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.

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

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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Audi TT 2007 ➤

6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

3 Exploded view - hydraulics (LHD)

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 28

4 - Clutch master cylinder

❑ Removing and installing

⇒ page 24

5 - Clip

❑ To remove and install

pipe/hose assembly, pull out clip as far as it will go

6 - Seal or O-ring

❑ Renew damaged seals

or 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 28

❑ 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 ⇒ page 18

8 - Clutch pedal

❑ Removing and installing ⇒ page 18

9 - Nut

❑ For securing mounting bracket to plenum chamber partition panel ❑ Tightening torque ⇒ Item 15 (page 16)

10 - Pipe/hose assembly

❑ Removing and installing ⇒ page 29 ❑ Different types depending on gearbox version ❑ For correct version, refer to ⇒ Electronic parts catalogue

11 - Bracket

❑ For pipe/hose assembly ⇒ Item 10 (page 27) ❑ Secured on body ❑ Identification of brackets ⇒ page 29

12 - Plastic pipe

❑ Removing and installing ⇒ page 29

3. Exploded view - hydraulics (LHD) 27

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

❑ Different types depending on gearbox version ❑ For correct version, refer to ⇒ Electronic parts catalogue

13 - Bracket

❑ For plastic pipe ⇒ Item 12 (page 27) ❑ Secured on body ❑ Identification of brackets ⇒ page 29

14 - Seal or O-ring

❑ Renew damaged seals or 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 28 ❑ For correct version, refer to ⇒ Electronic parts catalogue

15 - Bleeder connection

16 - Clip

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

17 - Bleeder screw

❑ 4.5 Nm ❑ Bleeding clutch system ⇒ page 31

18 - Dust cap

19 - Clutch slave cylinder with release bearing

❑ Can only be renewed after removing gearbox

20 - Gearbox

O-ring or seal for pipe/hose assembly or plastic pipe

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

Vehicles with plastic supply hose -1-

• Seals -2- must be fitted in supply hose.

28 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Identification of brackets

Dimension “a” (mm) Pipe version

8 Plastic pipe 6 Pipe/hose assembly

3.1 Removing and installing pipe/hose as‐

sembly or plastic pipe

Special tools and workshop equipment required

♦ Hose clamps, up to Ø 25 mm -3094-

Audi TT 2007 ➤

Removing

– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒

Rep. Gr. 24 .

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

master cylinder.

3. Exploded view - hydraulics (LHD) 29

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

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.

– To detach at clutch master cylinder, release retaining clip -3-

with a screwdriver.

– Pull off pipe/hose assembly -1- or plastic pipe with O-ring -2-

and detach from bracket.

Caution

Do not depress clutch pedal after removing pipe/hose assem‐ bly or plastic pipe.

Note

Place a cloth underneath to catch escaping brake fluid.

– To detach at bleeder connection, release retaining clip -2- with

a screwdriver and pull pipe/hose assembly -4- or plastic pipe with O-ring -3- off bleeder connection -1-.

Installing

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

Note

For distinction between O-rings -2- and seals, refer to

⇒ page 28

– Check O-ring -2- for damage and renew if necessary.

– Press pipe/hose assembly -1- or plastic pipe onto connection

on clutch master cylinder -4- so that retaining clip -3- snaps into place.

– Pull on pipe to check it is secure.

30 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Check O-ring -3- for damage and renew if necessary.

– Press pipe/hose assembly -4- or plastic pipe onto bleeder

connection so that retaining clip -2- snaps into place.

– Pull on pipe to check it is secure.

– Bleed clutch system ⇒ page 31 .

3.2 Bleeding clutch system

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.

♦

Before bleeding clutch system, top up brake fluid reservoir to “max.” marking with brake fluid.

Audi TT 2007 ➤

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment -VAS 5234-

♦ Brake fluid specification ⇒ Rep. Gr. 47.

Procedure

• Tightening torque ⇒ page 27

– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒

Rep. Gr. 24 .

3. Exploded view - hydraulics (LHD) 31

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Pull clutch pedal back to its normal rest position.

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

brake fluid reservoir.

– Remove protective cap from bleeder screw -arrow- and con‐

nect hose -A- from bleeder bottle to bleeder screw.

– Switch on bleeding equipment.

• Operating pressure 2.0 bar

–

Now open bleeder screw approx 1/4 turn and allow 100 cm

3

of brake fluid to run out.

– With bleeder screw open, pump clutch pedal rapidly all the way

in and out by hand 15 to 20 times (approx. 2 times per second).

– Close bleeder screw.

– Switch off brake filling and bleeding equipment -VAS 5234-

and relieve pressure from bleeding equipment.

– Now press clutch pedal slowly all the way in and out 10 times.

– Check that clutch system is functioning properly.

– Disconnect bleeder hose and fit protective cap.

– Remove brake filling and bleeding equipment -VAS 5234-

from brake fluid reservoir.

– Install air cleaner housing ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 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.

Audi TT 2007 ➤

6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

4 Exploded view - hydraulics (RHD)

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 33)

4 - Clutch master cylinder

❑ Removing and installing

⇒ page 24

5 - Clip

❑ To remove and install

pipe, pull out clip as far as it will go

6 - Seal or O-ring

❑ Matched to type of con‐

nection ⇒ page 28

❑ For correct version, re‐

fer to ⇒ Electronic parts catalogue

❑ Renew damaged seals

or O-rings

❑ Push onto pipe connec‐

tion

❑ Lubricate with brake flu‐

id before installing

7 - Retaining clip

❑ To remove and install retaining clip first detach master cylinder from clutch pedal ⇒ page 18

8 - Clutch pedal

9 - Nut

❑ For securing mounting bracket to plenum chamber partition panel ❑ 20 Nm

10 - Retainer

❑ Secured on body

11 - Pipe

❑ For correct version, refer to ⇒ Electronic parts catalogue

12 - Seal or O-ring

❑ Matched to type of connection ⇒ page 28 ❑ For correct version, refer to ⇒ Electronic parts catalogue ❑ Renew damaged seals or O-rings ❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing

4. Exploded view - hydraulics (RHD) 33

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

13 - Pipe/hose assembly

❑ For correct version, refer to ⇒ Electronic parts catalogue

14 - Bracket

❑ Secured to bracket for ABS/EDL

15 - Seal or O-ring

❑ Matched to type of connection ⇒ page 28 ❑ For correct version, refer to ⇒ Electronic parts catalogue ❑ Renew damaged seals or O-rings ❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing

16 - Clip

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

17 - Bleeder screw

❑ Bleeding clutch system ⇒ page 31 ❑ 4.5 Nm

18 - Dust cap

19 - Bleeder connection

20 - O-ring

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

21 - Clutch slave cylinder with release bearing

❑ Can only be renewed after removing gearbox ❑ Removing and installing ⇒ page 36

22 - Gearbox

34 Rep. Gr.30 - Clutch

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Audi TT 2007 ➤

6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

5 Exploded view - clutch release mechanism, slave cylinder

1 - Gearbox

❑ Removing and installing

⇒ page 82

2 - Input shaft oil seal

❑ Renewing ⇒ page 152

3 - Clutch slave cylinder with release bearing

❑ Slave cylinder and re‐

lease bearing are one unit and can only be re‐ newed together

❑ Do not wash out bear‐

ing; wipe clean only

❑ If bearing is noisy, re‐

new together with slave cylinder

❑ Removing and installing

⇒ page 36

❑ For some slave cylin‐

ders, divided supply line

⇒ page 35

4 - Bolt

❑ 12 Nm for metal clutch

slave cylinder

❑ 15 Nm for plastic clutch

slave cylinder ❑ 3x ❑ Renew ❑ Tighten bolts carefully in

several small steps and

in diagonal sequence;

make sure that mount‐

ing lugs on slave cylin‐

der do not break off

5 - O-ring

❑ Renew if damaged ❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing

Clutch slave cylinder -A- with divided supply line

On some versions the supply line for the slave cylinder is divided

-arrow-.

For correct version, refer to ⇒ Electronic parts catalogue

5. Exploded view - clutch release mechanism, slave cylinder 35

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

5.1 Removing and installing clutch slave cylinder together with release bearing

Note

Slave cylinder and release bearing are one unit and can only be renewed together.

Removing

• Gearbox removed ⇒ page 82 .

– Release retaining clip -2- with a screwdriver and pull bleeder

connection -4- off slave cylinder -1-.

– Remove bolts -arrows-.

– Take off slave cylinder together with release bearing -A-.

Installing

• Tightening torque ⇒ page 35

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

Caution

Tighten securing bolts for slave cylinder in small steps. Other‐ wise mounting lugs -arrows- can be damaged.

– Secure clutch slave cylinder with release bearing -arrows-.

– Check O-ring -3- for damage and renew if necessary.

– Press bleeder connection -4- onto connection on clutch slave

cylinder -1- so that retaining clip -2- snaps into place.

– Pull on bleeder connection to check it is secure.

– Bleed clutch system ⇒ page 31 .

36 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

6 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:

– Release fasteners -1 ... 4- and remove centre noise insulation.

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.

A - round contour -arrows- = Sachs version clutch

Exploded view - Sachs version clutch ⇒ page 39

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

Exploded view - LuK version clutch ⇒ page 45

6. Clutch identification 37

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

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

Exploded view - LuK version clutch ⇒ page 45

38 Rep. Gr.30 - Clutch

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Audi TT 2007 ➤

6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

7 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 41

2 - Clutch plate

❑ Removing and installing

⇒ page 41

❑ Always renew pressure

plate as well

❑ Installation position

⇒ page 44

❑ For diameter of clutch

plate, refer to ⇒ Elec‐ tronic parts catalogue

3 - Pressure plate

❑ With adjustment mech‐

anism

❑ Identification

⇒ page 40

❑ Removing and installing

⇒ page 41

❑ Checking ends of dia‐

phragm spring

⇒ page 40

❑ Checking springs and

riveting ⇒ page 40

❑ Checking wire ring or

sheet-metal ring ⇒ page 41

❑ Always renew clutch plate as well ❑ For correct version, refer to ⇒ Electronic parts catalogue ❑ Contact surface for clutch lining must be free of grooves, oil and grease

4 - Bolt

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

7. Exploded view - Sachs version clutch 39

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Identification of self-adjusting Sachs version clutch

♦ Pressure plate with stop mechanism (position sensor)

-arrow-.

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring

-arrows- is permissible.

Checking springs and riveting

I - Springs OK

• Slight kinking on the outside -arrows A- is normal on produc‐

tion parts.

II - Springs damaged

• Renew pressure plate if springs are broken or badly bent

-arrow B-.

40 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Check that rivets -arrows B- are secure at all springs

-arrows A-.

• Renew pressure plate if rivets -arrows B- are loose.

Checking wire ring or sheet-metal ring

– Check wire ring or sheet-metal ring -arrow- in pressure plate

for damage.

• Renew pressure plate if wire ring or sheet-metal ring is broken.

Audi TT 2007 ➤

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.

7.1 Removing and installing clutch (Sachs version)

Special tools and workshop equipment required

♦ Counterhold tool -3067-

7. Exploded view - Sachs version clutch 41

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

♦ Centring mandrel -T10097-

♦ Grease for clutch plate splines -G 000 100-

42 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Removing

• Gearbox removed ⇒ page 82 .

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 39

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

Audi TT 2007 ➤

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 gearbox hous‐ ing in area of clutch 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.

♦

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.

♦

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

♦

Only blow out dual-mass flywheel with compressed air.

♦

The friction surface of the pressure plate and the dual-mass flywheel must be cleaned (degreased) thoroughly.

♦

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).

7. Exploded view - Sachs version clutch 43

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Installation position of clutch plate

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

– Use counterhold tool -3067- .

– Fit pressure plate onto dowel pins.

– Use centring mandrel -T10097- to centralise 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:

– 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 39)

44 Rep. Gr.30 - Clutch

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Audi TT 2007 ➤

6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

8 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 grooves, oil and grease

❑ Observe instructions for

removal ⇒ page 47

2 - Clutch plate

❑ Removing and installing

⇒ page 47

❑ 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 47

❑ Checking position of ad‐

juster ring on new SAC pressure plate

⇒ page 49

❑ Checking ends of diaphragm spring ⇒ page 40 ❑ Checking spring connection and rivets ⇒ page 46 ❑ Checking metal ring ⇒ page 46 ❑ Contact surface for clutch lining must be free of grooves, oil and grease

4 - Bolt

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

8. Exploded view - LuK version clutch 45

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring

-arrows- is permissible.

Checking springs and riveting

I - Springs OK

• Slight kinking on the outside -arrows A- is normal on produc‐ tion parts.

II - Springs damaged

• Renew pressure plate if springs are broken or badly bent

-arrow B-.

– Check that rivets -arrows B- are secure at all springs

-arrows A-.

• Renew pressure plate if rivets -arrows B- are loose.

Checking metal ring

– Check metal ring -arrow- in pressure plate for damage.

• Renew pressure plate if metal ring is broken.

46 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

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.

8.1 Removing and installing clutch (LuK ver‐ sion)

Special tools and workshop equipment required

♦ Counterhold tool -3067-

Audi TT 2007 ➤

♦ Centring mandrel -T10097-

♦ Grease for clutch plate splines -G 000 100-

8. Exploded view - LuK version clutch 47

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Removing

• Gearbox removed ⇒ page 82 .

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

• Tightening torque ⇒ page 45

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 49

♦

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.

♦

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.

♦

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.

♦

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

♦

Only blow out dual-mass flywheel with compressed air.

♦

The friction surface of the pressure plate and the dual-mass flywheel must be cleaned (degreased) thoroughly.

♦

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).

48 Rep. Gr.30 - Clutch

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

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

Audi TT 2007 ➤

– Use counterhold tool -3067- .

– Fit pressure plate onto dowel pins.

– Use centring mandrel -T10097- to centralise 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 45)

8. Exploded view - LuK version clutch 49

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

34 – Controls, housing

1 Overview - selector mechanism

♦ ⇒ “1.1 Exploded view - gear knob and covers”, page 52

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

”, page 53

♦ ⇒ “1.3 Exploded view - gear lever and selector housing for

vehicles with vehicle ID No. up to 8J-7-013000”, page 55

♦ ⇒ “1.4 Exploded view - gear lever and selector housing for

vehicles with vehicle ID No. from 8J-7-013001 onwards”, page 58

♦ ⇒ “1.5 Dismantling and assembling selector mechanism for

vehicles with vehicle ID No. from 8J-7-013001 onwards”, page 59

♦ ⇒ “1.6 Removing and installing selector mechanism”,

page 63

♦ ⇒ “1.7 Exploded view - gear selector cable and gate selector

cable up to model year 2007”, page 68

♦ ⇒ “1.8 Exploded view - gearbox selector lever and gate relay

lever up to model year 2007”, page 70

♦ ⇒ “1.9 Exploded view - gear selector cable and gate selector

cable from model year 2008 onwards”, page 72

♦ ⇒ “1.10 Removing and installing gear selector cable and gate

selector cable”, page 77

♦ ⇒ “2 Adjusting selector mechanism”, page 79

-Arrow A- gear selection movement

-Arrow B- gate selection movement

50 Rep. Gr.34 - Controls, housing

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.

1 - Gear selector cable

2 - Gate selector cable

3 - Heat shield

❑ Detach before removing

selector mechanism

4 - Gate relay lever

5 - Gearbox selector lever

Audi TT 2007 ➤

6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

1. Overview - selector mechanism 51

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

1.1 Exploded view - gear knob and covers

1 - Gear knob with gear lever boot

❑ Cannot be separated

from each other ❑ Renew together ❑ Removing and installing

⇒ page 53

❑ Detaching from trim

panel for centre console

⇒ page 53

❑ Disconnecting from se‐

curing frame

⇒ page 53

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 53

❑ Detaching from gear

lever boot ⇒ page 53

4 - Securing frame

❑ Detaching from trim

panel for centre console

⇒ page 53

❑ Detaching from gear

lever boot ⇒ page 53

5 - Washer

❑ 4x

6 - Bolt

❑ 1.5 Nm ❑ 4x

7 - Noise insulation plate

8 - Noise insulation

9 - Gear lever

❑ Adjusting selector mechanism ⇒ page 79

52 Rep. Gr.34 - Controls, housing

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 02Q, front-wheel drive - Edition 04.2010

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-.

Audi TT 2007 ➤

1.2 Removing and installing gear knob with gear lever boot

Note

The gear knob is removed together with the gear lever boot and the cover for the centre console.

Special tools and workshop equipment required

♦ Removal wedge -3409-

1. Overview - selector mechanism 53

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

♦ Hose clip pliers -V.A.G 1275-

Removing

– Open ashtray.

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

– 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 53 .

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- .

54 Rep. Gr.34 - Controls, housing

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

1.3 Exploded view - gear lever and selector housing for vehicles with vehicle ID No. up to 8J-7-013000

Note

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

1 - Securing clip

❑ Removing and installing

⇒ page 57

2 - Bush

3 - Spring

4 - Bush

5 - Bolt

❑ 6 Nm

6 - Cover

7 - Damper

❑ For spring

⇒ Item 18 (page 55)

8 - Damper

9 - Bearing shell

10 - Gear lever guide

11 - Damping washer

12 - Gasket

❑ Between selector hous‐

ing and floor ❑ Self-adhesive ❑ Glue onto selector

housing

13 - Gear lever

14 - Selector housing

15 - Bearing bush

16 - Pivot pin

17 - Guide bush

❑ Press onto selector housing

18 - Spring

❑ Installing ⇒ page 57

19 - Gate selector lever

20 - Bolt

❑ 5 Nm

21 - Gasket

❑ Renew

22 - Floor plate

❑ Bend tabs open to remove ❑ Renew

1. Overview - selector mechanism 55

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

23 - Gate selector cable

❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79

24 - Gear selector cable

❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79

25 - Securing clip

❑ Renew ❑ Removing ⇒ page 56

26 - Nut

❑ 8 Nm ❑ 4x

27 - Bearing bush

❑ Only fits in one position

28 - Securing clip

❑ Renew

Detaching securing clip for gear selector cable -A- and gate se‐ lector cable -B-

– Use screwdriver to lift tab -arrow 1- and lever off securing clip

-arrow 2-.

56 Rep. Gr.34 - Controls, housing

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 02Q, front-wheel drive - Edition 04.2010

Removing and installing securing clip

– Hold gear lever -2- in position.

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

– Take off securing clip -1-.

Installing spring

– Insert arm -A- of spring in guide -1- from above.

– Pull down arm -B- of spring and insert it in the guide from be‐

low.

Audi TT 2007 ➤

Note

The gate selector lever is removed to give a better illustration.

1. Overview - selector mechanism 57

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

1.4 Exploded view - gear lever and selector housing for vehicles with vehicle ID No. from 8J-7-013001 onwards

Note

♦

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

♦

Dismantling and assembling selector mechanism ⇒ page 59

1 - Floor plate

❑ Bend tabs open to re‐

move

❑ Always renew

2 - Gasket

❑ Renew

3 - Gear lever

❑ Can be removed and in‐

stalled without removing gear lever guide

⇒ Item 15 (page 59)

4 - Damping washer

❑ Push onto gear lever as

far as stop -arrow-

5 - Retaining clip

❑ Take care not to dam‐

age selector cables when removing.

❑ Renew

6 - Gate selector cable

❑ Lever off gate selector

lever

❑ Press onto gate selector

lever inside selector mechanism

❑ Installation position

⇒ page 50

7 - Bush

8 - Gear selector cable

❑ Lever off gear lever

guide

❑ Press onto gear lever

guide inside selector mechanism

❑ Installation position ⇒ page 50

9 - Damper

10 - Bearing shell

❑ Will be damaged during removal ❑ Renew

11 - Bush

12 - Securing clip

❑ Removing and installing ⇒ page 57

58 Rep. Gr.34 - Controls, housing

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 02Q, front-wheel drive - Edition 04.2010

13 - Spring

14 - Bush

15 - Gear lever guide

16 - Nut

❑ 4x

• M6 - 8 Nm

• M8 - 25 Nm

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 removed

1.5 Dismantling and assembling selector mechanism for vehicles with vehicle ID No. from 8J-7-013001 onwards

Audi TT 2007 ➤

Special tools and workshop equipment required

♦ Thrust block -T10083-

Dismantling

– Remove selector mechanism ⇒ page 63

– 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 58 .

1. Overview - selector mechanism 59

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– 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.

Note

♦

Note guides -A- when performing the following steps.

♦

They must not be allowed to 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”.

60 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– 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.)

Audi TT 2007 ➤

– 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- .

• The gear lever guide should protrude out of the selector hous‐

ing as far as the stop.

1. Overview - selector mechanism 61

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– 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 gate selector lever -arrow 2-.

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

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

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

• The gear lever guide should protrude out of the selector hous‐ ing as far as the 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-.

62 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

• 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 ⇒ page 58 .

– Install selector mechanism ⇒ page 63 .

1.6 Removing and installing selector mech‐ anism

Special tools and workshop equipment required

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

Audi TT 2007 ➤

♦ Torque wrench -V.A.G 1331-

♦ Grease -G 000 450 02-

1. Overview - selector mechanism 63

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

Removing

– Remove gear knob together with trim panel for centre console

⇒ page 53 .

– Remove centre console ⇒ Rep. Gr. 68 .

– Remove noise insulation panels above selector mechanism.

– Remove nuts -arrows-.

– Remove complete air cleaner housing ⇒ Rep. Gr. 24 (does

not apply to engine codes BWA and BPY).

– Detach securing clip -1- for gear selector cable and pull cable

off pin.

Metal gate relay lever:

– Detach securing clip -2- for gate selector cable from gate relay

lever and pull cable off pin.

Plastic gate relay lever:

• To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing relay lever.

– 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 gate relay lever forwards (in direction of

-arrow 3-).

• Detach cable end-piece only when gate relay lever is removed

⇒ page 76 .

– Remove two bolts and one flange nut -arrows- and detach ca‐

ble support bracket from gearbox.

64 Rep. Gr.34 - Controls, housing

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 02Q, front-wheel drive - Edition 04.2010

– Unbolt bracket for exhaust system and cross piece -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-.

Audi TT 2007 ➤

– Remove bolts -arrows-.

– Lower front exhaust pipe with catalytic converter slightly.

– Unclip Lambda probe wire and remove heat shield towards

rear.

– Swing selector housing down and remove with selector ca‐

bles.

Installing

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

– Install selector mechanism and tighten nuts -arrows-. Tight‐

ening torque ⇒ Item 16 (page 59)

1. Overview - selector mechanism 65

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

– 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.

The cables and heat shield are held in the correct positions by clip -A-.

– Secure heat shield -arrows-.

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

cross piece -arrows- ⇒ Engine, mechanics; Rep. Gr. 26 .

66 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Attach cable support bracket to gearbox -arrows-. Tightening

torque ⇒ page 68

– Spread a small amount of grease -G 000 450 02- onto pins

-arrows- of gearbox selector lever -1- and, if necessary, gate relay lever -2-.

• If they are removed, always renew securing clip -3- and, on vehicles with metal gate relay lever, securing clip -4-.

– Fit gear selector cable and secure with securing clip -3-.

Metal gate relay lever:

– Fit gate selector cable and secure with securing clip -4-.

Plastic gate relay lever

– Insert gate selector cable in cable end-piece.

Continued for all vehicles:

– Adjust selector mechanism ⇒ page 79 .

– Fit noise insulation above selector mechanism and install cen‐

tre console ⇒ Rep. Gr. 68 .

– Install gear knob together with boot ⇒ page 53 .

– Install air cleaner housing ⇒ Rep. Gr. 24 (does not apply to

engine codes BWA and BPY).

Audi TT 2007 ➤

1. Overview - selector mechanism 67

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

1.7 Exploded view - gear selector cable and gate selector cable up to model year 2007

Note

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

1 - Securing clip

2 - Cable end-piece

❑ Secures gate selector

cable to gate relay lever ❑ Allocation ⇒ page 69 ❑ Release to adjust selec‐

tor mechanism

⇒ page 80

3 - Securing clip

4 - Cable end-piece

❑ Secures gear selector

cable to gearbox selec‐

tor lever ❑ Allocation ⇒ page 69 ❑ Release to adjust selec‐

tor mechanism

⇒ page 80

5 - Bush

6 - Grommet

7 - Gear selector cable

❑ Removing and installing

⇒ page 77

❑ From vehicle ID No.

8J-7-013001 onwards:

modified attachment on

gear lever inside selec‐

tor mechanism

⇒ Item 8 (page 58)

❑ Adjusting ⇒ page 79

8 - Securing clips

❑ Discontinued for vehicle

ID No. 8J-7-013001 on‐

wards ⇒ page 58

9 - Retaining clips

10 - Gate selector cable

❑ Removing and installing ⇒ page 77 ❑ From vehicle ID No. 8J-7-013001 onwards: modified attachment on gate selector lever inside selector

mechanism ⇒ Item 6 (page 58) ❑ Adjusting ⇒ page 79

11 - Bolt

❑ 20 Nm ❑ 2x

68 Rep. Gr.34 - Controls, housing

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 02Q, front-wheel drive - Edition 04.2010

12 - Cable support bracket

13 - Nut

❑ 20 Nm

Identification of cable end-pieces

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

Cable end-piece for: Dimension “a”

1. - Gear selector cable to gearbox selector lev‐

8.5 mm

er from 06.06 onwards

2. - Gear selector cable to gearbox selector lev‐

10 mm

er up to 05.06

2. - Gate selector cable to metal gate relay lever 8 mm

Audi TT 2007 ➤

From 06.06 onwards: smaller diameter of mounting pin for cable

end-piece (on gear selector cable)

Mounting pin for cable end-piece (on gear se‐

Dimension “a”

lector cable)

Up to 05.06 10 mm From 06.06 onwards 8.5 mm

1. Overview - selector mechanism 69

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

1.8 Exploded view - gearbox selector lever and gate relay lever up to model year 2007

Note

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

1 - Selector mechanism cover

❑ Removing and installing

(with gearbox installed)

⇒ page 156

2 - Selector shaft

❑ Removing and installing

(with gearbox installed)

⇒ page 156

3 - Bush

4 - Securing clip

❑ Removing ⇒ page 71

5 - Oil seal

❑ Renewing ⇒ page 154

6 - Securing clip

7 - Cable end-piece

❑ Secures gear selector

cable to gearbox selec‐ tor lever

⇒ Item 4 (page 68)

❑ Allocation ⇒ page 69

8 - Nut

❑ 23 Nm ❑ Self-locking ❑ Renew

9 - Gearbox selector lever

❑ With damper weight ❑ Install so that gap in

splines aligns with se‐ lector shaft

⇒ page 71

❑ Installation position

⇒ page 71

❑ Different diameters of mounting pin for cable end-piece ⇒ page 69

10 - Securing clip

11 - Cable end-piece

❑ Secures gate selector cable to gate relay lever ⇒ Item 2 (page 68) ❑ Allocation ⇒ page 69 ❑ Release to adjust selector mechanism ⇒ page 80

12 - Gate relay lever

❑ Installation position ⇒ page 71

70 Rep. Gr.34 - Controls, housing

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 02Q, front-wheel drive - Edition 04.2010

13 - Slide block

14 - Bush

15 - Angled rod

❑ For adjusting selector mechanism ⇒ page 79

Removing securing clip for gate relay lever

– Lift clip -arrow-.

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.

Audi TT 2007 ➤

Installation position: gearbox selector lever/gate relay lever

1 - Gearbox selector lever with damper weight

2 - Gate relay lever locates in guide rail of gearbox selector lever via slide block -arrow-.

– Coat guide rail and slide block -arrow- with grease -G 000 450

02- .

1. Overview - selector mechanism 71

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

1.9 Exploded view - gear selector cable and gate selector cable from model year 2008 onwards

Note

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

1 - Gearbox

2 - Clip

❑ Not fitted on all versions ❑ For gate relay lever from

08.2008 onwards

❑ Detaching and fitting

⇒ page 76

3 - Gearbox selector lever

❑ Fitting ⇒ page 74 ❑ Installation position

⇒ page 74

❑ After installing, adjust

selector mechanism

⇒ page 79

4 - Cable end-piece

❑ Secures gear selector

cable to gearbox selec‐

tor lever ❑ Allocation ⇒ page 73 ❑ Detaching from gear se‐

lector cable

⇒ page 74

5 - Securing clip

❑ Removing ⇒ page 75 ❑ Renew

6 - Nut

❑ Self-locking ❑ Renew ❑ 23 Nm

7 - Retaining clip

❑ Renew

8 - Gear selector cable

❑ Detaching and securing at gearbox selector lever ⇒ page 75 ❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79

9 - Gate selector cable

❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79

10 - Selector housing

11 - Retaining clips

❑ Renew

72 Rep. Gr.34 - Controls, housing

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

12 - Retaining clip

❑ Renew

13 - Cable support bracket

14 - Bolt

❑ 20 Nm ❑ 2x

15 - Grommet

16 - Bush

17 - Nut

❑ 20 Nm

18 - Gate relay lever

❑ Made of plastic ❑ Different versions available; for correct version refer to ⇒ Electronic parts catalogue ❑ Installation position ⇒ page 74 ❑ Detaching and securing gate relay lever (with detent catch) at gearbox selector lever ⇒ page 75 ❑ Detaching and securing gate relay lever (with clip) at gearbox selector lever ⇒ page 76

19 - Slide block

❑ Installation position ⇒ page 74

20 - Cable end-piece

❑ Secures gate selector cable to gate relay lever ❑ Allocation ⇒ page 69 ❑ Detaching from gate selector cable ⇒ page 74

21 - Angled rod

❑ For adjusting selector mechanism ⇒ page 79

Identification of cable end-pieces

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

Cable end-piece for: Dimension “a”

-1- Gear selector cable to gearbox selector lever 8.5 mm

-2- Gate selector cable to gate relay lever 10 mm

1. Overview - selector mechanism 73

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

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: gearbox selector lever/gate relay lever

1 - Gearbox selector lever

2 - Clip or detent catch (depending on version)

3 - Gate relay lever locates in guide rail of gearbox selector lever via slide block -arrow-.

– Coat guide rail and slide block -arrow- with grease -G 000 450

02- .

Detaching cable end-pieces from gear selector cable and gate selector cable

– Pull locking mechanism forwards -arrow 1- onto stop and then

turn to left -arrow 2- to lock.

– Take cable -B- out of cable end-piece -A-.

74 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Detaching and securing gear selector cable at gearbox selector

lever

Detaching

– Lift up tab and detach securing clip -3- for gear selector cable

from gearbox selector lever -1-.

– Pull gear selector cable -2- off pin -arrow-.

Securing

Note

♦

Renew securing clip for gear selector cable.

♦

Apply a small quantity of grease -G 000 450 02- to the pin

-arrow-.

– Push gear selector cable -2- onto gearbox selector lever -1-

and secure with securing clip -3-.

Detaching and securing gate relay lever (with detent catch) at

gearbox selector lever -arrow 1-

Detaching

– Press in detent -arrow 1- as far as stop and remove gate relay

lever together with cable end-piece (move relay lever in nor‐ mal direction of operation).

Audi TT 2007 ➤

Note

-Arrow 2- can be disregarded.

Securing

Note

To install, lubricate bearings and moving surfaces with grease -

G 000 450 02- .

– Press cable end-piece onto gate relay lever ⇒ page 76 .

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

• Gate relay lever is secured by detent -arrow 1-.

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

• Ensure that components engage securely.

1. Overview - selector mechanism 75

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Detaching and securing gate relay lever (with clip) at gearbox se‐ lector lever -arrow 1-

Detaching

– Remove clip -arrow 1- and take off gate relay lever together

with cable end-piece.

Securing

Note

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

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

– Press on clip -arrow 1-, making sure it engages securely.

Note

-Arrow 2- can be disregarded.

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

• Gate relay lever removed

– Apply plain slot screwdriver -A- between bush -B- and gate

relay lever.

Pressing cable end-piece for gate selector cable onto gate relay lever

• Gate relay lever removed

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

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

• Cable end-piece must be behind detent.

– Ensure that components engage securely.

76 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

1.10 Removing and installing gear selector cable and gate selector cable

Removing

– Remove selector mechanism ⇒ page 63 .

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

mechanism on floor plate and remove floor plate.

– Remove gasket.

Vehicles with vehicle ID No. up to 8J-7-013000:

– Detach securing clips -1- and -4- and pull both cables off pins.

Vehicles with vehicle ID No. from 8J-7-013001 onwards:

– Prise gear selector cable and gate selector cable off pins.

Continued for all vehicles:

– Take off securing clips -2 ... 3- and detach gear selector cable

and gate selector cable from selector housing.

Audi TT 2007 ➤

Release cable end-pieces -A- for gate selector cable and gear selector cable -B- as follows:

– Push locking sleeve forwards as far as stop -arrow 1-.

– Turn locking sleeve clockwise as far as stop -arrow 2- so that

it engages.

– Detach cable end-pieces from cables.

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

– Detach cable support bracket from cables.

1. Overview - selector mechanism 77

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

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 ... 4-.

Vehicles with vehicle ID No. from 8J-7-013001 onwards:

– Press gear selector cable and gate selector cable onto pins.

Continued for all vehicles:

– Fit new gasket and secure new floor plate to selector mecha‐

nism by bending over tabs -arrows-.

– Install selector mechanism ⇒ page 63 .

– Adjust selector mechanism ⇒ page 79 .

78 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

2 Adjusting selector mechanism

Special tools and workshop equipment required

♦ Locking pin -T10027 A-

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.

Audi TT 2007 ➤

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

2nd gear gate.

– Lift noise insulation plate.

– Then guide locking pin -T10027A- through hole -A- and into

hole -B-.

Note

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

2. Adjusting selector mechanism 79

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Remove complete air cleaner housing ⇒ Rep. Gr. 24 (does

not apply to engine codes BWA and BPY).

Release cable end-pieces -A- for gate selector cable and gear selector cable -B- as follows:

– Push locking sleeve forwards as far as stop -arrow 1-.

– Turn locking sleeve clockwise as far as stop -arrow 2- so that

it engages.

Note

It should be possible to move selector cable -B- in the cable endpiece.

• Gearbox in neutral.

Lock the selector shaft as follows:

– Press down gearbox selector lever -1- in direction of arrow

-A-.

– At the same time press and turn angled rod -2- in direction of

arrows -B- and -C- until it engages.

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

– Check that gate selector cable and gear selector cable -B- are

located in cable end-pieces -A- without tension.

– Release locking sleeve -arrow 1-.

– Allow locking sleeve to slide onto stop -arrow 2-.

Cable adjustment is now complete.

80 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Turn angled rod -A- back to initial position in direction of

-arrow 2- and pull out of gearbox in direction of -arrow 1-.

– Pull locking pin -T10027 A- out of selector mechanism.

Checking gear lever setting

• With the gearbox in neutral, the gear lever should rest in the

3rd/4th gear gate.

– Depress clutch.

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

operation of the reverse gear locking mechanism.

• The gear lever should return by itself from the reverse gear

gate to the 3rd/4th gear gate.

If the gear lever sticks or baulks repeatedly when engaging a gear, perform the adjustment procedure again.

– Fit cover and trim panel for centre console.

– Install air cleaner housing ⇒ Rep. Gr. 24 (does not apply to

engine codes BWA and BPY).

Audi TT 2007 ➤

2. Adjusting selector mechanism 81

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

3 Removing and installing gearbox

⇒ “3.1 Removing gearbox on vehicles with 2.0 ltr. FSI turbo‐ charged engine”, page 82 .

⇒ “3.2 Installing gearbox on vehicles with 2.0 ltr. FSI turbocharged engine”, page 93

⇒ “3.3 Transporting gearbox”, page 99

3.1 Removing gearbox on vehicles with 2.0 ltr. FSI turbocharged engine

Special tools and workshop equipment required

♦ Support bracket -10-222A-

♦ Rack -10 - 222 A /1-

♦ Hooks -10 - 222 A /10-

♦ Hose clamps, up to Ø 25

mm -3094-

♦ Gearbox support -3282-

♦ Pin -3282/29-

♦ Adjustment plate -3282/52-

♦ Safety support -3282/59-

♦ Adjustment plate -3282/33-

Special tools and workshop equipment required

82 Rep. Gr.34 - Controls, housing

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♦ Engine support -3300 A-

♦ Support -T10036-

Audi TT 2007 ➤

6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

♦ Adapter -VW 771/40-

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

♦ Bolt M6×20 (2x)

♦ Bolt M10×20

♦ Grease -G 000 450 02-

♦ Grease for clutch plate splines -G 000 100-

3. Removing and installing gearbox 83

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Procedure

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 .

– With ignition switched off, disconnect battery earth cable

-arrow- ⇒ Rep. Gr. 27 .

Vehicles with air filter element incorporated in engine cover panel (engine codes BWA and BPY)

– Remove engine cover panel with air filter element ⇒ Rep. Gr.

24 .

Vehicles with air cleaner housing on left side of engine compart‐ ment

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

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

housing.

84 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Carefully pull off engine cover panel -arrows-. Pull out engine

cover panel evenly, without jerking.

Continued for all vehicles

– Detach securing clip -1- and pull cable end-piece off pin.

Metal gate relay lever:

– Detach securing clip -2- and pull cable end-piece off gate relay

lever.

Audi TT 2007 ➤

Plastic gate relay lever:

• To prevent damage to gate selector cable, cable end-piece

must be detached from gate selector cable before removing relay lever.

– 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 gate relay lever forwards (in direction of

-arrow 3-).

• Detach cable end-piece only when gate relay lever is removed

⇒ page 76 .

Continued for all vehicles:

– Detach cable support bracket from gearbox -arrows-; then

move to one side and tie up together with selector cables.

3. Removing and installing gearbox 85

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Unscrew top engine/gearbox securing bolts -arrows-.

– Remove the two top bolts on radiator cowl -top arrows-.

– Raise vehicle.

– Remove noise insulation (centre) by releasing fasteners

-1 ... 4-.

– Remove noise insulation (left-side) -arrows-.

86 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Remove noise insulation frame -arrow-.

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

air hose.

Audi TT 2007 ➤

– Unplug electrical connector -2- for reversing light switch -F4- .

– Remove nut -1- and detach bracket from stud together with

electrical wiring.

– Move bracket and wiring clear to the side.

– Remove bottom bolt securing starter -1-.

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

3. Removing and installing gearbox 87

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Detach electrical connector -1-.

– Remove remaining bolts -bottom arrows- and take out radiator

cowl from below.

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

– Unbolt drive shafts (left and right) from gearbox flange shafts

-A-.

Note

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

– If fitted, remove small flywheel cover plate -A- -arrows-.

88 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– 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°.

– Using hose clamp -3094- , clamp off supply hose to master

cylinder.

Audi TT 2007 ➤

Note

In the following steps make sure that no brake fluid escapes onto the starter or onto the gearbox below. If this does happen, clean the affected area thoroughly.

– Pull clip -arrow- out as far as stop.

– Pull plastic pipe -A- out of bleeder connection for clutch slave

cylinder and seal end of pipe.

Caution

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

– Remove nut -B- and detach earth wire.

– Then remove upper securing bolt from starter -B-.

– Place starter to side onto longitudinal member.

3. Removing and installing gearbox 89

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Set up support bracket -10 - 222 A- together with racks -10 -

222 A /1- on wing mounting flanges.

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

(left-side).

– Partly take up weight of engine with spindle, but do not lift.

– Remove bolts on gearbox mounting -arrows-.

– By adjusting spindles on support bracket -10 - 222 A- , lower

gearbox by distance -a-.

• Dimension -a- = 60 mm

– Unbolt gearbox bracket from gearbox -arrows-.

90 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Metal gate relay lever -1-:

– Pull off securing clip -arrow- and remove gate relay lever -1-.

Plastic gate relay lever -1-:

– Removing gate relay lever (with detent catch) ⇒ page 75

– Removing gate relay lever (with clip) ⇒ page 75

Continued for all vehicles:

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

trated (if holes have not already been drilled).

• Dimension -a- = 11 mm.

• Dimension -b- = 98 mm

• Dimension -c- = 70 mm

Audi TT 2007 ➤

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

M6×20 bolts.

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

3. Removing and installing gearbox 91

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– 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.

– Move drive shaft (left-side) towards the rear as far as possible.

– Remove engine/gearbox connecting bolts (bottom) -4-.

To remove gearbox “02Q” set up gearbox support -3282- with adjustment plate -3282/33- .

– Fit gearbox support -3282- into engine/gearbox jack -V.A.G

1383A- .

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

ment plate .

– Bolt on support elements -A-, as illustrated on adjustment

plate .

– Screw in pin -3282/29- instead of support element -C-.

– Place engine/gearbox jack under vehicle; arrow symbol -B- on

adjustment plate points to front of vehicle.

– Align adjustment plate and gearbox parallel to one another.

– Secure adapter -VW 771/40- in tapped hole of gearbox hous‐

ing, as shown in illustration.

– Screw pin -3282/29- into hole for bolt that secures pendulum

support to gearbox (see next illustration).

– Secure gearbox to gearbox support -3282- with bolt M10x20

-A-.

Make sure pin -B- is flush at bottom with guide of gearbox support

-3282- -arrow-.

– Remove engine/gearbox connecting bolt -C-.

92 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– Remove last engine/gearbox connecting bolt -arrow-.

– Press gearbox off engine (dowel sleeves).

– Tilt gearbox to the front by turning spindle of gearbox support

-3282- in direction of -arrow-.

– Then tilt gearbox to the left by turning spindle of gearbox sup‐

port -3282- .

– Guide gearbox past subframe, push forwards slightly and and

lower out carefully.

– Transporting gearbox ⇒ page 99 .

Installing gearbox ⇒ page 93 .

Audi TT 2007 ➤

3.2 Installing gearbox on vehicles with 2.0 ltr. FSI turbocharged engine

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

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 ⇒ Electronic 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 for clutch plate splines -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.

♦

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).

– Use thread tap to remove any remaining locking fluid from all

threaded holes which will accommodate self-locking bolts.

3. Removing and installing gearbox 93

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

– 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 36 .

– Check that clutch plate is centralised ⇒ page 47 .

– Tilt gearbox to the front by turning spindle of gearbox support

-3282- in direction of -arrow-.

– Raise gearbox carefully and move to installation position using

gearbox support -3282- .

– Align gearbox with engine and install.

– Secure gearbox and starter to engine. Tightening torque

⇒ page 98

– Insert drive shaft (left-side) into gearbox flange.

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

– Lubricate bearings and moving surfaces of gate relay lever

-1- with grease -G 000 450 02- .

Metal gate relay lever -1-

– Insert gate relay lever -1- and secure with securing clip

-arrow-.

Plastic gate relay lever -1-

– Fit gate relay lever (with detent catch) ⇒ page 75 .

– Fit gate relay lever (with clip) ⇒ page 75 .

94 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Continued for all vehicles:

– Install gearbox bracket ⇒ page 101 .

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

spindles of support bracket -10 - 222 A- until gearbox bracket

-1- makes contact with gearbox mounting -2-.

Note

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

Audi TT 2007 ➤

– Install gearbox mounting ⇒ page 101 .

Note

When installing gearbox ensure engine/gearbox mountings are installed stress-free ⇒ Rep. Gr. 10 .

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.

– Install pendulum support ⇒ page 101 .

3. Removing and installing gearbox 95

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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, front-wheel drive - Edition 04.2010

Note

♦

Gearboxes manufactured from 28 05 7 onwards have thread inserts (e.g. “Heli-Coil”) in the bolt holes for the pendulum sup‐ port.

♦

These can be recognised by the shoulder on the first thread turn -arrow-.

♦

Please use the correct securing bolts and observe the speci‐ fied tightening torques ⇒ Item 2 (page 101) .

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

mechanics; Rep. Gr. 26 .

– If fitted, install small cover plate -A- at rear of bevel box

-arrow- ⇒ page 98 .

– Secure drive shafts (left and right) to gearbox ⇒ Running gear,

front-wheel drive and four-wheel drive; Rep. Gr. 40 .

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

⇒ page 98 .

– Install radiator cowl ⇒ Rep. Gr. 19 .

– Install starter ⇒ Rep. Gr. 27 .

– Plug in connector at reversing light switch -F4- .

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

onto retaining lug -A-.

– Install pipe/hose assembly or plastic pipe ⇒ page 29 .

– Bleed clutch system ⇒ page 31 .

96 Rep. Gr.34 - Controls, housing