Audi TT 60 User Manual

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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.

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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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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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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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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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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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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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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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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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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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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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

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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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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

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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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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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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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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

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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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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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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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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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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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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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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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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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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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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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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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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Note

Make sure that no brake fluid escapes onto the gearbox. If this does happen, clean the affected area thoroughly.

– Place a lint-free cloth under the clutch slave cylinder.

– Using hose clamps, up to Ø 25 mm -3094- , clamp off pipe/

hose assembly to clutch master cylinder.

– Pull out clip -1- as far as it will go, move pipe/hose assembly

-2- clear at bracket and disconnect from clutch slave cylinder.

Caution

Do not operate clutch pedal after disconnecting pipe/hose as‐ sembly.

Installing

Installation is carried out in the reverse order; note the following:

– Connect pipe/hose assembly to clutch slave cylinder

⇒ page 25 .

– Lubricate end of plunger with MoS2 grease.

Audi TT 2007 ➤

– Fit clutch slave cylinder and tighten bolts -1- and -2-. Tighten‐

ing torque ⇒ Item 15 (page 24) .

– Clip pipe/hose assembly into bracket -arrow-.

– Remove hose clamp 3094.

– Fit gearbox support and tighten bolts -arrows-. Tightening tor‐

ques ⇒ Item 1 (page 90)

– Bleed clutch system ⇒ page 29 .

– Assemble selector mechanism ⇒ page 62 .

– Adjust selector mechanism ⇒ page 68 .

4.2 Removing and installing pipe/hose as‐ sembly

Special tools and workshop equipment required

4. Exploded view - hydraulic system (LHD vehicles) 27

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

♦ Hose clamps, up to Ø 25 mm -3094-

Removing

– Remove air cleaner housing completely ⇒ Rep. Gr. 24 .

– Remove bolts -arrows- and detach bracket for air cleaner

housing.

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.

♦

Place a cloth underneath to catch escaping brake fluid.

– Use hose clamp -3094- to clamp off supply hose to clutch

master cylinder.

28 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Release clip -3- with a screwdriver and disconnect pipe/hose

assembly -1- from clutch master cylinder and clutch slave cyl‐ inder.

– Detach pipe/hose assembly -1- from bracket and remove.

Installing

Installation is carried out in reverse sequence; note the following:

Note

Observe distinction between seals -2- and O-rings ⇒ page 24

– Press pipe/hose assembly -1- into connection on clutch slave

cylinder and master cylinder -4- so that clip -3- snaps into place.

– Pull on pipe to check it is secure.

– Clip pipe/hose assembly into bracket -arrow-.

– Remove hose clamp 3094.

– Bleed clutch system ⇒ page 29 .

– Install complete air cleaner housing ⇒ Rep. Gr. 24 .

Audi TT 2007 ➤

4.3 Bleeding clutch system

Special tools and workshop equipment required

♦ -VAS 5234- Brake filling and bleeding equipment

Note

♦

The clutch system must be bled after performing work on the hydraulic clutch mechanism.

♦

In the following steps make sure that no brake fluid escapes onto the longitudinal member or onto the gearbox below.

♦

Prefilling the system is not necessary.

♦

Brake fluid specification ⇒ Rep. Gr. 47 .

4. Exploded view - hydraulic system (LHD vehicles) 29

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Pull clutch pedal back to its normal rest position.

– Connect brake filling and bleeding equipment -VAS 5234- or

-V.A.G 1869- .

– To bleed system, use bleed hose -V.A.G 1238/B- 3 - 670 mm

long, if necessary.

– Then connect bleeder hose to collector bottle of brake bleed‐

ing unit.

– Connect bleed hose to bleeder -arrow-.

– Now switch on bleeding equipment.

♦ Operating pressure 2.0 bar

– Open bleeder valve.

–

Bleed off about 100 cm3 of brake fluid.

– Close bleeder valve.

– Rapidly operate pedal from stop to stop 10 to 15 times.

– Open bleeder valve once again.

–

Bleed off an additional 50 cm3 of brake fluid.

– Tighten bleeder valve ⇒ Item 16 (page 24) .

– Disconnect bleeder hose and fit protective cap.

– Detach bleeder unit from brake fluid reservoir.

– Depress clutch pedal several times after bleeding process is

completed.

– Repeat bleeding procedure if necessary.

30 Rep. Gr.30 - Clutch

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Audi TT 2007 ➤

6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

5 Exploded view - hydraulic system (RHD vehicles)

1 - Brake fluid reservoir

2 - Seal

❑ For plastic supply hose ❑ Seals must be fitted in

supply hose.

3 - Supply hose

❑ Made of rubber or plas‐

tic, depending on ver‐ sion

❑ Plastic supply hose with

additional seals

⇒ Item 2 (page 31)

4 - Clutch master cylinder

❑ Removing and installing

⇒ page 21

5 - Clip

❑ To remove and install

pipe, pull out clip as far as it will go

6 - Seal or O-ring

❑ Renew damaged O-

rings

❑ Push onto pipe connec‐

tion

❑ Lubricate with brake flu‐

id before installing

❑ Whether a seal or an O-

ring is used depends on the type of connection

⇒ page 24

❑ For correct version, re‐

fer to ⇒ Electronic parts catalogue

7 - Retaining clip

❑ To remove and install retaining clip first detach clutch master cylinder from clutch pedal ❑ To remove and install retaining clip first detach clutch master cylinder from clutch pedal ⇒ page 15

8 - Clutch pedal

9 - Nut

❑ 20 Nm ❑ For securing mounting bracket to bulkhead

10 - Retainer

❑ Secured on body

11 - Pipe

❑ For correct version, refer to ⇒ Electronic parts catalogue ❑ Prior to removal, remove battery and battery tray ⇒ Rep. Gr. 27

12 - Seal or O-ring

❑ Renew damaged O-rings ❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing

5. Exploded view - hydraulic system (RHD vehicles) 31

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

❑ 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

13 - Pipe/hose assembly

❑ For correct version, refer to ⇒ Electronic parts catalogue ❑ Prior to removal, remove battery and battery tray ⇒ Rep. Gr. 27

14 - Retainer

❑ Secured to bracket for ABS/EDL

15 - Bracket

❑ For ABS/EDL

16 - Seal or O-ring

❑ Renew damaged O-rings ❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing ❑ 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

17 - Clip

❑ To remove and install pipe/hose assembly, pull out clip as far as it will go

18 - Clutch slave cylinder

❑ Removing and installing ⇒ page 25

19 - Bolt

❑ Tightening torque ⇒ Item 15 (page 24)

20 - Bleeder valve

❑ Tightening torque ⇒ Item 16 (page 24) ❑ Bleeding clutch system ⇒ page 29

21 - Dust cap

22 - Gearbox

23 - Bracket

24 - Bolt

❑ ⇒ Item 20 (page 24)

32 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.

6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

6 Exploded view - clutch release mechanism

1 - Gearbox

2 - Ball head stud

❑ 25 Nm ❑ Remove existing grease

from contact surface of release lever

❑ Lubricate with grease -

G 000 100-

3 - Input shaft oil seal

❑ Pressed into guide

sleeve ❑ Removing ⇒ page 34 ❑ Installing ⇒ page 34

4 - Guide sleeve

❑ With vulcanised O-ring

and oil seal for input

shaft

⇒ Item 3 (page 33)

❑ Renew guide sleeve if

O-ring is damaged ❑ Lubricate guide sleeve

in area of release bear‐

ing with MoS2 grease

Audi TT 2007 ➤

5 - Retaining spring

❑ Secure to clutch release

lever

6 - Socket head bolt

❑ 20 Nm

7 - Clutch release lever

❑ Remove and install to‐

gether with release

bearing ⇒ page 34

and ⇒ page 34 ❑ Remove existing grease ❑ Lubricate surface which contacts ball head stud with MoS2 grease

8 - Release bearing

❑ Do not wash out bearing; wipe clean only ❑ Renew bearing if noisy ❑ Lubricate surfaces which contact release lever with MoS2 grease

9 - Bolt

❑ Tightening torque ⇒ Item 15 (page 24) ❑ 2x

10 - Clutch slave cylinder

❑ Removing and installing ⇒ page 25

11 - Plunger

❑ Lubricate end of plunger with MoS2 grease

12 - Assembly bolt

❑ Secures the clutch release lever while installing gearbox

6. Exploded view - clutch release mechanism 33

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

❑ Unscrew after gearbox has been installed

Note

If the assembly bolt ( ⇒ Item 12 (page 33) ) is not avail‐ able, an M8 x 35 bolt can be used instead.

Removing and installing clutch release lever together with release bearing

– Unhook spring -arrow 1-.

– Pull off clutch release lever -arrow 2- and clutch release bear‐

ing.

Perform installation in reverse sequence of removal.

Removing and installing release bearing

– Press locking lugs -arrows- together on reverse side of clutch

release lever and remove release bearing -A- from clutch re‐ lease lever.

– To install, press release bearing -A- into clutch release lever

until locking lugs -arrows- engage.

Driving oil seal out of guide sleeve

Driving oil seal into guide sleeve (drive in onto stop)

34 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.

6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

7 Overview - servicing clutch

♦ ⇒ “7.1 Clutch identification”, page 35

♦ ⇒ “7.2 Exploded view - Sachs version clutch”, page 37

♦ ⇒ “7.3 Removing and installing clutch (Sachs version)”,

page 38

♦ ⇒ “7.4 Exploded view - LuK version clutch”, page 43

♦ ⇒ “7.5 Removing and installing clutch (LuK version)”,

page 44

7.1 Clutch identification

Note

The clutch fitted in the vehicle is supplied by either “Sachs” or “LuK”.

With gearbox installed, the clutch version fitted can be distin‐ guished as follows:

– Remove noise insulation panels -1- and -2- ⇒ Rep. Gr. 66 .

Audi TT 2007 ➤

A number of recesses -arrows- are located in lower area of sump between engine -A- and gearbox -B-.

– Check the contour of the flywheel visible through the recesses.

7. Overview - servicing clutch 35

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

A - round contour -arrows- = Sachs version clutch

Exploded view - Sachs version clutch ⇒ page 37

B - square contour -arrows 1- and annular groove -arrow 2- = LuK version clutch

Exploded view - LuK version clutch ⇒ page 43

B - round contour -arrows 1- and annular groove -arrow 2- = LuK version clutch

Exploded view - LuK version clutch ⇒ page 44

36 Rep. Gr.30 - Clutch

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Audi TT 2007 ➤

6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

7.2 Exploded view - Sachs version clutch

Note

The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.

1 - Dual-mass flywheel

❑ Removing and installing

⇒ Rep. Gr. 13 ❑ Ensure that dowel pins

fit tightly ❑ Contact surface for

clutch lining must be

free of grooves, oil and

grease ❑ Observe instructions for

removal ⇒ page 38

2 - Clutch plate

❑ Removing and installing

⇒ page 38

❑ Always renew pressure

plate as well ❑ Installation position

⇒ page 41

❑ For diameter of clutch

plate, refer to ⇒ Elec‐

tronic parts catalogue

3 - Pressure plate

❑ With adjustment mech‐

anism ❑ Identification

⇒ page 38

❑ Removing and installing

⇒ page 38

❑ Checking ends of dia‐

phragm spring

⇒ page 41

❑ Checking spring con‐

nections and rivets

⇒ page 41

❑ Always renew clutch plate as well ❑ For correct version, refer to ⇒ Electronic parts catalogue

4 - Bolt

❑ M6 - 13 Nm ❑ M7 - 20 Nm ❑ Loosen and tighten bolts consecutively in steps of 90°

7. Overview - servicing clutch 37

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Identification of self-adjusting Sachs version clutch

♦ Pressure plate with stop mechanism (position sensor)

-arrow-.

Instructions for removing dual-mass flywheel

Note

Do not use an impact wrench or pneumatic wrench to remove bolts -B-: this would severely damage the dual-mass flywheel. The bolts must always be removed by hand.

– Rotate dual-mass flywheel -A- so that the bolts are aligned

centrally behind the holes -arrows-.

– When removing the bolts, make sure that none of the bolt

heads contacts the dual-mass flywheel, as this would damage the flywheel when the bolts are unscrewed further.

7.3 Removing and installing clutch (Sachs version)

Special tools and workshop equipment required

♦ Counterhold tool -3067-

38 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

♦ Centring mandrel -3190 A-

♦ Grease for clutch plate splines -G 000 100-

Audi TT 2007 ➤

7. Overview - servicing clutch 39

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Removing

• Gearbox removed

⇒ “2 Removing and installing gearbox”, page 71 .

– Remove gearbox.

To prevent the pressure plate from becoming distorted during re‐ moval (causes clutch grab when driving off), always adhere to the following procedure when unbolting the pressure plate:

– Apply counter-hold tool -3067- in order to loosen bolts.

– Working clockwise, loosen all six bolts consecutively in steps

of 90° (1/4 turn) until the pressure plate is released.

• Stop -2- with pin -1- should come loose when the bolts are

slackened.

– If the stop does not come loose, push the pin towards the dual-

mass flywheel.

– Take off pressure plate and clutch plate.

Installing

• Tightening torque ⇒ page 37 .

Installation is carried out in reverse sequence; note the following:

Note

♦

The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.

♦

Always renew clutch plate and pressure plate together and select the correct parts according to engine code ⇒ Electronic parts catalogue .

♦

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.

♦

Clean input shaft splines and (in the case of a used clutch plate) the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.

♦

Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.

♦

Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert bolts.

♦

Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.

♦

If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

40 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Installation position of clutch plate

• Marking “Getriebeseite” (gearbox side) and the protruding spring cage face towards gearbox.

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring

-arrows- is permissible.

Audi TT 2007 ➤

Checking spring connections and rivets

– Check spring connections between pressure plate and cover

for cracks and make sure rivets are seated tightly.

• Renew pressure plate if spring connections are damaged or rivets are loose -arrows-.

– Use counter-hold tool -3067- .

– Fit pressure plate onto dowel pins.

– Use centring mandrel -3190 A- to centralise clutch plate.

7. Overview - servicing clutch 41

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

To prevent the pressure plate from becoming distorted during in‐ stallation (causes clutch grab when driving off), always adhere to the following procedure when installing the pressure plate:

– Make sure that the stop pin (position sensor) -arrow- is free to

move.

– Screw in all 6 bolts evenly by hand until bolt heads make con‐

tact with pressure plate.

– Working clockwise, tighten all six bolts consecutively in steps

of 90° (1/4 turn) until the housing makes contact with the fly‐ wheel.

• The stop pin -arrow- should then lift away from the pressure plate.

– Working clockwise, tighten all 6 bolts to final torque consecu‐

tively. Tightening torque ⇒ Item 4 (page 37) .

– Install gearbox ⇒ page 71 .

42 Rep. Gr.30 - Clutch

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Audi TT 2007 ➤

6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

7.4 Exploded view - LuK version clutch

Note

The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.

1 - Dual-mass flywheel

❑ Removing and installing

⇒ Rep. Gr. 13

❑ Ensure that dowel pins

fit tightly

❑ Contact surface for

clutch lining must be free of scoring, oil and grease

❑ Observe instructions for

removal ⇒ page 44

2 - Clutch plate

❑ Removing and installing

⇒ page 44

❑ Always renew SAC

pressure plate as well

❑ Installation position:

marking “Getriebeseite” (gear‐ box side) faces towards gearbox

❑ For diameter of clutch

plate, refer to ⇒ Elec‐ tronic parts catalogue

3 - SAC pressure plate

❑ “SAC” = self adjusting

clutch

❑ Always renew clutch

plate as well

❑ Removing and installing

⇒ page 44

❑ Checking position of ad‐

juster ring on new SAC pressure plate

⇒ page 46

❑ Only fits on flywheel in one position ❑ Checking ends of diaphragm spring ⇒ page 45 ❑ Checking spring connection and rivets ⇒ page 46

4 - Bolt

❑ M6 - 13 Nm ❑ M7 - 20 Nm ❑ Loosen and tighten bolts consecutively in steps of 90°

7. Overview - servicing clutch 43

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Removing dual-mass flywheel

Note

Do not use an impact wrench or pneumatic wrench to remove bolts -B-: this would severely damage the dual-mass flywheel. Bolts -B- must always be removed by hand.

– Rotate flywheel -A- so that bolts -B- are aligned centrally be‐

hind the holes -arrows-.

– When unscrewing bolts -B-, make sure the bolt heads do not

contact the flywheel -arrows- because this would damage the flywheel when the bolts are turned further.

7.5 Removing and installing clutch (LuK ver‐ sion)

Special tools and workshop equipment required

♦ Counterhold tool -3067-

♦ Centring mandrel -3190 A-

♦ Grease G 000 100

44 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Removing

– Remove gearbox

⇒ “2 Removing and installing gearbox”, page 71 .

– Attach counterhold tool -3067- before loosening bolts.

To prevent the pressure plate from becoming distorted during re‐ moval (causes clutch grab when driving off), always adhere to the following procedure when unbolting the pressure plate:

– Working clockwise, loosen all six bolts consecutively in steps

of 90° (1/4 turn) until the pressure plate is released.

– Take off pressure plate and clutch plate.

Installing

Installation is carried out in reverse sequence; note the following:

Note

♦

The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.

♦

Always renew clutch plate and pressure plate together and select the correct parts according to engine code ⇒ Electronic parts catalogue .

♦

Checking position of adjuster ring on new pressure plate

⇒ page 46

♦

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.

♦

Clean input shaft splines and (in the case of a used clutch plate) the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.

♦

Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.

♦

Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert bolts.

♦

Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.

♦

If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

Audi TT 2007 ➤

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring

-arrows- is permissible.

7. Overview - servicing clutch 45

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Checking spring connections and rivets

– Check spring connections -arrows A- for damage and make

sure riveted joints -arrows B- are seated tightly.

• Renew pressure plate if spring connections are broken or bad‐

ly bent, or if riveted joints are loose.

Checking position of adjustment mechanism (new SAC pressure plates only)

• The two edges -A- of the adjuster ring should be located be‐

tween the two notches -arrows B-.

• If the adjuster ring is in a different position on a new pressure

plate, the pressure plate and clutch plate must not be installed.

• The position of the adjuster ring can be outside the notches

on used clutches.

Installation position of clutch plate:

• The marking “Getriebeseite” (gearbox side) faces towards the

gearbox

46 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Use counter-hold tool -3067- .

– Position pressure plate on dowel pins.

– Use centring mandrel -3190 A- to centre clutch plate.

To prevent the pressure plate from becoming distorted during in‐ stallation (causes clutch grab when driving off), always adhere to the following procedure when installing the pressure plate:

– Screw in all 6 bolts evenly by hand until bolt heads make con‐

tact with pressure plate.

– Working clockwise, tighten all six bolts consecutively in steps

of 90° (1/4 turn) until the housing makes contact with the fly‐ wheel.

– Working clockwise, tighten all 6 bolts to final torque consecu‐

tively. Tightening torque ⇒ Item 4 (page 43) .

– Install gearbox ⇒ page 71 .

Audi TT 2007 ➤

7. Overview - servicing clutch 47

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

34 – Controls, housing

1 Overview - selector mechanism

♦ ⇒ “1.1 Gear knob and covers - exploded view”, page 49

♦ ⇒ “1.2 Removing and installing gear knob with gear lever boot

”, page 50

♦ ⇒ “1.3 Exploded view - selector mechanism”, page 52

♦ ⇒ “1.4 Dismantling and assembling selector mechanism”,

page 53

♦ ⇒ “1.5 Removing and installing selector mechanism”,

page 57

♦ ⇒ “1.6 Exploded view - gear selector cable, gate selector cable

and gearbox selector lever”, page 62

♦ ⇒ “1.7 Removing and installing gear selector cable and gate

selector cable”, page 66

♦ ⇒ “1.8 Adjusting selector mechanism”, page 68

A - Gear selector cable (gear selection movement)

B - Gate selector cable (gate selection movement)

C - Heat shield

❑ Detach before removing

selector mechanism.

-Arrow A- gear selection move‐

ment

-Arrow B- gate selection move‐

ment

1 - Gearbox selector lever

2 - Relay lever

48 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

1.1 Gear knob and covers - exploded view

1 - Gear knob with gear lever boot

❑ Cannot be separated

from each other

❑ Always renew as one

unit

❑ Removing and installing

⇒ page 50

❑ Detaching from cover

for centre console

⇒ page 50

❑ Disconnecting from se‐

curing frame

⇒ page 50

2 - Clip

❑ Secures gear knob to

gear lever

❑ Secure with hose clip

pliers -V.A.G 1275-

3 - Trim panel for centre con‐ sole

❑ Remove and install to‐

gether with gear knob

⇒ page 50

❑ Detaching from gear

lever boot ⇒ page 50

4 - Securing frame

❑ Detaching from trim

panel for centre console

⇒ page 50

❑ Detaching from gear

lever boot ⇒ page 50

5 - Washer

❑ 4x

6 - Bolt

❑ 1.5 Nm ❑ 4x

7 - Noise insulation plate

8 - Noise insulation

9 - Gear lever

❑ Adjusting selector mechanism ⇒ page 68

Audi TT 2007 ➤

1. Overview - selector mechanism 49

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Detaching trim panel for centre console and securing frame for gear lever boot

– Remove bolts -arrows-.

– Detach trim panel from securing frame

Detaching securing frame and gear lever boot

– Carefully release tabs -arrows- and lift off securing frame -1-

from gear lever boot -2-.

1.2 Removing and installing gear knob with gear lever boot

Special tools and workshop equipment required

♦ Removal wedge -3409-

♦ Hose clip pliers -V.A.G 1275-

Removing

• The gear knob is removed together with the gear lever boot

and the cover for the centre console.

50 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Open ashtray.

– Carefully lever off trim panel from centre console -arrows-.

Audi TT 2007 ➤

– Unplug electrical connector on trim panel.

– Pull trim panel -3- up and over gear knob.

– Open clip -1- and pull off gear knob -2- together with gear lever

boot and trim panel -3-.

– Detach gear lever boot and trim panel for centre console -3-

⇒ page 50 .

Installing

Installation is carried out in reverse sequence; note the following:

– Push gear knob onto gear lever until it contacts stop.

– Secure gear knob to gear lever with a new clip -1-, using hose

clip pliers -V.A.G 1275- .

1. Overview - selector mechanism 51

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

1.3 Exploded view - selector mechanism

Note

Lubricate bearings and moving surfaces with grease -G 000 450 02- .

1 - Floor plate

❑ Bend tabs open to re‐

move

❑ Always renew

2 - Gasket

❑ Always renew

3 - Gear lever

❑ Can be removed and in‐

stalled without removing gear lever guide

⇒ Item 15 (page 53)

4 - Damping washer

❑ Push onto gear lever as

far as stop -arrow-

5 - Securing clip

❑ Take care not to dam‐

age selector cables when removing.

❑ Always renew

6 - Gate selector cable

❑ Lever off gate selector

lever

❑ Press onto gate selector

lever inside selector mechanism

❑ Installation position

⇒ page 48

❑ Removing and installing

⇒ page 66

7 - Bush

8 - Gear selector cable

❑ Lever off gear lever

guide ❑ Press onto gear lever guide inside selector mechanism ❑ Installation position ⇒ page 48 ❑ Removing and installing ⇒ page 66

9 - Damper

10 - Bearing shell

❑ Will be damaged during removal ❑ Always renew

11 - Bush

12 - Securing clip

❑ Removing and installing ⇒ page 53

52 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

13 - Spring

14 - Bush

15 - Gear lever guide

16 - Nut

• M6 - 8 Nm

• M8 - 25 Nm ❑ 4x

17 - Gasket

❑ Between selector housing and floor ❑ Self-adhesive ❑ Glue onto selector housing

18 - Selector housing

❑ With spring and gate selector lever ❑ Spring and gate selector lever cannot be detached

Removing and installing securing clip

– Hold gear lever -2- in position.

– Press spacer bush -3- in direction indicated (arrow).

– Take off securing clip -1-.

Audi TT 2007 ➤

1.4 Dismantling and assembling selector

mechanism

Special tools and workshop equipment required

♦ Thrust block -T10083-

1. Overview - selector mechanism 53

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Dismantling

– Remove selector mechanism ⇒ page 57

– Using a screwdriver, bend open tabs -arrows- on all sides of

floor plate and remove floor plate.

– Remove gasket from selector housing.

– Remove gear selector cable and gate selector cable from se‐

lector housing ⇒ page 66 .

– Lift top spring arm -A- over tab on gate selector lever.

– Using a screwdriver, press lugs -arrows- on ball socket to‐

wards ball on gear lever guide; if necessary, break off lugs.

– Prise ball socket -A- out of selector housing together with gear

lever guide and gear lever -B-.

– Then press ball socket -A- off ball on gear lever guide and

remove.

54 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Note

♦

Note guides -A- when performing the following steps.

♦

They must not break off.

– Swivel bottom spring arm -arrow 1- onto stop on shoulder of

gate selector lever.

Caution

During the following steps, the bottom spring arm (-arrow 1-) can become dislodged and snap downwards off the shoulder of the gate selector lever.

– Pull gear lever guide upwards as far as stop and at the same

time pull ball-head pin -arrow 2- out of gate selector lever.

– Press spring -arrow 1- carefully off the shoulder of the gate

selector lever.

The spring arms will then compress “diagonally”.

Audi TT 2007 ➤

– Then turn gear lever guide in direction of -arrow 1-.

• The pin -arrow 2- should be positioned in the recess on the

selector housing.

– Next, swivel gear lever guide out in direction of -arrow 3- to‐

gether with gear lever.

Assembling selector mechanism

– Release spring arms -A- and -B-.

• Spring arms -A- and -B- must point in opposite directions.

(Shown here with gear lever guide installed.)

1. Overview - selector mechanism 55

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Insert gear lever guide into selector housing together with gear

lever.

• Pin -arrow 1- should be positioned just inside recess on se‐ lector housing.

– Turn gear lever guide in direction of -arrow 2- until ball-head

pin -A- is above recess on selector housing.

– Position selector housing with gear lever guide onto thrust

block -T10083- .

• The gear lever guide rests in the larger recess -arrow- in the thrust block -T10083- .

• Gear lever guide should protrude out of selector housing as far as stop.

– Insert arm -A- of spring in guide from above.

– Pull arm -B- of spring downwards and insert it next to the guide

(towards ball head).

Note

For illustration purposes, only part of the gate selector lever is shown.

– Carefully take selector housing off thrust block -T10083- to‐

gether with gear lever guide.

– Move gate selector lever rearwards as far as stop in direction

of -arrow 1-.

– Grease ball-head pin.

– Press ball-head pin into hole in gate selector lever -arrow 2-.

• Guides -A- and tabs -B- must not be damaged.

56 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Now insert gear lever guide (which is now fitted in selector

housing) into larger recess -arrow- in thrust block -T10083again.

• Gear lever guide should now protrude out of selector housing as far as stop.

– Lift top spring arm -A- over pin on gate selector lever.

• Use a new ball socket -B-.

– Grease ball socket and ball of gear lever guide.

– Press ball socket onto ball of gear lever guide as far as stop.

– Remove selector housing from thrust block -T10083- .

– Press ball socket into selector housing in direction of

-arrows-.

Audi TT 2007 ➤

• All four lugs -arrows- must engage.

– Lift top spring arm -A- over pin on gate selector lever into

guide.

– Insert bottom spring arm into guide.

– Fit gear lever, gear selector cable, gate selector cable and

floor plate.

– Install selector mechanism ⇒ page 60 .

1.5 Removing and installing selector mech‐

anism

Special tools and workshop equipment required

♦ Engine and gearbox jack -V.A.G 1383 A-

1. Overview - selector mechanism 57

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

♦ Torque wrench -V.A.G 1331-

♦ Grease -G 000 450 02-

Removing

– Remove gear knob together with trim panel for centre console

⇒ page 50 .

– Remove centre console ⇒ Rep. Gr. 68 .

– Remove noise insulation above selector mechanism.

– Remove nuts -arrows-.

– Detach cable support bracket from gearbox -arrows-.

58 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Remove securing clip -1-.

– Pull gear selector cable -2- off pin.

Release gate selector cable as follows:

– Pull locking mechanism forwards in direction of -arrow 1- onto

stop and then turn in direction of -arrow 2- to lock.

– Press relay lever forwards (in direction of -arrow 3-) and pull

out gate selector cable.

Audi TT 2007 ➤

– Unbolt bracket for exhaust system and tunnel brace -arrows-.

Note

To prevent damage, the flexible joints in the front exhaust pipe must not be bent further than 10°.

– Support front exhaust pipe and catalytic converter with engine

and gearbox jack -V.A.G 1383 A- .

– Disconnect exhaust system at clamp -arrows-.

1. Overview - selector mechanism 59

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Remove bolts -arrows-.

– Lower front exhaust pipe with catalytic converter slightly.

– Unclip Lambda probe wire and remove heat shield towards

rear.

– Remove selector housing with selector cables.

Installing selector mechanism

Installation is carried out in reverse sequence; note the following:

Fit and secure selector housing ⇒ Item 16 (page 53) .

– Route cables -1- from selector mechanism -2- to gearbox as

follows:

• The cables must run parallel and must not be crossed.

• The cables must be routed in the slot provided in heat shield

-3-.

Note

The enlargement shows the heat shield from above.

60 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Secure heat shield -arrows-.

– Assemble exhaust system so it is free of stress and install

tunnel brace -arrows- ⇒ Rep. Gr. 26 .

Audi TT 2007 ➤

– Secure cable support bracket -arrows-. Tightening torque

⇒ Item 6 (page 62) .

– Apply a small quantity of grease -G 000 450 02- to pin of gear‐

box selector lever.

– Position gear selector cable -2- on pin of gearbox selector lev‐

er and secure with new securing clip -1-.

– Insert gate selector cable in cable end-piece.

– Adjust selector mechanism ⇒ page 68 .

– Fit noise insulation above selector mechanism and install cen‐

tre console ⇒ General body repairs, interior; Rep. Gr. 68 .

– Install gear knob together with boot ⇒ page 50 .

1. Overview - selector mechanism 61

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

1.6 Exploded view - gear selector cable, gate selector cable and gearbox selec‐ tor lever

Note

Lubricate all bearings and moving surfaces with grease -G 000 450 02- .

1 - Gear selector cable

❑ Installation position

⇒ page 48

❑ Removing and installing

⇒ page 66

❑ Adjusting ⇒ page 68 ❑ Secure to gate selector

cable with cable tie

⇒ page 64

2 - Gate selector cable

❑ Installation position

⇒ page 48

❑ Removing and installing

⇒ page 66

❑ Adjusting ⇒ page 68 ❑ Secure to gear selector

cable with cable tie

⇒ page 64

3 - Bush

4 - Selector housing

❑ Dismantling and assem‐

bling ⇒ page 52

5 - Retaining clips

❑ Take care not to dam‐

age selector cables

when removing. ❑ Always renew

6 - Bolt

❑ 20 Nm ❑ 3x ❑ For support bracket

7 - Support bracket

❑ With cable guide

8 - Grommet

❑ For support bracket mounting on gearbox

9 - Bush

10 - Cable end-piece

❑ Secures gear selector cable to gearbox selector lever ❑ Do not interchange; cable end-pieces for gate selector cable and gear selector cable are different

⇒ Fig. “ A - Identification according to diameter of bore in cable end-piece “ , page 63

❑ Release to adjust selector mechanism ⇒ page 69

62 Rep. Gr.34 - Controls, housing

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Audi TT 2007 ➤

6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

11 - Securing clip

12 - Cable end-piece

❑ Secures gate selector cable to relay lever ❑ Do not interchange; cable end-pieces for gate selector cable and gear selector cable are different

⇒ Fig. “ A - Identification according to diameter of bore in cable end-piece “ , page 63

❑ Detaching from gate selector cable ⇒ page 65 ❑ Detaching from relay lever ⇒ page 65 ❑ Pressing onto relay lever ⇒ page 66 ❑ Release to adjust selector mechanism ⇒ page 69

13 - Relay lever

❑ Installation position ⇒ page 64 ❑ Removing and installing ⇒ page 65

14 - Slide block

15 - Gearbox selector lever

❑ With damper weight ❑ Install so that gap in splines aligns with selector shaft ⇒ page 64 ❑ After installing, adjust selector mechanism ⇒ page 68 ❑ Installation position ⇒ page 64

16 - Nut

❑ 25 Nm ❑ Self-locking ❑ Always renew

A - Identification according to diameter of bore in cable end-piece

The holes in the cable end-pieces have different diameters.

Cable end-piece for: Distance “a”

Gear selector cable to gearbox selector lever 8.5 mm Gate selector cable to relay lever 10 mm

1. Overview - selector mechanism 63

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Installing gearbox selector lever

– When installing gearbox selector lever, make sure that the gap

in the splines -arrow A- aligns with the wider spline -arrow Bon the selector shaft.

Installation position of gearbox selector lever and relay lever

1 - Gearbox selector lever with damper weight

2 - Arrow marking

- Points to pin on relay lever (in neutral position)

3 - Relay lever

- Locates in guide rail of gearbox selector lever via slide block

-arrow-.

Position of cable tie securing selector cables

– Wrap cable tie round selector cables in a “figure-of-eight”

-arrow- and secure cable tie as shown in illustration.

64 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Disconnecting cable end-piece from gate selector cable

Note

♦

Cable end-piece must be detached from gate selector cable before removing relay lever.

♦

Do not detach cable end-piece from relay lever until relay lever has been removed.

– Pull locking mechanism forwards in direction of -arrow 1- onto

stop and then turn to left in direction of -arrow 2- to lock.

– Then press relay lever forwards (in direction of -arrow 3-).

Removing and installing relay lever

– Press detent -arrow 1- down onto stop and remove relay lever

together with cable end-piece. Move relay lever in normal di‐ rection of operation.

Note

Audi TT 2007 ➤

-Arrow 2- can be disregarded.

Installing relay lever

Note

To install, lubricate bearings and moving surfaces with grease G 000 450 02- .

– Press cable end-piece onto relay lever ⇒ page 66 .

– Insert relay lever with cable end-piece as far as stop.

• Relay lever is secured by detent -arrow 1-.

• Cable end-piece is secured by detent -arrow 2-.

• Ensure that components engage securely.

Levering cable end-piece for gate selector cable off plastic relay lever

• Relay lever is removed.

– Insert a plain slot screwdriver -A- between bush -B- and relay

lever.

1. Overview - selector mechanism 65

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Pressing cable end-piece onto plastic relay lever

• Relay lever is removed.

• Press on cable end-piece only at bush -arrow-.

• Cable end-piece must move freely on relay lever.

• Cable end-piece must be behind detent -arrow 2-.

• Ensure that components engage securely.

1.7 Removing and installing gear selector cable and gate selector cable

Removing

– Remove selector mechanism ⇒ page 57

– Using a screwdriver, bend open tabs -arrows- for selector

mechanism on floor plate and remove floor plate.

– Remove gasket.

66 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Pull off securing clips -1 ... 2-.

– Lever off gate selector cable -3- / gear selector cable -4- with

a screwdriver and pull cable out of selector housing.

Release cable end-piece -A- as follows:

– Push sleeve forwards onto stop -arrow 1-.

– Turn sleeve clockwise onto stop -arrow 2- so that it engages.

– Detach cable end-piece -A- from cable -B-.

Audi TT 2007 ➤

– Pull off securing clips -1- and -2-.

– Detach support bracket from cables.

Installing

Installation is carried out in reverse sequence; note the following:

– Secure gear selector cable and gate selector cable to selector

housing with securing clips -1 ... 2-.

– Press gate selector cable -3- onto relay lever.

– Press gear selector cable -5- onto gearbox selector lever.

Make sure sleeve -4- engages securely.

1. Overview - selector mechanism 67

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Fit gasket and secure floor plate to selector mechanism by

bending over tabs -arrows-.

– Install selector mechanism ⇒ page 60 .

– Adjust selector mechanism ⇒ page 68 .

1.8 Adjusting selector mechanism

Special tools and workshop equipment required

♦ Locking pin -T10027A-

Requirements for adjustment

• Gear selector linkage must be in proper condition and undam‐

aged.

• Selector mechanism must move freely.

• Gearbox, clutch and clutch mechanism must be in proper con‐

dition.

• Gearbox in neutral.

Adjusting

– Open ashtray.

– Carefully lever off trim panel from centre console -arrows-.

– Pull trim panel up and over gear knob.

68 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– With gearbox in neutral, guide gear lever to the left into 1st/

2nd gear gate.

– Lift noise insulation plate and lock gear lever in position with

locking pin -T10027A- .

Note

The noise insulation panels are removed to give a better illustra‐ tion.

Release cable end-pieces for gate selector cable and gear se‐ lector cable as follows:

– Push locking sleeves on gear selector cable and gate selector

cable forward as far as they will go -arrow 1-.

– Turn locking sleeve as far as it will go in direction of arrow

-2- so that it engages.

Audi TT 2007 ➤

Note

It should now be possible to move the cables in the cable endpieces.

• Gearbox in neutral.

Lock the selector shaft as follows:

– Push gearbox selector lever down into 1st/2nd gear gate

-arrow 1-. At the same time, turn locking pin -2- in direction of arrow -B- until it engages.

The selector shaft is then locked and can no longer be moved.

– Ensure that the gate selector cable and the gear selector cable

are located free of tension in the cable end-pieces.

– Now turn locking sleeves on gear selector cable and gate se‐

lector cable as far as they will go in the direction indicated (arrow).

The spring presses the locking sleeve back into the original po‐ sition.

Note

Cable adjustment is now complete.

1. Overview - selector mechanism 69

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Now turn locking pin -A- back to original position (direction of

arrow).

– Pull locking pin -T10027A- out of selector mechanism.

Check gear lever setting as follows:

• The gear lever should rest in the 3rd/4th gear gate when the

gearbox is in neutral.

– Depress clutch.

– Select all gears several times. Pay particular attention to the

operation of the reverse gear locking mechanism.

Should a gear fail to engage smoothly after repeated selection, check the play (lift movement) of the selector shaft as follows:

– Engage 1st gear.

– Push gear lever as far as it will go to the left and release.

– At the same time observe selector shaft on gearbox (2nd me‐

chanic).

– The selector shaft should move up and down approx. 1 mm

(in direction of -arrow-) when the gear lever is moved.

If this is not the case, adjust selector mechanism again

⇒ page 68 .

– Fit gear lever boot.

70 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

2 Removing and installing gearbox

⇒ “2.1 Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine”, page 72 .

⇒ “2.2 Installing gearbox on vehicles with 1.8 ltr. FSI turbocharged engine”, page 81

⇒ “2.3 Transporting gearbox”, page 88

Audi TT 2007 ➤

2. Removing and installing gearbox 71

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

2.1 Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine

Special tools and workshop equipment required

♦ Support bracket -10 - 222

A-

♦ Gearbox support -3282-

♦ Adjustment plate -3282/39-

♦ Engine and gearbox jack -

V.A.G 1383 A-

♦ Engine support -3300 A-

♦ Support -T10036-

♦ Bolt M6×20 (2x)

♦ Bolt M10×20

♦ Grease for clutch plate

splines -G 000 100-

72 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Caution

When disconnecting the battery there is a risk of serious dam‐ age to electronic components:

♦ Observe the correct procedure for disconnecting the bat‐

tery ⇒ Electrical system; Rep. Gr. 27 .

– Take out luggage compartment floor cover.

– Release retaining clips -arrows- and remove cover for nega‐

tive terminal.

Note

Remove rear cross panel trim if necessary for access to negative terminal of battery ⇒ Rep. Gr. 70 .

Audi TT 2007 ➤

– With ignition switched off, disconnect battery earth strap

-arrow-.

– Remove engine cover panel -arrows-.

– Remove air cleaner housing completely ⇒ Rep. Gr. 24 .

– Remove bolts -arrows- and detach bracket for air cleaner

housing.

2. Removing and installing gearbox 73

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Detach cable support bracket from gearbox -arrows-.

– Remove bracket -B- from gearbox and disconnect from pipe/

hose assembly -A-.

– Detach securing clip -arrow 1- and pull off gear selector cable.

– Press detent -arrow 2- down onto stop and remove relay lever

together with cable end-piece. Move relay lever in normal di‐ rection of operation.

– Tie cables with cable support bracket to one side.

– Remove nut -arrow 3- and detach gearbox selector lever -A-.

– Remove brace -1-.

– Move clear hydraulic line going to clutch slave cylinder.

– Unbolt clutch slave cylinder -arrows- and place to one side; do

not disconnect pipe.

Caution

Do not depress clutch pedal after removing slave cylinder.

– Unplug electrical connector -1-.

– Disconnect B+ wire from starter solenoid -2-.

– Disconnect earth wire -3- and remove top bolt securing starter.

– Unplug electrical connector -4- at reversing light switch -F4- .

74 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Remove engine/gearbox securing bolts -1 and 2- (accessible

from above).

– Remove the two bolts (top) on radiator cowl -1-.

Audi TT 2007 ➤

– Assemble support bracket -10 - 222 A- and place onto wing

panel flange, as shown in illustration.

– Engage hook of spindle in engine lifting eye (left-side).

– Take up weight of engine/gearbox assembly with spindle; do

not lift.

– Raise vehicle.

– Remove noise insulation (centre) -1- ⇒ Rep. Gr. 66 .

2. Removing and installing gearbox 75

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Remove front left wheel.

– Remove left noise insulation -arrows-.

– Remove frame for noise insulation -arrow- ⇒ Rep. Gr. 50 .

– Remove nut -arrow- and detach bracket for electrical wiring.

– Remove bottom bolt securing starter and take out starter.

– Slightly lift retaining clip -1- and loosen hose clip -2- to remove

air hose.

76 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Detach electrical connector -2-.

– Remove bolts -3- and take out radiator cowl from below.

– Unbolt heat shield for drive shaft (right-side) -arrows-.

– Unbolt drive shafts (left and right) from flange shafts on gear‐

box.

– Lift drive shafts (left and right) up and secure with cable tie.

Note

Audi TT 2007 ➤

Make sure you do not damage surface coating on drive shafts.

– Remove bolts -1 ... 3- and detach pendulum support.

– Spay rust remover onto studs on turbocharger -arrows-.

– Remove nuts -arrows-.

– Detach catalytic converter from turbocharger and secure cat‐

alytic converter to prevent it from falling to the ground.

Note

♦

To prevent damage, the flexible joints in the front exhaust pipe must not be bent further than 10°.

♦

-Item 1- and -item 2- can be disregarded.

2. Removing and installing gearbox 77

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Remove bolts -arrows- on gearbox mounting.

– Lower engine/gearbox assembly using spindle of support

bracket -10 - 222 A- until distance -a- is obtained between gearbox housing and gearbox mounting.

• Dimension -a- = 50 mm

– Unbolt gearbox bracket -A- from gearbox -arrows-.

– Unplug electrical connector -1- at oil level and oil temperature

sender -G266- .

– Unclip bracket -2- for electrical wiring leading to oil level and

oil temperature sender -G266- at subframe.

78 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– If fitted, unbolt heat shield for power steering control unit -

J500- from subframe -arrows-.

– Drill two 7 mm diameter holes in support -T10036- , as illus‐

trated (if holes have not already been drilled).

• Dimension -a- = 70 mm

• Dimension -b- = 98 mm

• Dimension -c- = 11 mm

Audi TT 2007 ➤

– Bolt support -T10036- onto subframe -arrows- using two

M6×20 bolts.

– Bolt engine support -3300 A- onto support -T10036- .

2. Removing and installing gearbox 79

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Press engine towards front of vehicle using spindle of engine

support -3300 A- . Pay special attention to the following points:

• The air conditioner compressor -2- must not contact refriger‐

ant line -1- -arrow-.

• Alternator must not make contact with refrigerant line.

• Pressure pipe must not make contact with radiator.

Set up gearbox support -3282- with adjustment plate -3282/39and mount on engine and gearbox jack -V.A.G 1383 A- .

– Align arms of gearbox support according to holes in adjust‐

ment plate -3282/39- .

– Bolt on support elements -A- and -C-, as illustrated on adjust‐

ment plate .

• The arrow symbol -B- on the adjustment plate points in the

direction of travel.

– Place engine and gearbox jack -V.A.G 1383 A- underneath

vehicle.

– Align gearbox support -3282- parallel with gearbox.

– Screw pin -3282/29- into gearbox.

– Insert the two remaining support elements in gearbox as illus‐

trated.

– Support gearbox from underneath by raising engine and gear‐

box jack -V.A.G 1383 A- .

– Remove remaining engine/gearbox securing bolts -5 and 6-.

80 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Push the gearbox off the dowel sleeves and swing carefully

towards the subframe.

Then guide flange shaft (right-side) -1- past recess -arrow- in in‐ termediate plate.

– Incline gearbox via spindles of gearbox support -3282- .

• The differential must face upwards.

• Pivot gearbox downwards in area of 6th gear.

Audi TT 2007 ➤

– Guide gearbox with differential past subframe -A- and swivel

out.

– When lowering the gearbox, change position of gearbox using

the spindles on gearbox support -3282- .

Transporting gearbox ⇒ page 88 .

Installing gearbox ⇒ page 81

2.2 Installing gearbox on vehicles with 1.8 ltr. FSI turbocharged engine

Installation is carried out in reverse sequence; note the following:

• Tightening torques ⇒ page 88

2. Removing and installing gearbox 81

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Note

♦

Renew self-locking nuts and bolts when performing assembly work.

♦

Renew oil seals, gaskets, O-rings and bolts which are tight‐ ened by turning through a specified angle.

♦

Secure all hose connections with the correct hose clips (as original equipment); refer to ⇒ Parts catalogue .

♦

All cable ties which are released or cut open during removal must be fitted in the same position when installing.

♦

Clean input shaft splines and (in the case of a used clutch plate) the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.

♦

When renewing the gearbox, the gearbox selector lever must be transferred to the new assembly.

♦

Use thread tap to remove any remaining locking fluid from all threaded holes which will accommodate self-locking bolts.

♦

Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.

♦

If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

– Make sure that the intermediate plate is engaged on the seal‐

ing flange and fitted on the dowel sleeves -arrows-.

– Check release bearing for wear. Renew slave cylinder and re‐

lease bearing if necessary ⇒ page 25 .

– Check that clutch plate is centralised ⇒ page 44 .

– Incline gearbox via spindles of gearbox support -3282- .

• The differential must face upwards.

• Pivot gearbox downwards in area of 6th gear.

– Then raise gearbox carefully.

– Guide gearbox with differential past subframe -A- and swivel

in direction of -arrow-.

82 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Make sure longitudinal member -B- is not in the way.

• Guide flange shaft (right-side) -1- past recess -arrow- in inter‐

mediate plate.

– Align gearbox with engine in installation position and install.

– Bolt gearbox onto engine. Tightening torques ⇒ page 88

– Detach gearbox jack with gearbox support -3282- from gear‐

box after bolting gearbox to engine.

Audi TT 2007 ➤

– Remove engine support -3300 A- and support -T10036- .

– Secure gearbox bracket -A- to gearbox with new bolts

-arrows-. Tightening torque ⇒ Item 8 (page 90) .

– Pull gearbox up to support arm of gearbox mounting with spin‐

dle on support bracket -10 - 222 A- .

2. Removing and installing gearbox 83

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Align engine/gearbox in installation position. To do so, raise

engine/gearbox until gearbox bracket makes full contact with gearbox mounting.

Note

Gearbox mounting and gearbox bracket must be parallel to avoid causing damage to thread of gearbox bracket.

– Use new bolts -arrows- to secure gearbox mounting to gear‐

box bracket. Tightening torque ⇒ Item 12 (page 90) .

WARNING

Do not remove support bracket -10 - 222 A- until all bolts se‐ curing the left-hand engine/gearbox mounting have been tight‐ ened to the specified torque.

– Fit pendulum support with new bolts -1 … 3- in accordance

with installation instructions ⇒ page 94 . Tightening torques

⇒ page 90

– Check adjustment of engine/gearbox mountings ⇒ Rep. Gr.

10 .

– Fit radiator cowl and and tighten bottom bolts -3-.

– Attach electrical connector -2-.

– Install air intake hose. Make sure retaining clip -arrow- snaps

onto retaining lug -A-.

84 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Secure catalytic converter to turbocharger -arrows- ⇒ Engine,

mechanics; Rep. Gr. 26 .

– Secure drive shafts (left and right) to gearbox ⇒ Rep. Gr. 40 .

– Secure guard plate for drive shaft (right-side) -arrows-.

Audi TT 2007 ➤

– Install starter ⇒ Rep. Gr. 27 .

– Fit bracket and secure with nut -arrow-.

– Connect earth strap at upper engine/gearbox securing bolt.

– Tighten top bolts for radiator cowl -1-.

2. Removing and installing gearbox 85

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Install clutch slave cylinder -arrows-. Tightening torque

⇒ Item 15 (page 24) .

– Install brace -1-. Tightening torque ⇒ Item 1 (page 90) .

Note

To install, lubricate bearings and moving surfaces with grease G 000 450 02- .

– Install gearbox selector lever -3- ⇒ page 64 .

– Tighten hexagon nut -4- to specified torque

⇒ Item 16 (page 63) .

– Insert relay lever -5- with cable end-piece as far as stop. In‐

stallation position ⇒ page 64

– Attach gear selector cable -1- to gearbox selector lever and

secure with securing clip -2-.

– Ensure that components engage securely.

• Cable end-piece is secured by detent -arrow 1-.

• Cable end-piece must be behind detent -arrow 1-.

• Relay lever is secured by detent -arrow 2-.

86 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Secure cable support bracket -arrows-. Tightening torque

⇒ Item 6 (page 62)

– Fit bracket -B- to gearbox. Tightening torque

⇒ Item 20 (page 24) .

– Push pipe/hose assembly -A- into bracket -B- on gearbox.

– Unplug electrical connector -arrow- at reversing light switch -

F4- .

– Adjust selector mechanism ⇒ page 68 .

Audi TT 2007 ➤

– Fit bracket -1- for air cleaner housing -arrows-.

– Install complete air cleaner housing ⇒ Rep. Gr. 24 .

– Install engine cover panel.

– Raise vehicle.

– Check gear oil level in gearbox ⇒ page 95 .

– Install noise insulation frame -arrow- ⇒ Rep. Gr. 50 ; Remov‐

ing and installing noise insulation frame .

2. Removing and installing gearbox 87

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Install left noise insulation -arrows-.

– Install noise insulation (centre) -1- ⇒ Rep. Gr. 66 .

– Connect battery ⇒ Electrical system; Rep. Gr. 27 .

Tightening torques

Securing gearbox to 1.8 ltr. TFSI engine

Item Bolt Nm

1, 2 M12x65 80

3

4

1)2)

M12x150 80

M12x165 80

5 M10x50 40 6 M12x85 80 A Dowel sleeves for centralising

1)

•

Bolt with stud M8.

2)

•

Also starter to gearbox

Component Nm

Bracket for electrical wiring at bottom starter bolt 23 Heat shield for drive shaft to cylinder block 25

2.3 Transporting gearbox

Special tools and workshop equipment required

88 Rep. Gr.34 - Controls, housing

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♦ Gearbox lifting tackle -3336-

♦ Workshop hoist -VAS 6100-

Audi TT 2007 ➤

6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Bolt gearbox lifting tackle -3336- to clutch housing.

– Set support arm on sliding bracket by means of locking pin

-arrow-.

Number of holes visible = 5

– Lift gearbox using workshop hoist -VAS 6100- and gearbox

lifting tackle 3336.

– Set down gearbox as required (for example in transport con‐

tainer).

2. Removing and installing gearbox 89

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

3 Exploded view - assembly mountings

1 - Bolt

❑ 20 Nm + 90° ❑ Gearbox support to

gearbox and gearbox bracket

❑ Tightening sequence

⇒ page 91

❑ Always renew

2 - Gearbox support

❑ To gearbox bracket and

gearbox

3 - Engine mounting with en‐ gine support

❑ Removing and installing

⇒ Rep. Gr. 10

❑ Tightening torques ⇒

Rep. Gr. 10

4 - Bolt

❑ 100 Nm + 90° ❑ Pendulum support to

subframe

❑ Always renew

5 - Pendulum support

❑ Removing and installing

⇒ page 94

6 - Bolts

❑ 50 Nm + 90° ❑ Pendulum support to

gearbox

❑ Always renew

7 - Bolts

❑ 50 Nm + 90° ❑ Pendulum support to gearbox ❑ Always renew

8 - Bolt

❑ 40 Nm + 90° ❑ Gearbox bracket to gearbox ❑ Always renew

9 - Gearbox bracket

10 - Gearbox mounting

❑ Removing and installing ⇒ page 91 ❑ Fit to gearbox bracket

11 - Bolt

❑ 40 Nm + 90° ❑ Gearbox mounting to body ❑ Tightening sequence ⇒ page 91 ❑ Always renew

90 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

12 - Bolt

❑ 60 Nm + 90° ❑ Gearbox mounting to gearbox bracket ❑ Always renew

Attaching gearbox mounting to gearbox bracket

– Renew bolts.

– Tighten all bolts hand-tight.

– Tighten bolts to specified torque.

Gearbox support to gearbox bracket and gearbox

– Renew bolts.

– Initially tighten both bolts -arrows- hand-tight.

– Tighten bolts to specified torque.

Audi TT 2007 ➤

3.1 Removing and installing gearbox mounting

Special tools and workshop equipment required

♦ Support bracket -10 - 222 A-

3. Exploded view - assembly mountings 91

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

Removing

– Remove engine cover panel -arrows- ⇒ Rep. Gr. 10 .

– Remove air cleaner housing completely ⇒ Rep. Gr. 24 .

– Remove bolts -arrows- and detach bracket for air cleaner

housing.

– Set up support bracket -10 - 222 A- with adapters -10 - 222 A /

1- on wing mounting flanges.

– Engage hook of spindle -10 - 222 A /11- in lifting eye.

– Take up weight of engine evenly with spindles; do not lift.

– Remove bolts -arrows-.

92 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

– Open retainers for wiring duct -arrows-.

– Cut open cable tie -1- and push electrical wiring to one side.

– Unclip wiring duct.

– Remove bolts -1- and detach gearbox mounting -A-.

Installing

Installation is carried out in reverse sequence; note the following:

• Tightening torques ⇒ page 90

– Fit gearbox mounting -A- with new bolts -1- to longitudinal

member.

Audi TT 2007 ➤

Caution

The threads in the gearbox bracket can be damaged if the bolts are not inserted straight.

♦ Before fitting the bolts -arrows-, the gearbox bracket and

the support arm of the gearbox mounting must be aligned absolutely parallel. If necessary, push the gearbox up at the rear with a trolley jack.

– Pull gearbox up with spindle on support bracket until gearbox

bracket contacts support arm of gearbox mounting.

– Adjust assembly mountings ⇒ Rep. Gr. 10 .

– Bolt support arm of gearbox mounting to gearbox bracket

-arrows-.

– Detach support bracket -10 - 222 A- from engine.

– Install engine cover panel ⇒ Rep. Gr. 10 .

– Install air cleaner housing ⇒ Rep. Gr. 24 .

3. Exploded view - assembly mountings 93

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

3.2 Removing and installing pendulum sup‐ port

Removing

– Remove noise insulation (centre) -1- ⇒ Rep. Gr. 66 .

– Unscrew bolts -1 ... 3- and remove pendulum support.

Installing pendulum support

Installation is carried out in reverse sequence; note the following:

• Tightening torques ⇒ page 90

– First secure pendulum support to gearbox -arrow B- and

-arrow C-, then on subframe -arrow A-.

– Install noise insulation (centre) ⇒ Rep. Gr. 66 .

94 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

4 Checking gear oil level and filling up

with gear oil

Caution

It is not possible to check the gear oil level by removing the oil filler plug.

Audi TT 2007 ➤

Due to the inclination of the engine/gearbox assembly, the oil lev‐ el -arrow 2- will be above the lower edge of the filler hole

-arrow 1-.

The gear oil level can only be checked by draining the gear oil completely and then filling up again:

Special tools and workshop equipment required

♦ Used oil collection and extraction unit -V.A.G 1782-

4. Checking gear oil level and filling up with gear oil 95

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Audi TT 2007 ➤ 6-speed manual gearbox 02S, front-wheel drive - Edition 05.2008

♦ Torque wrench -V.A.G 1331-

♦ Hose (length approx. 600 mm, outer circumference 10 mm)

with funnel (commercially available)

4.1 Preparations

Gear oil for direct shift gearbox ⇒ Electronic parts catalogue

– Remove air cleaner housing ⇒ Rep. Gr. 24 .

– Remove noise insulation (centre) -1- ⇒ Rep. Gr. 66 .

Clean gearbox.

Caution

A pivot pin for the selector forks in the gearbox must be re‐ moved in order to drain the gear oil.

The selector shaft must be locked to prevent the position of the selector forks from being changed, e.g. due to accidental op‐ eration of the selector mechanism.

Lock the selector shaft as follows:

– Press selector shaft down (direction of -arrow 1-).

– While pressing selector shaft down, move angled rod -A- up‐

wards in direction of -arrow 2-. At the same time press angled rod carefully into selector shaft until it engages.

4.2 Draining off gear oil

Use a clean container (capacity 3.0 ltr.) with a graduated scale to collect gear oil.

• Selector shaft must be locked ⇒ page 96

96 Rep. Gr.34 - Controls, housing