Audi TT 62 User Manual
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive
Edition 06.2009
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt D3E802054D6
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 0A6, four-wheel drive - Edition 06.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Bevel box identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Code letters, allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Overview - clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Exploded view - pedal cluster, clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Exploded view - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Removing and installing pipe/hose assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Exploded view - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Exploded view - clutch release mechanism, clutch slave cylinder . . . . . . . . . . . . . . . . . . . . 30
4.1 Removing and installing clutch slave cylinder with release bearing . . . . . . . . . . . . . . . . . . 31
5 Exploded view - LuK version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 Exploded view - gear knob and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Removing and installing gear knob with gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 Assembly overview - gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Exploded view - gear selector cable and gate selector cable . . . . . . . . . . . . . . . . . . . . . . 51
4.1 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 52
5 Exploded view - gearbox selector lever and gate relay lever . . . . . . . . . . . . . . . . . . . . . . . . 54
6 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.1 Removing gearbox - vehicles with 2.5 ltr. TFSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.2 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10 Removing and installing bevel box (gearbox installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
11 Checking oil level in manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12 Overview - gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12.1 Checking gear oil level in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contents i
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
12.2 Topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
13 Securing gearbox to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
14 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
14.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
14.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
14.3 Exploded view - removing and installing gearbox housing and selector unit . . . . . . . . . . . . 94
14.4 Exploded view - removing and installing input shaft, output shafts, differential, selector rods
and bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
14.5 Dismantling and assembling sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
15 Servicing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
16 Servicing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
17 Servicing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
17.1 Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
18 Exploded view - dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . 120
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2 Exploded view - output shaft for 1st and 2nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.1 Dismantling and assembling output shaft for 1st and 2nd gear . . . . . . . . . . . . . . . . . . . . . . 130
3 Exploded view - output shaft for 3rd – 6th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.1 Dismantling and assembling output shaft for 3rd – 6th gear . . . . . . . . . . . . . . . . . . . . . . . . 142
4 Exploded view - output shaft for reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.1 Dismantling and assembling output shaft for reverse gear . . . . . . . . . . . . . . . . . . . . . . . . 153
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1 Renewing stub shaft oil seal (left-side) with gearbox installed . . . . . . . . . . . . . . . . . . . . . . 162
2 Renewing stub shaft oil seal (right-side) with bevel box installed . . . . . . . . . . . . . . . . . . . . 165
3 Renewing oil seal between gearbox and bevel box with gearbox installed . . . . . . . . . . . . 168
4 Exploded view - oil seals in bevel box and stub shaft bearing in bevel box . . . . . . . . . . . . 170
4.1 Renewing oil seal between gearbox and bevel box (on bevel box) . . . . . . . . . . . . . . . . . . 171
4.2 Renewing stub shaft oil seals (with bevel box removed) . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.3 Renewing output flange oil seal on bevel box (bevel box removed) . . . . . . . . . . . . . . . . . . 175
4.4 Renewing needle bearing (polygon bearing) on stub shaft of bevel box . . . . . . . . . . . . . . 180
5 Exploded view - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7 Rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
ii Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
00 – Technical data
1 Gearbox identification
The 6-speed manual gearbox 0A6, four-wheel drive is installed in
the Audi TT 2007 ▸. Allocation ⇒ page 2 .
Location on gearbox
♦ Code letters and date of manufacture -arrow 1-
♦ Manual gearbox 0A6, four-wheel drive -arrow 2-
Manual gearbox 0A6, four-wheel drive -arrow 2-
Audi TT 2007 ➤
Code letters and date of manufacture of gearbox -arrow 1-
Example: LNA 04 03 9
Additional data identify the factory where the unit was built.
Note
I I I I
Code letters Day Month Year of manufac‐
ture (2007)
The code letters for the gearbox are also given on the vehicle data
stickers.
1. Gearbox identification 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
2 Code letters, allocation, transmission ratios, capacities
Manual gearbox 0A6 four-wheel drive
Code letters
Manufactured from 07.08 03.09
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸
Ratio Final drive I
for 1st/2nd gear
i = Z2 : Z
1
for 3rd – 6th gear
for reverse gear
Capacity of manual gearbox 2.3 litres
Capacity of bevel box 0.9 litres
Clutch actuation Hydraulic
The following data can be found in the ⇒ Electronic parts catalogue .
♦ Individual gear ratios
♦ Gear oil specification
♦ Allocation of bevel box
♦ Allocation of drive shaft flange type
♦ Allocation of clutch type
♦ Rear final drive identification
to
LNA MCK
Engine 2.5 ltr. TFSI - 250 kW 2.5 ltr. TFSI - 250 kW
64 : 17 = 3.765 64 : 17 = 3.765
Final drive II
Final drive III
64 : 22 = 2.909 64 : 22 = 2.909
64 : 20 = 3.200 64 : 20 = 3.200
2 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
3 Bevel box identification
The bevel box 0AU or 0A6 is used in conjunction with the 6-speed
manual gearbox 0A6 (four-wheel drive).
♦ ⇒ “3.1 Code letters, allocation, capacities”, page 3
Location on bevel box
Code letters and part number of bevel box -arrow-
-Arrow A- part number of bevel box
-Arrow B- code letters of bevel box
-Arrow C- bevel box 0AU or 0A6
♦ If the code letters are not shown, the unit can be identified via
the Part No. ⇒ Electronic parts catalogue .
Additional data are manufacture-related.
Audi TT 2007 ➤
3.1 Code letters, allocation, capacities
Bevel box 0AU/0A6
Code letters LGS LGY LGZ
Manufactured from
to
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
Engine 2.5 ltr. TFSI - 250 kW 2.5 ltr. TFSI - 250 kW 2.5 ltr. TFSI - 250 kW
Capacity 0.9 litres
The following data can be found in the ⇒ Electronic parts catalogue .
♦ Bevel box gear oil specification
♦ Allocation of manual gearbox
07.08 07.08 07.08
3. Bevel box identification 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
4 Transmission layout
Identification
Note
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 1st/2nd
gear
6 - Output shaft for reverse
gear
7 - Output shaft for 3rd – 6th
gear
8 - Differential
9 - Bevel box
10 - Propshaft
11 - Haldex coupling
12 - Rear final drive
13 - Differential
Ratio
Note
-Arrows- point in direction of travel.
4 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
W1 - Front bevel gears
W2 - Rear bevel gears
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
4. Transmission layout 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
5 General repair instructions
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. The usual basic safety
precautions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
5.1 Contact corrosion!
♦ The gearbox housing components can be made of a magne‐
sium or aluminium alloy.
♦ Bolts and other components which are in direct contact with
the gearbox have a surface treatment which is compatible with
the housing material.
♦ If the incorrect parts are used (bolts, nuts, washers etc.), this
will cause contact corrosion and damage the gearbox housing
components.
♦ If you are not sure whether used parts can be re-installed, al‐
ways fit new parts ⇒ Electronic parts catalogue .
Caution
Damage caused by contact corrosion is not covered under
warranty.
5.2 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 manual gearbox, ensure that the dowel
sleeves between the engine and the gearbox are correctly lo‐
cated.
♦ 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
⇒ “11 Checking oil level in manual gearbox”, page 85 or
⇒ “12.1 Checking gear oil level in bevel box”, page 86 .
♦ Capacities and specifications ⇒ page 2
6 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
Oil seals, seals, O-rings and gaskets
♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ 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 such that the
sealing lip does not contact the shaft in the same place as the
old seal (make use of installation depth tolerances).
♦ 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
⇒ “11 Checking oil level in manual gearbox”, page 85 or
⇒ “12.1 Checking gear oil level in bevel box”, page 86 .
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.
Audi TT 2007 ➤
5. General repair instructions 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
Locking elements
♦ Do not over-stretch circlips.
♦ Renew circlips which have been damaged or over-tensioned.
♦ Circlips must be properly seated in the base of the groove.
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.
Nuts, bolts
♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Renew self-locking nuts and bolts.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
♦ For all threaded connections, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with
wax until after assembly is completed.
Bearings
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Lubricate all bearings (except tapered roller bearings) with
gear oil before installing in gearbox.
♦ Heat inner races of tapered roller bearings to approx. 100°C
before installing. Press in onto stop when installing so there is
no axial clearance.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ If required, renew the tapered roller bearings on one shaft to‐
gether and use new bearings from a single manufacturer.
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to obtain the exact shim
thickness required.
♦ Check for burrs and damage. Install only shims which are in
perfect condition.
Synchro-rings
8 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
♦ 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 with gear oil before installing.
Gear wheels
♦ Before installing, clean and heat on a hotplate to approx. 100°
C.
♦ 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
♦ After installing, check 1st to 6th speed selector gears for min‐
imal axial play and freedom of movement.
Audi TT 2007 ➤
♦ Abnormal wear on synchro-ring or selector gear:
A - Worn ends of dog teeth on synchro-ring or selector gear.
♦ In comparison: intact synchro-ring or selector gear:
B - Intact ends of dog teeth on synchro-ring or selector gear.
5. General repair instructions 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
♦ Abnormal wear on locking collar:
C - Worn ends of internal splines on locking collar.
♦ In comparison: intact locking collar:
D - Intact ends of internal splines on locking collar.
Clutch actuation
♦ 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 clutch housing,
flywheel and parts of the engine facing the gearbox in order to
prevent odour.
♦ Only blow out dual-mass flywheel with compressed air.
♦ Pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the
clutch plate, the pressure plate may not be cleaned. Otherwise
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.
♦ If the clutch pedal does not return to its initial position after it
is released (clutch pedal in rest position), you must bleed the
clutch system.
10 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
30 – Clutch
1 Overview - clutch mechanism
I -
⇒ “2 Exploded view - pedal
cluster, clutch master cylin‐
der”, page 12
⇒ “2.1 Removing and installing
over-centre spring”, page 13
⇒ “2.2 Removing and installing
clutch pedal”, page 15
⇒ “2.3 Removing and installing
mounting bracket”, page 18
⇒ “2.4 Removing and installing
clutch position sender G476 ”,
page 20
Audi TT 2007 ➤
⇒ “2.5 Removing and installing
clutch master cylinder”,
page 21
II -
⇒ “3 Exploded view - hydraul‐
ics (LHD)”, page 24
⇒ “3.1 Removing and installing
pipe/hose assembly”,
page 25
III -
⇒ “3.2 Exploded view - hy‐
draulics (RHD)”, page 27
⇒ “3.3 Bleeding clutch sys‐
tem”, page 28
1. Overview - clutch mechanism 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
2 Exploded view - pedal cluster, clutch master cylinder
1 - Bulkhead
❑ With mounting for
mounting bracket
2 - Gasket
❑ Renew
❑ Between mounting
bracket and bulkhead
❑ Self-adhesive
❑ Bond onto mounting
bracket
3 - Mounting bracket
❑ For clutch pedal
❑ Removing and installing
⇒ page 18
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 13
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 15
9 - Retaining clip
❑ For operating rod for
clutch master cylinder
10 - Seal
❑ Renew
❑ Between clutch master
cylinder and mounting
bracket
11 - Clutch master cylinder
❑ Removing and installing ⇒ page 21
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 20
❑ Can be checked in “Guided Fault Finding”, using vehicle diagnostic, testing and information system -
VAS 5051-
13 - Retaining clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
14 - Supply hose
❑ To brake fluid reservoir
15 - Nut
❑ For securing mounting bracket to bulkhead
❑ 20 Nm
❑ 3x
❑ Self-locking
❑ Renew
12 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
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
Audi TT 2007 ➤
2.1 Removing and installing over-centre spring
Special tools and workshop equipment required
♦ Assembly tool -T10178-
♦ Grease -G 000 450 02-
2. Exploded view - pedal cluster, clutch master cylinder 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
Removing
• Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,
remove nut -2- and pull out bolt -5-.
Note
The clutch pedal does not have to be detached from the operating
rod on the clutch master cylinder.
– Pivot clutch pedal down slightly and and take over-centre
spring -4- out of mounting bracket.
Installing
• Tightening torque ⇒ page 12
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nut.
♦
Lubricate all bearings and contact surfaces with grease -G 000
450 02- .
– Fit over-centre spring -2- into mounting bracket from above
while holding end of spring in correct position with assembly
tool -T10178- .
14 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
• Socket -arrow- of over-centre spring must be in vertical posi‐
tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press clutch pedal slightly, push bolt through and tighten self-
locking nut.
– Install crash bar ⇒ page 13 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2.2 Removing and installing clutch pedal
Special tools and workshop equipment required
♦ Pliers -T10005-
Audi TT 2007 ➤
♦ Assembly tool -T10178-
♦ Grease -G 000 450 02-
2. Exploded view - pedal cluster, clutch master cylinder 15
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
Removing
• Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,
remove nut -2- and pull out bolt -5-.
Note
-Item 4- can be disregarded.
– Release retaining clip for operating rod on clutch pedal using
pliers -T10005- .
– Remove clutch pedal.
16 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
Installing
• Tightening torque ⇒ page 12
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nut.
♦
Lubricate all bearings and contact surfaces with grease -G 000
450 02- .
– Position retaining clip -2- on operating rod -1- for clutch 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- .
Audi TT 2007 ➤
• Socket -arrow- of over-centre spring must be in vertical posi‐
tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press top of clutch pedal forwards against spring pressure of
over-centre spring, push through bolt and tighten self-locking
nut.
Note
It is easier to press the 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 13 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2. Exploded view - pedal cluster, clutch master cylinder 17
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 0A6, four-wheel drive - Edition 06.2009
2.3 Removing and installing mounting bracket
Special tools and workshop equipment required
♦ Hose clamps, up to Ø 25 mm -3094-
♦ Torque wrench -V.A.G 1331-
♦ Sealing tool -T10249-
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.
♦
Place a lint-free cloth under the master cylinder.
18 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
– Use hose clamp -3094- to clamp off supply hose to clutch
master cylinder.
– Pull supply hose -1- off master cylinder.
– Additionally seal off supply hose -1- using sealing tool -
T10249/1- (⇒ illustration above).
– Release securing clip -2- and disconnect pipe -3-.
– Unclip and detach clutch position sender -G476- from clutch
master cylinder -arrow-. Electrical connector -4- can remain
connected.
Audi TT 2007 ➤
– 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).
2. Exploded view - pedal cluster, clutch master cylinder 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
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 12
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nuts.
♦
Renew O-rings
♦
Secure all hose connections with the correct hose clips (as
original equipment); refer to ⇒ Electronic parts catalogue .
– Fit mounting bracket -1- and tighten nuts -2-.
– Install pipe/hose assembly ⇒ page 25 .
– Bleed clutch system ⇒ page 28 .
– Install crash bar ⇒ page 13 .
– 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
– Unclip clutch position sender -G476- at clutch master cylinder
in direction of -arrow- and remove.
– Unplug electrical connector -4-.
Note
-Items 1, 2 and 3- can be disregarded.
20 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
Installing
– Fit clutch position sender -G476- at clutch master cylinder and
engage -arrow-.
– Attach electrical connector -4-.
Note
-Items 1, 2 and 3- can be disregarded.
2.5 Removing and installing clutch master cylinder
Audi TT 2007 ➤
Special tools and workshop equipment required
♦ Pliers -T10005-
Removing
– Remove mounting bracket ⇒ page 18 .
– Release retaining clip for operating rod on clutch pedal using
pliers -T10005- .
2. Exploded view - pedal cluster, clutch master cylinder 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.
•
Length of spacer = approx. 40 mm (e.g. 1/2” socket)
– Release retaining clip -B- and pull clutch master cylinder out
of mounting bracket -arrow 1- and -arrow 2-.
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.
– 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 clutch master cylinder on mounting bracket -arrow 1-
and -arrow 2-.
22 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
– Press operating rod -1- for clutch master cylinder in direction
of -arrow- so that retaining clip -2- snaps into place in clutch
pedal.
– Install mounting bracket ⇒ page 18 .
Audi TT 2007 ➤
2. Exploded view - pedal cluster, clutch master cylinder 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
3 Exploded view - hydraulics (LHD)
1 - Brake fluid reservoir
2 - Seal
❑ 2x
❑ Seals must be fitted in
supply hose
⇒ Item 3 (page 24)
3 - Supply hose
4 - Retaining clip
❑ To remove and install
retaining clip, first de‐
tach clutch master cylin‐
der from clutch pedal
⇒ page 15
5 - Clutch pedal
❑ Removing and installing
⇒ page 15
6 - Clutch master cylinder
❑ Removing and installing
⇒ page 21
7 - Clip
❑ To remove and install
pipe/hose assembly,
pull out clip as far as it
will go
8 - Nut
❑ For securing mounting
bracket to bulkhead
❑ Tightening torque
⇒ Item 15 (page 12)
9 - Seal or O-ring
❑ Renew damaged O-
rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 25
❑ For correct version, refer to ⇒ Electronic parts catalogue
10 - Pipe/hose assembly
❑ Removing and installing ⇒ page 25
❑ For correct version, refer to ⇒ Electronic parts catalogue
11 - Bracket
❑ For pipe/hose assembly ⇒ Item 10 (page 24)
❑ Secured on body
12 - Seal or O-ring
❑ Renew damaged O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 25
❑ For correct version, refer to ⇒ Electronic parts catalogue
24 Rep. Gr.30 - Clutch
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
13 - Bleeder connection
14 - Seal or O-ring
❑ Renew damaged O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 25
❑ For correct version, refer to ⇒ Electronic parts catalogue
15 - Clip
❑ To remove and install pipe/hose assembly or bleeder connection, pull out clip as far as it will go.
16 - Bleeder screw
❑ 4.5 Nm
❑ Bleeding clutch system ⇒ page 28
17 - Dust cap
18 - Clutch slave cylinder with release bearing
❑ Can only be renewed after removing gearbox
❑ Removing and installing ⇒ page 31
19 - Gearbox
Seal/O-ring for pipe/hose assembly
1 - O-ring
♦ Connection with annular groove -arrow 1-
2 - Seal
♦ Connection with shoulder -arrow 2-
3.1 Removing and installing pipe/hose as‐
sembly
Special tools and workshop equipment required
♦ Hose clamps, up to Ø 25 mm -3094-
Removing
– Remove air cleaner housing completely ⇒ Rep. Gr. 24 .
3. Exploded view - hydraulics (LHD) 25
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009
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.
Note
Place a cloth underneath to catch escaping brake fluid.
– Release retaining clip -3- on clutch master cylinder with a
screwdriver.
– Disconnect pipe/hose assembly -1- and detach from bracket.
Note
Place a cloth underneath to catch escaping brake fluid.
– Release retaining clip -2- on bleeder connection -1- with a
screwdriver and disconnect pipe/hose assembly -4-.
Installing
Installation is carried out in reverse sequence; note the following:
Note
For distinction between O-rings -2- and seals on different ver‐
sions, refer to ⇒ page 25 .
– Check O-ring -2- for damage and renew if necessary.
– Press pipe/hose assembly -1- onto connection on clutch mas‐
ter cylinder -4- so that retaining clip -3- snaps into place.
– Pull on pipe to check it is secure.
26 Rep. Gr.30 - Clutch
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