.235 72 : 17 = 4.235
for 1st to 4th gear
Z2 : Z
1
Final drive II
for 5th/6th gear and
reverse gear
72 : 22 = 3.273 72 : 22 = 3.273 72 : 22 = 3.273
1st gear 47 : 14 = 3.357 47 : 14 = 3.357 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087 48 : 23 = 2.087
2. Code letters, allocation, transmission ratios, 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 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
Manual gearbox 5/6-speed 02Y, four-wheel drive
3rd gear 47 : 32 = 1.469 47 : 32 = 1.469 47 : 32 = 1.469
4th gear 45 : 41 = 1.098 46 : 40 = 1.150 37 : 34 = 1.088
5th gear 41 : 37 = 1.108 43 : 36 = 1.194 41 : 37 = 1.108
6th gear 38 : 41 = 0.927 39 : 40 = 0.975 31 : 34 = 0.912
Reverse gear 23 : 14 x 34 : 14 =
3.990
23 : 14 x 34 : 14 =
3.990
23 : 14 x 34 : 14 =
3.990
Capacity 2.6 litres
Specification ⇒ Parts catalogue
Clutch actuation Hydraulic
Clutch plate ∅ 240 mm 240 mm 240 mm
Drive shaft flange ∅ 108 mm 108 mm 108 mm
Overall ratio i
in top gear 3.033 3.191 2.984
ov.
Allocation: rear final drive Designation 02D ⇒ Parts catalogue
Manual gearbox 5/6-speed 02Y, four-wheel drive
Gearbox Code letters GQV
Manufac‐
tured
from
to
01.04
Allocation Model Audi TT 1999 ▸
Ratios Final drive I
Z2 : Z
1
Engine 3.2 ltr. - 184 kW
for 1st to 4th gear
Final drive II
72 : 17 = 4.235
72 : 22 = 3.273
for 5th/6th gear and
reverse gear
1st gear 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469
4th gear 37 : 34 = 1.088
5th gear 41 : 37 = 1.108
6th gear 31 : 34 = 0.912
Reverse gear 23 : 14 x 34 : 14 =
3.990
Capacity 2.6 litres
Specification ⇒ Parts catalogue
Clutch actuation Hydraulic
Clutch plate ∅ 240 mm
Drive shaft flange ∅ 108 mm
Overall ratio i
in top gear 2.984
ov.
Allocation: rear final drive Designation 02D ⇒ Parts catalogue
2.1 Calculating ratio “i”
Example:
6th gear Final drive
Drive gear ZG1 = 34 ZA1 = 19
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.
Audi TT 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
6th gear Final drive
Driven gear ZG2 = 31 ZA2 = 63
i = Z2 : Z1 (Z1 = number of teeth on drive gear, Z2 = number of
teeth on driven gear)
iG = gear ratio = ZG2 : ZG1 = 31 : 34 = 0.912
iA = axle ratio = ZA2 : ZA1 = 63 : 19 = 3.316
iov = overall ratio = iG x iA = 0.912 x 3.316 = 3.023
2. Code letters, allocation, transmission ratios, capacities 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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
3 Transmission layout
Note
Arrows point in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 5th/6th/re‐
verse gear (pinion shaft II)
6 - Output shaft for 1st-4th gear
(pinion shaft I)
7 - Differential
8 - Bevel box
9 - Propshaft
10 - Haldex coupling
11 - Rear final drive
12 - Differential
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
T - Speedometer drive
W1 - Front bevel gears
W2 - Rear bevel gears
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
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.
4.1 Contact corrosion
♦ The housing of the manual gearbox in the Audi TT is made of
a magnesium alloy.
♦ Bolts and other components which are in direct contact with
the gearbox casing are surface treated for compatibility with
magnesium.
♦ If the incorrect components are used (bolts, nuts, washers
etc.), this will cause contact corrosion. The gearbox housing
will be damaged.
♦ If you are not sure whether used parts can be re-installed, al‐
ways fit new parts.
Audi TT 1999 ➤
Caution
♦ Only use Genuine Audi parts.
♦ Damage resulting from contact corrosion is not covered
by the warranty.
4.2 Special tools
For a complete list of special tools used in this Workshop Manual
⇒ Special tools, Workshop equipment .
4.3 Components
Gearbox
♦ When installing, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ When assembling mounting brackets as well as other waxed
components, the contact surfaces must be cleaned. The con‐
tact surfaces must be free of wax and grease.
♦ When installing a new gearbox or bevel box fill with gear oil.
♦ Capacities and specifications ⇒ page 2 .
O-rings, oil seals, gaskets
♦ Always install new 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.
♦ Clean joints thoroughly and apply sealant -AMV 188 200 03- .
♦ Apply sealant evenly and not too thickly.
Before installing:
4. General repair instructions 7
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
♦ Lightly oil the outer circumference of oil seals and fill the space
between the sealing lips -arrow- about 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 sealing lip does not contact the shaft in the same place
as the old seal (make use of insertion depth tolerances).
After installation:
♦ Check gear oil level in manual gearbox with bevel box
⇒ page 115 .
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
Locking elements
♦ 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
♦ Nuts and bolts for securing covers and housings must be
slackened and tightened in diagonal sequence.
♦ Parts which are particularly sensitive (e.g. clutch pressure
plates) must be kept straight. Slacken and tighten them in
stages and in diagonal sequence.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Always renew self-locking bolts and nuts.
♦ For all threaded connections, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with
wax until after assembly is completed.
Bearings
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Lubricate all bearings (except tapered roller bearings) with
gear oil before installing in gearbox.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er as a set and use new bearings from a single manufacturer.
♦ Heat inner races of tapered roller bearings to approx. 100°C
before installing. Press in 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).
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
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.
Synchroniser rings
♦ Do not interchange. When reusing synchroniser rings, always
fit to the same gear wheel.
♦ Check for wear; renew if necessary.
♦ Lubricate with gear oil before installing.
Gear wheels
♦ Before installing, clean and heat on a hotplate to approx. 100°
C.
♦ The temperature can be checked with Temperature tester -
V.A.G 1558- .
Audi TT 1999 ➤
4. General repair instructions 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
Selector gears
♦ After installing, check 1st to 6th speed selector gears for min‐
imal axial play and freedom of movement.
Clutch actuation
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts in a diagonal sequence and in several gradual
stages.
♦ 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.
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
30 – Clutch
1 Servicing clutch mechanism
I - Pedal cluster - exploded
view of components
⇒ page 12
II - Hydraulics - exploded view
of components ⇒ page 16
Note
♦
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 ➤
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
1.1 Pedal cluster - exploded view of components
1 - Cross panel
❑ 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 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Renew
7 - Connecting plate
8 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Renew
9 - Mounting bush
10 - Pivot pin
11 - Clutch pedal
❑ Removing and installing
⇒ page 15
12 - Retaining clip
❑ Removing and installing
⇒ Item 4 (page 16)
13 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Renew
14 - Clutch master cylinder
❑ Removing and installing ⇒ page 18
15 - Supply hose
16 - Over-centre spring
❑ Removing and installing ⇒ page 14
17 - Mounting for over-centre spring
❑ Install in mounting bracket
❑ When renewing: remove and install clutch master cylinder ⇒ page 18
18 - Clutch pedal switch -F36-
❑ Removing and installing
⇒ “1.2 Removing and installing clutch pedal switch F36 (square housing)”, page 13 or
⇒ “1.3 Removing and installing clutch pedal switch F36 (round housing)”, page 13
19 - Stop for clutch pedal
❑ Installation position ⇒ page 20
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
20 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Renew
1.2 Removing and installing clutch pedal switch -F36- (square housing)
Note
Switch may only be fitted once so as to ensure a firm fit.
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.
Audi TT 1999 ➤
Installing
Installation is carried out in reverse sequence; note the following:
– Pull operating rod of clutch pedal switch out onto stop.
– Push clutch pedal down by hand.
– Insert switch in mounting hole and secure by turning clockwise
through 90° -arrows-.
– Release clutch pedal
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. Gr. 68 .
1.3 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.
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 in anti-clockwise di‐
rection through 45°.
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
Installing
Installation is carried out in reverse sequence; note the following:
– Pull out operating rod -arrow- all the way before installing
clutch pedal switch.
• The clutch pedal should be in the normal position (i.e. not
pressed down).
– Guide clutch pedal switch through mounting hole, press oper‐
ating rod against clutch pedal and attach switch by turning 45°
clockwise.
– Install storage compartment on driver's side ⇒ General body
repairs, interior; Rep. Gr. 68 .
1.4 Removing and installing over-centre
spring
Special tools and workshop equipment required
♦ Assembly clip -3317-
Removing
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. Gr. 68 .
– Press down clutch pedal to compress the over-centre spring
and fit assembly clip -3317- from the top onto over-centre
spring.
• The drilling -arrow- faces towards clutch pedal.
– Return clutch pedal to normal position and remove over-centre
spring together with assembly clip -3317- .
Installing
– Pull clutch pedal into passenger compartment.
– Insert over-centre spring into rear mounting -arrow B- first,
then operate clutch pedal until the assembly clip -3317- seats
against the mounting lug -arrow A- of the clutch pedal.
–
– Return clutch pedal to normal position and remove assembly
clip -3317- .
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
1.5 Removing and installing clutch pedal
Removing
– Remove over-centre spring ⇒ page 14 .
– Remove clutch pedal switch
⇒ “1.2 Removing and installing clutch pedal switch F36
(square housing)”, page 13 or
⇒ “1.3 Removing and installing clutch pedal switch F36 (round
housing)”, page 13 .
– Separate clutch pedal from master cylinder ⇒ page 18 and
push operating rod towards bulkhead onto stop.
– Remove nut -A-.
– Pull bolt out until the clutch pedal can be removed.
Installing
Installation is carried out in reverse sequence; note the following:
– Install over-centre spring ⇒ page 14 .
• The retaining clip -A- must be fitted on the master cylinder op‐
erating rod -B-.
– Press clutch pedal in direction of -arrow- to engage. Ensure
that pedal is correctly located.
– Install clutch pedal switch
⇒ “1.2 Removing and installing clutch pedal switch F36
(square housing)”, page 13 or
⇒ “1.3 Removing and installing clutch pedal switch F36 (round
housing)”, page 13 .
Audi TT 1999 ➤
1. Servicing clutch mechanism 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 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
1.6 Hydraulics - exploded view of components
1 - Brake fluid reservoir
2 - Supply hose
3 - Clutch master cylinder
❑ Removing and installing
⇒ page 18
4 - Retaining clip
❑ Only renew when clutch
master cylinder has
been removed
❑ Lever off to remove
⇒ page 17
❑ Pressing on
⇒ page 17
5 - Clutch pedal
❑ Removing and installing
⇒ page 15
6 - Hexagon nut, 25 Nm
❑ 2 x
❑ Self-locking
❑ Renew
7 - Seal/O-ring
❑ Renew; for correct ver‐
sion refer to ⇒ Parts
catalogue
❑ Whether a seal or an O-
ring is used depends on
the type of connection
⇒ page 17 .
❑ Lubricate with brake flu‐
id before installing
❑ Push onto pipe connec‐
tion
8 - Pipe/hose assembly
❑ With frequency modulator
❑ Disconnecting from clutch master cylinder and installing ⇒ page 19
❑ Disconnecting from clutch slave cylinder ⇒ page 62
❑ For correct version refer to ⇒ Parts catalogue
9 - Retainer
❑ Attached to body
10 - Seal/O-ring
❑ Renew; for correct version refer to ⇒ Parts catalogue
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 17 .
❑ Lubricate with brake fluid before installing
❑ Push onto pipe connection
11 - Bleeder connection
12 - Seal/O-ring
❑ Renew; for correct version refer to ⇒ Parts catalogue
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 17 .
❑ Lubricate with brake fluid before installing
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
❑ Push onto pipe connection
13 - Clip
❑ To remove pipe, pull out clip as far as limit stop ⇒ page 19
14 - Bleeder valve
❑ Bleeding clutch system ⇒ page 21
15 - Dust cap
16 - Clip
❑ To remove pipe, pull out clip as far as limit stop ⇒ page 19
17 - Clutch slave cylinder (release bearing with hydraulic actuator)
❑ Can only be removed after removing gearbox
❑ Removing and installing ⇒ page 21
18 - Clip
❑ To remove pipe, pull out clip as far as limit stop ⇒ page 19
Levering off retaining clip
– Lever retaining clip -A- off in direction of -arrow- using pliers.
Audi TT 1999 ➤
Pressing master cylinder operating rod into retaining clip
– Press master cylinder operating rod into retaining clip -A-
-arrow-.
Seals/O-rings for pipe/hose assemblies
1 - For metal pipe/hose assemblies
2 - For synthetic pipe/hose assemblies
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
1.7 Removing and installing clutch master cylinder
Special tools and workshop equipment required
♦ Pliers -T10005-
Removing
– Remove cover panel (front left) -arrows-.
Vehicles with 4-cylinder engine:
– Detach air intake hose at throttle valve module -J338- (slacken
hose clip -4-).
– Unplug electrical connector for air mass meter -G70- -1-.
– If fitted, detach hose -5- from air cleaner housing.
– Remove bolts -2- and -3-.
– Take out air cleaner housing.
Vehicles with 6-cylinder engine:
– Detach air intake hose -2- at throttle valve module -J338- .
– Unplug electrical connector for air mass meter -G70- -3-.
– Remove bolts -1- and -4-.
– Move electrical wire -arrow- clear.
– Take out air cleaner housing.
18 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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
All models:
– Pull off supply hose -A- going to brake fluid reservoir and seal.
– Pull out clip -B- for pipe/hose assembly.
– Pull pipe/hose assembly -C- out from master cylinder and seal.
– Remove storage compartment on driver's side ⇒ General
body repairs, interior; Rep. Gr. 68 .
– Remove clutch pedal switch
⇒ “1.2 Removing and installing clutch pedal switch F36
(square housing)”, page 13 or
⇒ “1.3 Removing and installing clutch pedal switch F36 (round
housing)”, page 13 .
– Pull clutch pedal lightly towards the passenger compartment
to separate master cylinder operating rod from clutch pedal
and press both sides of retaining clip inwards -arrows- using
pliers -T10005- .
Audi TT 1999 ➤
– Remove connecting plate -A- -arrows 1-.
– Remove nuts -arrows 2- and take off mounting bracket -B-.
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
– Turn stop -A- for clutch pedal in direction of -arrow- and re‐
move.
– Then push master cylinder in the direction of -arrow 1- onto
stop.
• It must not be covered in upper area by over-centre spring
mounting -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:
• The retaining clip -A- must be fitted on the master cylinder op‐
erating rod -B-.
– Press clutch pedal in direction of -arrow- to engage. Ensure
that pedal is correctly located.
– Fit stop -A- for clutch pedal again.
• Installation position: the angled tabs -arrow- point towards the
master cylinder -B-.
– Install clutch pedal switch
⇒ “1.2 Removing and installing clutch pedal switch F36
(square housing)”, page 13 or
⇒ “1.3 Removing and installing clutch pedal switch F36 (round
housing)”, page 13 .
– Bleed clutch system ⇒ page 21 .
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.
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
1.8 Removing and installing clutch slave cylinder (release bearing with hydraulic actuator)
Note
Slave cylinder and release bearing are one unit and can only be
renewed together.
Removing
– Remove gearbox
⇒ “2.1 Removing gearbox - vehicles with 4-cylinder engine”,
page 56 or
⇒ “2.3 Removing gearbox - vehicles with 6-cylinder engine”,
page 75 .
– Remove bolts -arrows-.
– Pull out release bearing -A- together with clutch slave cylinder.
Installing
Installation is carried out in reverse sequence; note the following:
– Install gearbox
⇒ “2.2 Installing gearbox - vehicles with 4-cylinder engine”,
page 67 or
⇒ “2.4 Installing gearbox - vehicles with 6-cylinder engine”,
page 87 .
– Bleed clutch system ⇒ page 21 .
Tightening torque
Audi TT 1999 ➤
Component Nm
Clutch slave cylinder to gearbox 12
1.9 Bleeding clutch system
Special tools and workshop equipment required
♦ Brake charge and bleed equipment -VAS 5234-
Brake fluid specification ⇒ Brake system; Rep. Gr. 47 .
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 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
Procedure
Note
♦
The clutch system must be bled after performing work on the
hydraulic clutch mechanism.
♦
It is not necessary to prefill the system.
♦
When performing the following steps, make sure that no brake
fluid escapes onto the gearbox.
– Pull clutch pedal back to its normal rest position.
– Connect brake charge and bleed equipment -VAS 5234- to
brake fluid reservoir (do not switch on at this stage).
– If necessary, use bleed hose -V.A.G 1238 B/3- (670 mm) to
bleed system.
– Connect bleed hose to collector bottle of brake charge and
bleed equipment -VAS 5234- .
– Connect bleed hose -V.A.G 1238 B/3- to bleeder valve
-arrow-.
Note
Ensure that bleed hose is correctly fitted during bleeding opera‐
tion.
– Open bleeder valve -arrow-.
– Switch on bleeding equipment.
• Operating pressure 2.0 bar
–
Bleed off about 100 cm3 of brake fluid.
– Close bleeder valve.
– Rapidly operate clutch pedal from stop to stop 15 times.
–
Bleed off an additional 50 cm3 of brake fluid.
– Close bleeder valve. Tightening torque 4.5 Nm.
– Depress clutch pedal several times after bleeding process is
completed.
– Bleed system once again if necessary.
– Remove bleed hose and fit protective cap.
– Remove brake charge and bleed equipment -VAS 5234- from
brake fluid reservoir.
22 Rep. Gr.30 - Clutch
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
2 Servicing clutch release mechanism
2.1 Clutch release mechanism - exploded view of components
1 - Gearbox
2 - Oil seal
❑ For input shaft
❑ Renewing ⇒ page 23
3 - Release bearing with hy‐
draulic actuator
❑ One unit; can only re re‐
newed together
❑ Do not wash out bear‐
ing; wipe clean only
❑ Renew complete re‐
lease bearing with hy‐
draulic actuator if noises
occur.
❑ Removing and installing
⇒ page 21
4 - Bolt, 12 Nm
❑ 3 x
❑ For correct version
check engine code and
refer to ⇒ Parts cata‐
logue
5 - Seal/O-ring
❑ Renew; for correct ver‐
sion refer to ⇒ Parts
catalogue
❑ Whether a seal or an O-
ring is used depends on
the type of connection
⇒ page 17 .
❑ Lubricate with brake flu‐
id before installing
❑ Push onto pipe connec‐
tion
2.2 Renewing input shaft oil seal
Special tools and workshop equipment required
2. Servicing clutch release mechanism 23
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
5/6-speed manual gearbox 02M/02Y, four-wheel drive - Edition 12.2004
♦ Thrust piece -T40008-
Procedure
– Prise out input shaft oil seal carefully using a screwdriver.
Note
Take care not to damage contact surface for oil seal on input
shaft.
– Drive in new oil seal with thrust piece -T40008- as far as the
stop.
– Pack space between sealing lip and dust lip half-full with seal‐
ing grease -G 052 128 A1- .
24 Rep. Gr.30 - Clutch
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