Audi TT 60 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive
Edition 05.2008
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 - 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 A005TT02520
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Overview - clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 10
2.1 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 10
3 Exploded view - pedal cluster, clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Exploded view - hydraulic system (LHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Removing and installing pipe/hose assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Exploded view - hydraulic system (RHD vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Exploded view - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 Overview - servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1 Clutch identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2 Exploded view - Sachs version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.3 Removing and installing clutch (Sachs version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4 Exploded view - LuK version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.5 Removing and installing clutch (LuK version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 Gear knob and covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2 Removing and installing gear knob with gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.3 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.4 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.6 Exploded view - gear selector cable, gate selector cable and gearbox selector lever . . . . 62
1.7 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 66
1.8 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine . . . . . . . . . . . . . . . . 72
2.2 Installing gearbox on vehicles with 1.8 ltr. FSI turbocharged engine . . . . . . . . . . . . . . . . . . 81
2.3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.2 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4 Checking gear oil level and filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.2 Draining off gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.3 Filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Contents i
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
5 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.1 Exploded view - dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2 Exploded view - removing and installing gearbox housing cover and 5th/6th gear . . . . . . 100
5.3 Exploded view - removing and installing gearbox housing and selector mechanism . . . . . . 103
5.4 Exploded view - removing and installing input shaft, output shaft (pinion shaft), differential
and selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.5 Dismantling and assembling sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6 Exploded view - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.1 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7 Exploded view - gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.1 Servicing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8 Exploded view - servicing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.1 Dismantling and assembling selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9 Exploded view - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.1 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3 Exploded view - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5 Exploded view - reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.1 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.1 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.2 Renewing flange shaft oil seal and sleeve (right-side; one-piece oil seal and sleeve) . . . . 175
2 Exploded view - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
00 – Technical data
1 Gearbox identification
• ⇒ “1.1 Code letters, allocation, transmission ratios, capaci‐
ties”, page 1
Location on gearbox
♦ Code letters and date of manufacture -arrow 1-
♦ Manual gearbox 02S -arrow 2-
Manual gearbox 02S -arrow 2-
Audi TT 2007 ➤
Code letters and date of manufacture of gearbox
Example: GLB 18 07 3
Additional data are production-related.
Note
I I I I
Code letters Day Month Year (2003) of
manufacture
The code letters for the gearbox are also given on the vehicle data
stickers.
1.1 Code letters, allocation, transmission ratios, capacities
Manual gearbox 6-speed 02S
to
JWX KVT
Code letters
Manufactured from 02.08 05.08
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸
Ratio Final drive 62 : 17 = 3.647 62 : 17 = 3.647
Z2 : Z1 = i
Engine 1.8 ltr. - 118 kW TFSI 1.8 ltr. - 118 kW TFSI
1st gear 34 : 9 = 3.778 34 : 9 = 3.778
1. Gearbox identification 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Manual gearbox 6-speed 02S
Overall ratio i
in top gear 2.644 2.644
ov.
2nd gear 33 : 16 = 2.063 33 : 16 = 2.063
3rd gear 32 : 22 = 1.455 32 : 22 = 1.455
4th gear 31 : 28 = 1.107 31 : 28 = 1.107
5th gear 28 : 32 = 0.875 28 : 32 = 0.875
6th gear 29 : 40 = 0.725 29 : 40 = 0.725
Reverse gear 36 : 20 x 18 : 9 = 3.600 36 : 20 x 18 : 9 = 3.600
Capacity 2.1 litres
Clutch actuation Hydraulic
The following data can be found in the ⇒ Electronic parts catalogue .
♦ Gear oil specification
♦ Allocation of drive shaft flanges
♦ Allocation of clutch type
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
2 Transmission layout
Note
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft (main shaft)
5 - Output shaft / pinion shaft
6 - 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
Audi TT 2007 ➤
2. Transmission layout 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
3 Calculating ratio “i”
Example:
6th gear Final drive
Drive gear ZG1 = 38 ZA1 = 17
Driven gear ZG2 = 31 ZA2 = 62
i = Z2 : Z1
1)
iG = gear ratio = ZG2 : ZG1 = 31 : 38 = 0.816
iA = axle ratio = ZA2 : ZA1 = 62 : 17 = 3.647
iov = overall ratio
iov = iG x iA = 0.816 x 3.647 = 2.975
1) Z1 = No. of teeth on drive gear, Z2 = No. of teeth on driven gear
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
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 .
Gearbox
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing, ensure that the dowel sleeves between the
engine and gearbox are correctly located.
♦ For allocation of bolts and other components, refer to ⇒ Elec‐
tronic parts catalogue .
♦ Clean contact surfaces when assembling mounting brackets
and waxed components. The contact surfaces must be free of
wax and grease.
♦ After installing a replacement gearbox, check oil level and top
up with gear oil as required ⇒ page 95 .
♦ Capacities and specifications ⇒ page 1
Sealants
♦ Thoroughly clean joint surfaces on gearbox housing etc. be‐
fore applying sealing paste.
♦ Apply sealing paste -AMV 188 200 03- evenly and not too
thick.
♦ Breather holes must remain free of sealing paste.
Oil seals, seals, O-rings and gaskets
♦ Always renew seals, O-rings 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.
♦ 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 seal should face the side containing
the fluid.
♦ 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 installation depth toleran‐
ces).
♦ Lightly lubricate O-rings with oil before installation to prevent
them being trapped during assembly.
♦ Check oil level after installing new gaskets, O-rings and oil
seals ⇒ page 95 .
Audi TT 2007 ➤
4. General repair instructions 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
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
♦ 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.
♦ Renew self-locking nuts and bolts.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ 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.
♦ 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.
♦ Use inductive heater -VAS 6414- to heat inner races of tapered
roller bearings to approx. 100°C before installing. Press home
onto stop when installing so there is no axial clearance.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ If required, renew the tapered roller bearings on one shaft to‐
gether and use new bearings from a single manufacturer.
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
Shims
♦ Use a micrometer to measure the shims at several points.
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
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
♦ Do not interchange synchro-rings. When reusing always fit to
the same gear.
♦ 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”, “visible traces of wear” and
“blue discolouration (caused by overheating)”.
♦ Check chamfer on selector gear for scoring and visible traces
of wear.
♦ Lubricate with gear oil before installing.
Gear wheels
♦ Clean before pressing on.
♦ Use inductive heater -VAS 6414- to heat to approx. 100°C be‐
fore installing. Press home onto stop when installing so there
is no axial clearance.
Selector gears and locking collars
♦ After installing, check 1st to 6th speed selector gears for min‐
imal axial play and freedom of movement.
Audi TT 2007 ➤
♦ Abnormal wear on synchro-ring or selector gear:
A - Worn ends of dog teeth on synchro-ring or selector gear.
♦ In comparison: intact synchro-ring or selector gear:
B - Intact ends of dog teeth on synchro-ring or selector gear.
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 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
♦ Abnormal wear on locking collar:
C - Worn ends of internal splines on locking collar.
♦ In comparison: intact locking collar:
D - Intact ends of internal splines on locking collar.
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.
♦ 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.
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
30 – Clutch
1 Overview - clutch mechanism
Note
If you suspect that a clutch master cylinder or clutch slave cylinder
is defective, observe and perform the following prior to renewing.
♦ ⇒ “2 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 10
♦ ⇒ “2.1 Function check for clutch master cylinder and slave
cylinder”, page 10
I -
⇒ “3 Exploded view - pedal
cluster, clutch master cylin‐
der”, page 12
⇒ “3.1 Removing and installing
over-centre spring”, page 13
Audi TT 2007 ➤
⇒ “3.2 Removing and installing
clutch pedal”, page 15
⇒ “3.3 Removing and installing
mounting bracket”, page 18
⇒ “3.4 Removing and installing
clutch position sender G476 ”,
page 20
⇒ “3.5 Removing and installing
clutch master cylinder”,
page 21
II -
⇒ “4 Exploded view - hydraulic
system (LHD vehicles)”,
page 23
⇒ “4.1 Removing and installing
clutch slave cylinder”,
page 25
⇒ “4.3 Bleeding clutch sys‐
tem”, page 29
III -
⇒ “5 Exploded view - hydraulic
system (RHD vehicles)”,
page 31
1. Overview - clutch mechanism 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 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
2 Notes on removing and installing
clutch master cylinder and slave cyl‐
inder
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective you must first carry out
a function check
⇒ “2.1 Function check for clutch master cylinder and slave
cylinder”, page 10 .
♦ If slave cylinder is removed from gearbox with pipe/hose as‐
sembly still attached, make sure you do not press clutch pedal.
Otherwise, the piston will be pressed out of the slave cylinder
and be destroyed.
♦ After installing the slave cylinder, carefully press the clutch
pedal. If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down fur‐
ther. The plunger of the slave cylinder is likely to have been
guided past the clutch release lever. The slave cylinder would
then be destroyed once pedal force exceeds approx. 300 N.
2.1 Function check for clutch master cylin‐
der and slave cylinder
Before you renew the clutch master cylinder or slave cylinder you
must - in the case of the following faults - first carry out the ap‐
propriate checks.
Noises when operating the clutch:
♦ First check the over-centre spring / clutch pedal switch for
noise.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains depressed / does not
return to its initial position.
♦ Check whether the clutch pedal returns all the way to its initial
position, thereby uncovering the vent opening in the master
cylinder.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside.
♦ The vent opening must be uncovered, otherwise the perma‐
nent self-bleeding function for the hydraulic clutch system will
no longer be effective.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time. This could
impair the self-bleeding function of the clutch system as the
vent opening in the master cylinder can no longer function.
♦ The self-bleeding function of the clutch system can be im‐
paired if the footwell trim or floor mats get trapped, if the clutch
pedal switch jams or if the driver rests his foot on the clutch
pedal for long periods of time.
Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks
(visual inspection).
10 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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 29 .
Pedal forces:
♦ approx. 140 N for complete service life of the clutch
High pedal force:
♦ Mechanically defective pressure plate/clutch plate
⇒ page 35 .
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 29 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines
(due to corrosion or dirt, etc.)
♦ Foreign body in clutch system
♦ Mechanically defective pressure plate/clutch plate
⇒ page 35 .
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate or dowel
sleeves).
Audi TT 2007 ➤
2. Notes on removing and installing clutch master cylinder and slave cylinder 11
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
3 Exploded view - pedal cluster, clutch master cylinder
1 - Bulkhead
❑ With mounting for
mounting bracket
2 - Gasket
❑ Always renew
❑ Between mounting
bracket and bulkhead
❑ Self-adhesive
❑ Bond onto mounting
bracket
3 - Mounting bracket
❑ For clutch pedal
❑ Removing and installing
⇒ page 18
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 13
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 15
9 - Retaining clip
❑ For operating rod on
master cylinder
10 - Seal
❑ Always renew
❑ Between clutch master
cylinder and mounting
bracket
11 - Clutch master cylinder
❑ Removing and installing ⇒ page 21
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 20
❑ Can be checked in “Guided Fault Finding”, using vehicle diagnostic, testing and information system -
VAS 5051- .
13 - Retaining clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
14 - Supply hose
❑ To brake fluid reservoir
15 - Nut
❑ 20 Nm
❑ 3x
❑ For securing mounting bracket to bulkhead
❑ Self-locking
❑ Always renew
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
16 - Nut
❑ 25 Nm
❑ Self-locking
❑ Always renew
17 - Stop
❑ For clutch pedal
Crash bar - tightening torque
– Install crash bar -2- and tighten 1 or 2 bolts (depending on
version) -arrows B-.
• M6 10 Nm
• M8 20 Nm
Audi TT 2007 ➤
3.1 Removing and installing over-centre spring
Special tools and workshop equipment required
♦ Lever -T10178-
3. Exploded view - pedal cluster, clutch master cylinder 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Removing
• Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,
remove nut -2- and pull out bolt -5-.
Note
The clutch pedal does not have to be detached from the operating
rod on the clutch master cylinder.
– Pivot clutch pedal down slightly and and take over-centre
spring -4- out of mounting bracket.
Installing
• Tightening torques ⇒ page 12
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nut.
♦
Lubricate all bearings and contact surfaces with grease -G 000
450 02- .
– Fit over-centre spring -2- into mounting bracket from above
while holding end of spring in correct position with assembly
tool -T10178- .
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
• Socket -arrow- of over-centre spring must be in vertical posi‐
tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press clutch pedal slightly, push bolt through and tighten self-
locking nut.
– Install crash bar ⇒ page 13 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
3.2 Removing and installing clutch pedal
Special tools and workshop equipment required
♦ Pliers -T10005-
Audi TT 2007 ➤
♦ Lever -T10178-
3. Exploded view - pedal cluster, clutch master cylinder 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 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Removing
• Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,
remove nut -2- and pull out bolt -5-.
– Pivot clutch pedal forward slightly and and take over-centre
spring -4- out of mounting bracket.
– Release retaining clip for operating rod on clutch master cyl‐
inder using pliers -T10005- .
– Remove clutch pedal.
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Installing
• Tightening torques ⇒ page 12
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nut.
♦
Lubricate all bearings and contact surfaces with grease -G 000
450 02- .
– Fit retaining clip -2- on operating rod -1- for clutch master cyl‐
inder.
– Press retaining clip into mounting on clutch pedal so that it
snaps into place audibly.
– Fit over-centre spring -2- into mounting bracket from above
while holding end of spring in correct position with assembly
tool -T10178- .
Audi TT 2007 ➤
• Socket -arrow- of over-centre spring must be in vertical posi‐
tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press top of clutch pedal forwards against spring pressure of
over-centre spring, push through bolt and tighten self-locking
nut.
Note
It is easier to press the pedal against the spring if you pull back
the bottom of the pedal carefully as you bring the top of the pedal
into position.
– Install crash bar ⇒ page 13 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
3. Exploded view - pedal cluster, clutch master cylinder 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
3.3 Removing and installing mounting bracket
Special tools and workshop equipment required
♦ Hose clamps, up to Ø 25 mm -3094-
Hose clip pliers -VAS 6340-
Removing
Note
In the following steps make sure that no brake fluid escapes onto
the longitudinal member or onto the gearbox below. If this does
happen, clean the affected area thoroughly.
– Using hose clamp -3094- , clamp off supply hose to master
cylinder.
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
– Disconnect supply hose at clutch master cylinder (if necessa‐
ry, release spring-type clip -3- using hose clip pliers -VAS
6340- ).
– Release retaining clip -2- with a screwdriver and disconnect
pipe/hose assembly -1- from master cylinder.
– Unclip and detach clutch pedal position sender -G476- from
master cylinder -arrow-. Electrical connector -4- can remain
connected.
– Move driver's seat to rear as far as possible and move steering
wheel into uppermost position.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
Audi TT 2007 ➤
Note
When performing work in the footwell, put cloths on the carpet to
protect it from possible brake fluid spills.
– Remove nuts -2-.
– Take out mounting bracket -1-.
Installing
Installation is carried out in reverse sequence; note the following:
• Tightening torques ⇒ page 12
Note
♦
Renew self-locking nuts.
♦
Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Parts catalogue .
3. Exploded view - pedal cluster, clutch master cylinder 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 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
– Fit mounting bracket -1- and tighten nuts -2-. Tightening torque
⇒ Item 15 (page 12) .
– Connect pipe/hose assembly ⇒ page 25 .
– Bleed clutch system ⇒ page 29 .
– Install crash bar ⇒ page 13 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
3.4 Removing and installing clutch position sender -G476-
Removing
– Unplug electrical connector -4-.
– Unclip clutch position sender -G476- at clutch master cylinder
in direction of -arrow- and remove.
Note
Items -1 ... 3- can be disregarded.
Installing
Perform installation in reverse sequence of removal.
– Fit clutch position sender -G476- at clutch master cylinder and
engage -arrow-.
– Attach electrical connector -4-.
Note
Items -1 ... 3- can be disregarded.
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
3.5 Removing and installing clutch master cylinder
Special tools and workshop equipment required
♦ Pliers -T10005-
Removing
– Remove mounting bracket ⇒ page 18 .
– Release retaining clip for operating rod on clutch pedal using
pliers -T10005- .
Audi TT 2007 ➤
– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.
•
Length of spacer = approx. 40 mm (e.g. 1/2” socket)
– Release retaining clip -B- and pull clutch master cylinder out
of mounting bracket -arrows 1 and 2-.
3. Exploded view - pedal cluster, clutch master cylinder 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Installing
• Clutch pedal in “released” position.
– Install retaining clip -2- on operating rod -1- for clutch master
cylinder.
– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.
♦
Length of spacer = approx. 40 mm (e.g. 1/2” socket)
– Lock clutch master cylinder on mounting bracket
-arrows 1 and 2-.
– Press operating rod -1- for clutch master cylinder in direction
of -arrow- so that retaining clip -2- snaps into place in clutch
pedal.
– Install mounting bracket ⇒ page 18 .
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
4 Exploded view - hydraulic system (LHD vehicles)
1 - Brake fluid reservoir
2 - Hose clip (spring-type clip)
❑ Not fitted in all vehicles
3 - Supply hose
❑ Made of rubber or plas‐
tic, depending on ver‐
sion
❑ Plastic supply hose with
additional seals
⇒ page 24
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 21
5 - Clip
❑ To remove and install
pipe/hose assembly,
pull out clip as far as it
will go
6 - Retaining clip
❑ For operating rod for
clutch master cylinder
❑ To remove and install
retaining clip first detach
clutch master cylinder
from clutch pedal
⇒ page 15
7 - Clutch pedal
❑ Removing and installing
⇒ page 15
8 - Nut
❑ Tightening torque
⇒ Item 15 (page 12)
❑ Secures mounting bracket to body
❑ Always renew
9 - Seal or O-ring
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 24
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Renew damaged O-rings
❑ Push onto pipe connection
❑ Lubricate O-rings with brake fluid
10 - Pipe/hose assembly
❑ With frequency modulator
❑ Removing and installing ⇒ page 27
❑ Disconnecting from clutch master cylinder and slave cylinder ⇒ page 25
11 - Bracket
❑ For pipe/hose assembly ⇒ Item 10 (page 23)
❑ Secured on body
12 - Seal or O-ring
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 24
Audi TT 2007 ➤
4. Exploded view - hydraulic system (LHD vehicles) 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Renew damaged O-rings
❑ Push onto pipe connection
❑ Lubricate O-rings with brake fluid
13 - Clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
14 - Clutch slave cylinder
❑ Removing and installing ⇒ page 25
15 - Bolt
❑ 20 Nm
❑ 2x
16 - Bleeder valve
❑ 6 Nm
❑ Bleeding clutch system ⇒ page 29
17 - Dust cap
18 - Gearbox
19 - Bracket
❑ For pipe/hose assembly
20 - Bolt
❑ 20 Nm
Vehicles with plastic supply hose -1-
• Seals -2- must be fitted in supply hose.
Seal/O-ring for pipe/hose assembly
1 - O-ring
♦ Connection with annular groove -arrow 1-
♦ Check O-ring for damage and renew if necessary
2 - Seal
♦ Connection with shoulder -arrow 2-
♦ Position seal -2- onto connection -arrow 2- before fitting
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.
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Disconnecting/connecting pipe/hose assembly from/to clutch
master cylinder or clutch slave cylinder
– To remove, release clip -3- with a screwdriver and disconnect
pipe/hose assembly -1- from clutch master cylinder or clutch
slave cylinder -4-.
Installing
Note
Observe distinction between seals -2- and O-rings ⇒ page 24
– Press pipe/hose assembly -1- into connection on clutch slave
cylinder or clutch master cylinder -4- until clip -3- snaps into
place.
– Pull on pipe to check it is secure.
4.1 Removing and installing clutch slave cylinder
Audi TT 2007 ➤
Special tools and workshop equipment required
♦ -V.A.G 1331- Torque wrench
♦ Hose clamps, up to Ø 25 mm -3094-
4. Exploded view - hydraulic system (LHD vehicles) 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 2007 ➤
6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008
Removing
– Detach cable support bracket from gearbox -arrows-.
– Remove securing clip -1-.
– Pull gear selector cable -2- off pin.
– Pull locking mechanism forwards in direction of -arrow 1- onto
stop and then turn to left in direction of -arrow 2- to lock.
– Press relay lever forwards (in direction of -arrow 3-) and pull
out gate selector cable.
– Tie back gear selector cable and gate selector cable.
– Detach gearbox support -arrows A-.
– Remove clutch slave cylinder -arrows B-.
26 Rep. Gr.30 - Clutch
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