Audi TT 61 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive
Edition 04.2010
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT00920
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 02Q, front-wheel drive - Edition 04.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Overview - clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 12
1.2 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 13
2 Exploded view - pedal cluster, clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Exploded view - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Removing and installing pipe/hose assembly or plastic pipe . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Exploded view - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Exploded view - clutch release mechanism, slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 36
6 Clutch identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7 Exploded view - Sachs version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1 Removing and installing clutch (Sachs version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 Exploded view - LuK version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1 Removing and installing clutch (LuK version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.1 Exploded view - gear knob and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.2 Removing and installing gear knob with gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.3 Exploded view - gear lever and selector housing for vehicles with vehicle ID No. up to
8J-7-013000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.4 Exploded view - gear lever and selector housing for vehicles with vehicle ID No. from
8J-7-013001 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.5 Dismantling and assembling selector mechanism for vehicles with vehicle ID No. from
8J-7-013001 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.7 Exploded view - gear selector cable and gate selector cable up to model year 2007 . . . . 68
1.8 Exploded view - gearbox selector lever and gate relay lever up to model year 2007 . . . . 70
1.9 Exploded view - gear selector cable and gate selector cable from model year 2008
onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.10 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 77
2 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Removing gearbox on vehicles with 2.0 ltr. FSI turbocharged engine . . . . . . . . . . . . . . . . 82
3.2 Installing gearbox on vehicles with 2.0 ltr. FSI turbocharged engine . . . . . . . . . . . . . . . . . . 93
3.3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
4 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1 Removing gearbox mounting - vehicles with 2.0 ltr. TFSI engine . . . . . . . . . . . . . . . . . . . . 102
4.2 Installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5 Checking oil level in manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.1 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.3 Exploded view - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . 112
6.4 Exploded view - input shaft, output shafts, differential and selector rods . . . . . . . . . . . . . . 114
6.5 Dismantling and assembling gearbox (version without circlip A for input shaft sealing cap)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.6 Dismantling and assembling gearbox (version with circlip A for input shaft sealing cap) . . 126
7 Exploded view - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.1 Servicing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
8 Exploded view - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.1 Servicing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9 Renewing input shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
10 Exploded view - selector mechanism in gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.2 Removing and installing selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
11 Exploded view - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
11.1 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.2 Modifications in area of grooved ball bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2 Exploded view - output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.1 Dismantling and assembling output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . 173
2.2 Adjusting output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3 Exploded view - output shaft for 5th, 6th and reverse gear . . . . . . . . . . . . . . . . . . . . . . . . 189
3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gear . . . . . . . . . . . . . . 191
3.2 Adjusting output shaft for 5th, 6th and reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1 Renewing flange shaft oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.1 Renewing flange shaft oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.2 Renewing flange shaft oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2 Exploded view - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.2 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
ii Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 02Q, front-wheel drive is installed
in the Audi TT 2007 > in conjunction with the 2.0 ltr. FSI turbo‐
charged engine.
Allocation ⇒ page 1 .
Location on gearbox
♦ Code letters and date of manufacture -arrow 1-
♦ Manual gearbox 02Q -arrow 2-
Audi TT 2007 ➤
Manual gearbox 02Q -arrow-
Code letters and date of manufacture of gearbox -arrow-
Example: HJH 17 05 6
Additional data identify the factory where the unit was built.
Note
I I I I
Code letters Day Month Year of manufac‐
ture (2006)
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 02Q
Code letters HJH JLZ KDR
Manufactured from 05.05 08.06 06.07
Allocation Model Audi TT 2007 > Audi TT 2007 > Audi TT 2007 >
to 06.05 05.07 02.08
1. Gearbox identification 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
Manual gearbox 6-speed 02Q
Code letters HJH JLZ KDR
Engine 2.0 ltr. - 147 kW FSI tur‐bo2.0 ltr. - 147 kW FSI tur‐bo2.0 ltr. - 147 kW FSI tur‐
bo
Ratio Final drive I
71 : 18 = 3.944 71 : 18 = 3.944 71 : 18 = 3.944
for 1st to 4th
gear
Z2 : Z1 = i
Final drive II
71 : 23 = 3.087 71 : 23 = 3.087 71 : 23 = 3.087
for 5th/6th gear
and reverse
gear
Overall ratio i
in top gear 3.010 3.010 3.010
ov.
1st gear 47 : 14 = 3.357 47 : 14 = 3.357 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469 47 : 32 = 1.469 47 : 32 = 1.469
4th gear 46 : 40 = 1.150 46 : 40 = 1.150 46 : 40 = 1.150
5th gear 43 : 36 = 1.194 43 : 36 = 1.194 43 : 36 = 1.194
6th gear 39 : 40 = 0.975 39 : 40 = 0.975 39 : 40 = 0.975
Reverse gear 34 : 23 x 14 : 14 = 3.990 34 : 23 x 14 : 14 = 3.990 34 : 23 x 14 : 14 = 3.990
Gear oil capacity 2.3 litres
Clutch actuation Hydraulic
The following data can be found in the ⇒ Electronic parts catalogue .
♦ Gear oil specification
♦ Allocation of drive shaft flange type
♦ Allocation of clutch type
Manual gearbox 6-speed 02Q
Code letters KNX KZU
Manufactured from 02.08 06.09
to 06.09
Allocation Model Audi TT 2007 > Audi TT 2007 >
Engine 2.0 ltr. - 147 kW FSI tur‐bo2.0 ltr. - 147 kW FSI tur‐
bo
Ratio Final drive I
71 : 18 = 3.944 71 : 18 = 3.944
for 1st to 4th
gear
Z2 : Z1 = i
Final drive II
71 : 23 = 3.087 71 : 23 = 3.087
for 5th/6th gear
and reverse
gear
Overall ratio i
in top gear 3.010 3.010
ov.
1st gear 47 : 14 = 3.357 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469 47 : 32 = 1.469
4th gear 46 : 40 = 1.150 46 : 40 = 1.150
5th gear 43 : 36 = 1.194 43 : 36 = 1.194
6th gear 39 : 40 = 0.975 39 : 40 = 0.975
Reverse gear 34 : 23 x 14 : 14 = 3.990 34 : 23 x 14 : 14 = 3.990
Gear oil capacity 2.3 litres
Clutch actuation Hydraulic
2 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
Manual gearbox 6-speed 02Q
Code letters KNX KZU
The following data can be found in the ⇒ Electronic parts catalogue .
♦ Gear oil specification
♦ Allocation of drive shaft flange type
♦ Allocation of clutch type
Audi TT 2007 ➤
1. Gearbox identification 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
2 Transmission layout
Identification
Note
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft II for 5th, 6th
and reverse gear
6 - Output shaft I for 1st - 4th
gear
7 - Differential
Ratio
Arrows point in direction of travel
4 Rep. Gr.00 - Technical data
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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 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
2. Transmission layout 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
3 Calculating ratio “i”
Example:
6th gear Final drive
Drive gear ZG1 = 40 ZA1 = 23
Driven gear ZG2 = 39 ZA2 = 71
i = ZG2 : ZG1
1)
iG = gear ratio = ZG2 : ZG1 = 39 : 40 = 0.975
iA = axle ratio = ZA2 : ZA1 = 71 : 23 = 3.087
iov = overall ratio = iG x iA = 0.975 x 3.087 = 3.010
1) Z1 = No. of teeth on drive gear, Z2 = No. of teeth on driven gear
6 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
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 are summarised here. They apply to the work
described in this Manual.
4.1 Contact corrosion!
Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ The gearbox casing is made of a magnesium alloy.
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
Audi TT 2007 ➤
Caution
Damage caused by contact corrosion is not covered under
warranty.
4.2 Repair instructions
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 the gearbox, ensure that the dowel sleeves
between the engine and the 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 107 .
♦ Capacities ⇒ page 1 .
♦ Specifications ⇒ Electronic parts catalogue .
4. General repair instructions 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
Oil seals, seals, O-rings and gaskets
♦ Always renew oil 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 107 .
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.
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-.
8 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
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.
Audi TT 2007 ➤
Shims
♦ Use a micrometer to measure the shims at several points. Dif‐
ferent shim thicknesses make it possible to obtain the exact
thickness required.
♦ Check for burrs and damage.
♦ Install only shims which are in perfect condition.
4. General repair instructions 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
Synchro-rings
♦ Do not interchange synchro-rings. When reusing always fit to
the same selector 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 synchro rings 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.
♦ Abnormal wear on synchro-ring or selector gear:
A - Worn chamfer on dog teeth of synchro-ring or selector gear.
♦ In comparison: intact synchro-ring or selector gear:
B - Intact chamfer on dog teeth of synchro-ring or selector gear.
10 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
♦ Abnormal wear on locking collar:
C - Worn chamfer on internal splines of locking collar.
♦ In comparison: intact locking collar:
D - Intact chamfer on internal splines of locking collar.
Clutch actuation, clutch
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures ⇒ page 12 ).
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts consecutively in steps of 90°.
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.
♦ Only blow out dual-mass flywheel with compressed air.
♦ Clutch pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the
clutch plate, the pressure plate must not be cleaned. Other‐
wise the service life of the clutch will be considerably reduced.
♦ The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
Audi TT 2007 ➤
4. General repair instructions 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
30 – Clutch
1 Overview - clutch mechanism
Note
If you suspect a defective clutch master cylinder or clutch slave
cylinder, pay attention to
⇒ “1.1 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 12 and perform
⇒ “1.2 Function check for clutch master cylinder and slave cylin‐
der”, page 13 prior to renewing.
I -
⇒ “2 Exploded view - pedal
cluster, clutch master cylin‐
der”, page 15
⇒ “2.1 Removing and installing
over-centre spring”, page 16
⇒ “2.2 Removing and installing
clutch pedal”, page 18
⇒ “2.3 Removing and installing
mounting bracket”, page 21
⇒ “2.4 Removing and installing
clutch position sender G476 ”,
page 23
⇒ “2.5 Removing and installing
clutch master cylinder”,
page 24
II -
⇒ “3 Exploded view - hydraul‐
ics (LHD)”, page 27
⇒ “3.1 Removing and installing
pipe/hose assembly or plastic
pipe”, page 29
⇒ “3.2 Bleeding clutch sys‐
tem”, page 31
III -
⇒ “4 Exploded view - hydraul‐
ics (RHD)”, page 33
1.1 Notes on removing and installing clutch master cylinder and slave cylinder
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective you must first carry out
a function check
12 Rep. Gr.30 - Clutch
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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
⇒ “1.2 Function check for clutch master cylinder and slave
cylinder”, page 13 .
♦ If the slave cylinder is removed from gearbox with the pipe/
hose assembly still attached, make sure you do not press the
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.
1.2 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).
Audi TT 2007 ➤
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 12 .
Pedal forces:
♦ approx. 140 N for complete service life of the clutch
1. Overview - clutch mechanism 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
High pedal force:
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 39 or
⇒ page 45
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 12 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
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 39 or
⇒ page 45
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate or dowel
sleeves).
14 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
2 Exploded view - pedal cluster, clutch master cylinder
Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Plenum chamber partition
panel
❑ With mounting for
mounting bracket
2 - Gasket
❑ Renew
❑ Between mounting
bracket and plenum
chamber partition panel
❑ Self-adhesive
❑ Bond onto mounting
bracket
3 - Mounting bracket
❑ For clutch pedal
❑ Removing and installing
⇒ page 21
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 16
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 18
❑ If fitting new pedal rub‐
ber, cut to required size
as described
⇒ page 16
9 - Retaining clip
❑ For operating rod on
clutch master cylinder
10 - Seal
❑ Renew
❑ Between master cylinder and mounting bracket
11 - Clutch master cylinder
❑ Removing and installing ⇒ page 24
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 23
❑ Checking in “Guided Fault Finding” ⇒ Vehicle diagnosis, 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
2. Exploded view - pedal cluster, clutch master cylinder 15
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
14 - Supply hose
❑ To brake fluid reservoir
❑ Made of rubber or plastic, depending on version
❑ Plastic supply hose with additional seals ⇒ page 28
15 - Nut
❑ For securing mounting bracket to plenum chamber partition panel
❑ 20 Nm
❑ 3x
❑ Self-locking
❑ Renew
16 - Nut
❑ 25 Nm
❑ Self-locking
❑ Renew
17 - Stop
❑ For clutch pedal
Crash bar - tightening torque
– Fit crash bar -2- and tighten 1 or 2 bolts (depending on version)
-arrows B-.
• M6 10 Nm
• M8 20 Nm
Renewing pedal rubber for clutch pedal
– Cut new clutch pedal rubber to size as illustrated.
• Dimension -x- = 20 mm
2.1 Removing and installing over-centre spring
Special tools and workshop equipment required
16 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
♦ Assembly tool -T10178-
♦ Grease -G 000 450 02-
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).
Audi TT 2007 ➤
– 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.
2. Exploded view - pedal cluster, clutch master cylinder 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
Installing
• Tightening torque ⇒ page 15
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- .
• 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 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2.2 Removing and installing clutch pedal
Special tools and workshop equipment required
♦ Pliers -T10005-
18 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
♦ Assembly tool -T10178-
♦ Grease -G 000 450 02-
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).
Audi TT 2007 ➤
– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,
remove nut -2- and pull out bolt -5-.
– Pivot clutch pedal down slightly and and take over-centre
spring -4- out of mounting bracket.
2. Exploded view - pedal cluster, clutch master cylinder 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
– Release retaining clip for operating rod on master cylinder us‐
ing pliers -T10005- .
– Remove clutch pedal.
Installing
• Tightening torque ⇒ page 15
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- .
– Install retaining clip -2- on operating rod -1- of master cylinder.
– Press retaining clip into mounting on clutch pedal so that it
snaps into place.
– Fit over-centre spring -2- into mounting bracket from above
while holding end of spring in correct position with assembly
tool -T10178- .
20 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
• 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 clutch pedal against the spring if you pull
back the bottom of the pedal carefully as you bring the top of the
pedal into installation position.
– Install crash bar ⇒ page 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2.3 Removing and installing mounting
bracket
Audi TT 2007 ➤
Special tools and workshop equipment required
♦ Hose clamp, up to Ø 25 mm -3094-
♦ Hose clip pliers -VAS 6340-
2. Exploded view - pedal cluster, clutch master cylinder 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
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.
– Use hose clamp -3094- to clamp off supply hose to clutch
master cylinder.
– 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- or plastic pipe from clutch master cyl‐
inder.
– Unclip and detach clutch position sender -G476- from clutch
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).
22 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
Note
When working in the footwell, put cloths on the floor covering to
protect it from possible brake fluid spills.
– Remove nuts -2-.
– Take out mounting bracket -1-.
Installing
• Tightening torque ⇒ page 15
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nuts.
♦
Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .
Audi TT 2007 ➤
– Fit mounting bracket -1- and tighten nuts -2-.
– Install pipe/hose assembly or plastic pipe ⇒ page 29 .
– Bleed clutch system ⇒ page 31 .
– Install crash bar ⇒ page 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2.4 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, 2 and 3- can be disregarded.
2. Exploded view - pedal cluster, clutch master cylinder 23
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Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
Installing
– Fit clutch position sender -G476- at clutch master cylinder and
engage -arrow-.
– Attach electrical connector -4-.
2.5 Removing and installing clutch master cylinder
Special tools and workshop equipment required
♦ Pliers -T10005-
Removing
Note
♦
If you suspect a defective clutch master cylinder, perform
function test prior to renewing
⇒ “1.1 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 12 .
♦
When working in the footwell, put cloths on the floor covering
to protect it from possible brake fluid spills.
24 Rep. Gr.30 - Clutch
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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
– Remove mounting bracket ⇒ page 21 .
– Release retaining clip for operating rod on clutch pedal using
pliers -T10005- .
– 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 retainer clip -B- and pull master cylinder out of mount‐
ing bracket -arrow 1- and -arrow 2-.
Audi TT 2007 ➤
Installing
• Move clutch pedal back as far as stop until it is in normal po‐
sition.
– Install retaining clip -2- on operating rod -1- for clutch master
cylinder.
2. Exploded view - pedal cluster, clutch master cylinder 25
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010
– 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)
– Secure master cylinder on mounting bracket -arrow 1- and
-arrow 2-.
– Press operating rod -1- for master cylinder in direction of
-arrow- so that retaining clip -2- snaps into place in clutch ped‐
al.
– Install mounting bracket ⇒ page 21 .
26 Rep. Gr.30 - Clutch
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