Audi TT 62 User Manual

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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.

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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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

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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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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

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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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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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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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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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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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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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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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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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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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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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

– Push pipe/hose assembly -4- into bleeder connection -1- so

that retaining clip -2- snaps into place.

– Pull on pipe to check it is secure.

– Bleed clutch system ⇒ page 28 .

3.2 Exploded view - hydraulics (RHD)

1 - Brake fluid reservoir

2 - Seal

❑ 2x ❑ Seals must be fitted in

supply hose

⇒ Item 3 (page 27)

3 - Supply hose

4 - Clutch master cylinder

❑

5 - Clip

❑ To remove and install

pipe, pull out clip as far as it will go

6 - Seal or O-ring

❑ Renew damaged O-

rings

❑ Push onto pipe connec‐

tion

❑ Lubricate with brake flu‐

id before installing

❑ Whether a seal or an O-

ring is used depends on the type of connection

⇒ page 25

❑ For correct version, re‐

fer to ⇒ Electronic parts catalogue

7 - Retaining clip

❑ To remove and install

retaining clip first detach master cylinder from clutch pedal ⇒ page 15

8 - Clutch pedal

9 - Nut

❑ For securing mounting bracket to bulkhead ❑ Tightening torque ⇒ Item 15 (page 12)

10 - Bracket

❑ Secured on body

Audi TT 2007 ➤

3. Exploded view - hydraulics (LHD) 27

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

11 - Pipe

❑ Can be combined as one unit with pipe/hose assembly ⇒ Item 13 (page 28) on some versions ❑ For correct version, refer to ⇒ Electronic parts catalogue

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

13 - Pipe/hose assembly

❑ Can be combined as one unit with pipe ⇒ Item 11 (page 27) on some versions ❑ For correct version, refer to ⇒ Electronic parts catalogue

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

❑ Bleeding clutch system ⇒ page 28

17 - Dust cap

18 - Bleeder connection

19 - 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

20 - Clutch slave cylinder with release bearing

❑ Can only be renewed after removing gearbox ❑ Removing and installing ⇒ page 31

21 - Gearbox

3.3 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.

Special tools and workshop equipment required

28 Rep. Gr.30 - Clutch

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

♦ Brake filling and bleeding equipment -VAS 5234-

♦ Brake fluid specification ⇒ Rep. Gr. 47.

Procedure

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

– 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 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. Tightening torque ⇒ Item 16 (page 25)

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

and release operating pressure (2.0 bar).

– Press clutch pedal slowly down with your foot 10 times and

check that clutch system is functioning properly.

– Remove brake filling and bleeding equipment -VAS 5234-

from brake fluid reservoir.

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

Audi TT 2007 ➤

3

3. Exploded view - hydraulics (LHD) 29

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

4 Exploded view - clutch release mechanism, clutch slave cylinder

1 - Gearbox

2 - Input shaft oil seal

❑ Removing ⇒ page 116 ❑ Driving in ⇒ page 116

3 - Clutch slave cylinder with release bearing

❑ Are one unit; can only be

renewed together

❑ Do not wash out bear‐

ing; wipe clean only

❑ If bearing is noisy, re‐

new together with clutch slave cylinder

❑ Tighten bolts carefully in

several small steps and in diagonal sequence; make sure that mount‐ ing lugs on clutch slave cylinder do not break off

❑ For some slave cylin‐

ders, divided supply line

⇒ page 30

❑ Removing and installing

⇒ page 31

4 - Bolt

❑ Always renew ❑ 3x ❑ 15 Nm

5 - O-ring

❑ Renew if damaged ❑ Push onto pipe connec‐

tion

❑ Lubricate with brake flu‐

id before installing

Slave cylinder -A- with divided supply line

The supply line for some slave cylinders is divided in the area of the -arrow-.

For correct version, refer to ⇒ Electronic parts catalogue

30 Rep. Gr.30 - Clutch

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

4.1 Removing and installing clutch slave cylinder with release bearing

Note

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

Removing

• Gearbox removed ⇒ page 61 .

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

connection -4- off clutch slave cylinder -1-.

Audi TT 2007 ➤

– Remove bolts -arrows-.

– Take off clutch slave cylinder together with release bearing

-A-.

Installing

• Tightening torque ⇒ page 30

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

Caution

Tighten securing bolts for clutch slave cylinder in small steps. Otherwise mounting lugs -arrows- can be damaged.

– Secure clutch slave cylinder and 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 28 .

4. Exploded view - clutch release mechanism, clutch slave cylinder 31

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

5 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.

♦

Select the correct clutch plate and pressure plate according to engine code ⇒ Electronic parts catalogue .

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 33

2 - Clutch plate

❑ Removing and installing

⇒ page 33

❑ Always renew SAC

pressure plate as well

❑ Installation position:

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

❑ For correct version, re‐

fer to ⇒ Electronic parts catalogue

3 - SAC pressure plate

❑ “SAC” = self adjusting

clutch

❑ Always renew clutch

plate as well

❑ Removing and installing

⇒ page 33

❑ Checking position of ad‐

juster ring on new SAC pressure plate

⇒ page 35

❑ Checking ends of diaphragm spring ⇒ page 35 ❑ Checking spring connection and rivets ⇒ page 35

4 - Bolt

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

32 Rep. Gr.30 - Clutch

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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.

5.1 Removing and installing clutch

Special tools and workshop

equipment required

♦ Counterhold tool -3067-

♦ Centring mandrel -T10372-

♦ Torque wrench -V.A.G

1331-

♦ Grease for clutch plate

splines -G 000 100-

Audi TT 2007 ➤

5. Exploded view - LuK version clutch 33

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

• Gearbox removed ⇒ page 61 .

– 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 32

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 35

♦

If the clutch has burnt out, thoroughly clean the clutch housing, flywheel and parts of the engine facing the gearbox in order to reduce the smell of burnt linings.

♦

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

♦

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

♦

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

♦

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

♦

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

34 Rep. Gr.30 - Clutch

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring

-arrows- is permissible.

Checking spring connections and rivets

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

sure riveted joints -arrows B- are seated tightly.

• Renew pressure plate if spring connections are broken or bad‐ ly bent, or if riveted joints are loose.

Audi TT 2007 ➤

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

5. Exploded view - LuK version clutch 35

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

– Use counter-hold 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 32)

36 Rep. Gr.30 - Clutch

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

34 – Controls, housing

1 Overview - selector mechanism

♦ ⇒ “2 Exploded view - gear knob and covers”, page 39

♦ ⇒ “2.1 Removing and installing gear knob with gear lever boot

”, page 40

♦ ⇒ “3 Assembly overview - gear lever and selector housing”,

page 42

♦ ⇒ “3.1 Removing and installing selector mechanism”,

page 43

♦ ⇒ “3.2 Dismantling and assembling selector mechanism”,

page 46

♦ ⇒ “4 Exploded view - gear selector cable and gate selector

cable”, page 51

♦ ⇒ “4.1 Removing and installing gear selector cable and gate

selector cable”, page 52

♦ ⇒ “5 Exploded view - gearbox selector lever and gate relay

lever”, page 54

♦ ⇒ “6 Adjusting selector mechanism”, page 58

-Arrow A- gear selection movement

-Arrow B- gate selection movement

Audi TT 2007 ➤

1. Overview - selector mechanism 37

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

A - Gear selector cable (gear selection movement)

B - Gate selector cable (gate selection movement)

C - Heat shield

❑ Remove before remov‐

ing selector mechanism

1 - Gearbox selector lever

2 - Gate relay lever

38 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 0A6, four-wheel drive - Edition 06.2009

2 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 40

❑ Detaching from trim

panel for centre console

⇒ page 40

❑ Disconnecting from se‐

curing frame

⇒ page 40

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 40

❑ Detaching from gear

lever boot ⇒ page 40

4 - Securing frame

❑ Detaching from trim

panel for centre console

⇒ page 40

❑ Detaching from gear

lever boot ⇒ page 40

5 - Washer

❑ 4x

6 - Bolt

❑ 4x ❑ 1.5 Nm

7 - Noise insulation cover (upper)

8 - Noise insulation cover (lower)

9 - Gear lever

❑ Adjusting selector mechanism ⇒ page 58

Audi TT 2007 ➤

2. Exploded view - gear knob and covers 39

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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 securing frame -1- off

gear lever boot -2-.

2.1 Removing and installing gear knob with gear lever boot

Note

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

Special tools and workshop equipment required

♦ Removal wedge -3409-

40 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

♦ Hose clip pliers -V.A.G 1275-

Removing

– Open ashtray.

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

Audi TT 2007 ➤

– Unplug electrical connector at trim panel.

– Pull trim panel -3- up and over gear knob -2-.

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

boot and trim panel -3-.

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

⇒ page 40 .

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- .

2. Exploded view - gear knob and covers 41

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

3 Assembly overview - gear lever and selector housing

Note

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

1 - Floor plate

❑ Bend tabs open to re‐

move

❑ Renew

2 - Gasket

❑ Renew

3 - Gear lever

❑ Can be removed and in‐

stalled without removing gear lever guide

-item 15-

4 - Damping washer

❑ Push onto gear lever as

far as stop -arrow-

5 - Securing clip

❑ Renew

6 - Gate selector cable

❑ Lever off gate selector

lever

❑ Press onto gate selector

lever inside selector mechanism

❑ Installation position

⇒ page 37

7 - Bush

8 - Gear selector cable

❑ Lever off gear lever

guide

❑ Press onto gear lever

guide inside selector mechanism

❑ Installation position

⇒ page 37

9 - Damper

10 - Ball socket

❑ Will be damaged during removal ❑ Renew

11 - Bush

12 - Securing clip

❑ Removing and installing ⇒ page 43

42 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

13 - Spring

14 - Bush

15 - Gear lever guide

16 - Nut

❑ 8 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 detached

Removing securing clip

– Hold gear lever -2- firmly.

– Press spacer bush -3- in direction of -arrow- and remove se‐

curing clip -1-.

Audi TT 2007 ➤

3.1 Removing and installing selector mech‐ anism

Removing

– Remove gear knob together with trim panel for centre console

⇒ page 40 .

– Remove centre console ⇒ Rep. Gr. 68 .

– Remove noise insulation covers above selector mechanism.

– Remove nuts -arrows-.

3. Assembly overview - gear lever and selector housing 43

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

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

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

turn to left -arrow 2- to lock.

– Press gate relay lever forwards -arrow 3- and pull gate selector

cable out of cable end-piece.

– Detach securing clip -1- for gear selector cable from gearbox

selector lever -2- and pull selector cable off pin -arrow-.

– Unscrew bolts -arrows-, remove cable support bracket from

gearbox and tie up on left side.

– Remove propshaft ⇒ Rear final drive 0BY; Rep. Gr. 39 .

44 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Remove bolts and nuts -arrows- and detach heat shield to‐

wards rear.

– Swing selector mechanism down and remove together with

selector cables.

Installing

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

• Tightening torques ⇒ page 42 , ⇒ page 51

Audi TT 2007 ➤

Note

Renew securing clip for gear selector cable.

– Fit selector mechanism and align parallel to body. Tighten nuts

-arrows-.

– Secure gear selector cable to gearbox selector lever

⇒ page 56 .

3. Assembly overview - gear lever and selector housing 45

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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

follows:

• After the point where they cross over, the cables must run parallel as far as the cable support bracket.

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

-3-.

Note

The enlargement shows the heat shield from above.

– Secure gear selector cable and gate selector cable with cable

tie -arrow- ⇒ page 52 .

– Adjust selector mechanism ⇒ page 58 .

– Fit noise insulation covers above selector mechanism and in‐

stall centre console ⇒ Rep. Gr. 68 .

– Install gear knob with gear lever boot ⇒ page 40 .

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

– Install propshaft ⇒ Rear final drive 0BY; Rep. Gr. 39 .

3.2 Dismantling and assembling selector

mechanism

Special tools and workshop equipment required

♦ Thrust block -T10083-

Dismantling

– Remove selector mechanism ⇒ page 43 .

– Open out tabs -arrows- all round with screwdriver and remove

floor plate.

– Detach gasket from selector mechanism.

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

lector housing ⇒ page 42 .

46 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– 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-.

– Press ball socket off ball on gear lever guide and remove.

Audi TT 2007 ➤

Note

Note guides -A- when performing the following steps; they must not be broken off.

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

selector lever.

– Pull gear lever guide upwards as far as stop and pull ball-head

pin out of gate selector lever in direction of -arrow 2-.

3. Assembly overview - gear lever and selector housing 47

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Turn gear lever guide anti-clockwise -arrow 1-.

• The pin -arrow 2- must be in the recess in the selector housing.

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

gether with gear lever.

Assembling

• Tightening torques ⇒ page 42

Note

Renew ball socket ⇒ Item 10 (page 42) .

Caution

Risk of accident.

♦ During the following steps, the bottom spring arm

(-arrow 1- ⇒ page 47 ) can become dislodged and snap suddenly down off the shoulder of the gate selector lever.

– Carefully press bottom spring arm off shoulder of gate selector

lever.

• The spring arms will then compress “diagonally” (this will be accompanied by a loud noise).

– Release the tension on spring arms -A- and -B- by turning

them both clockwise.

• Spring arms must point in opposite directions.

Note

The installation position is shown with the gear lever guide instal‐ led.

– 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 clockwise -arrow 2- until ball-head pin

-A- is above recess on selector housing.

48 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Insert selector housing with gear lever guide in larger recess

-arrow- in thrust block -T10083- .

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

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

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

(towards ball head).

Note

Audi TT 2007 ➤

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 back as far as stop (away from

mounting holes for gear selector cable and gate selector ca‐ ble) -arrow 1-.

– Grease ball-head pin and press it into gate selector lever

-arrow 2-.

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

– Insert selector housing with gear lever guide in larger recess

-arrow- in thrust block -T10083- .

3. Assembly overview - gear lever and selector housing 49

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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

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

– Grease ball socket -B- 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-.

• All four lugs must engage.

– Insert bottom spring arm -C- into guide.

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

guide.

– Install selector mechanism ⇒ page 43 .

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.

Audi TT 2007 ➤

6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

4 Exploded view - gear selector cable and gate selector cable

Note

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

1 - Cable end-piece

❑ Secures gate selector

cable to gate relay lever ❑ Allocation ⇒ page 55 ❑ Release to adjust selec‐

tor mechanism

⇒ page 59

2 - Cable support bracket

3 - Retaining clips

❑ Renew

4 - Retainer

5 - Gear selector cable

❑ Removing and installing

⇒ page 52

❑ Adjusting ⇒ page 58

6 - Gate selector cable

❑ Removing and installing

⇒ page 52

❑ Adjusting ⇒ page 58

7 - Retaining clips

❑ Renew

8 - Selector housing

9 - Clip

10 - Bolt

❑ 20 Nm

11 - Bolt

❑ 3.5 Nm

12 - Grommet

13 - Bush

14 - Cable end-piece

❑ Secures gear selector cable to gearbox selector lever ❑ Allocation ⇒ page 55 ❑ Release to adjust selector mechanism ⇒ page 59

15 - Securing clip

4. Exploded view - gear selector cable and gate selector cable 51

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

Securing gear selector cable and gate selector cable with cable tie

– Wrap cable tie -arrow- in a figure-of-eight round gear selector

cable -A- and gate selector cable -B-.

– Secure cables as shown in illustration.

4.1 Removing and installing gear selector cable and gate selector cable

Removing

– Remove selector mechanism ⇒ page 43 .

– Open out tabs -arrows- on floor plate all round with screwdriver

and remove floor plate.

– Detach gasket from selector mechanism.

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

– Detach securing clips and remove gear selector cable and

gate selector cable from selector mechanism.

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

– Push locking sleeve forwards onto stop -arrow 1- and turn fully

clockwise -arrow 2- so that it engages.

– Detach cable end-pieces from selector cables.

– Remove securing clips -1- and -2-.

– Detach cable support bracket from selector cables.

52 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

Installing

Note

Renew gasket and floor plate for selector housing.

– Secure gear selector cable and gate selector cable to selector

housing with securing clips -1 ... 4-.

– Secure gear selector cable and gate selector cable with cable

tie ⇒ page 52 .

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

The remaining installation steps are carried out in reverse se‐ quence; note the following:

– Install selector mechanism ⇒ page 43 .

– Adjust selector mechanism ⇒ page 58 .

Audi TT 2007 ➤

4. Exploded view - gear selector cable and gate selector cable 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 0A6, four-wheel drive - Edition 06.2009

5 Exploded view - gearbox selector lever and gate relay lever

Note

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

1 - Selector unit

❑ Servicing ⇒ page 117

2 - Gearbox selector lever

❑ With damper weight ❑ Fitting ⇒ page 55 ❑ Installation position

⇒ page 55

❑ After installing, adjust

selector mechanism

⇒ page 58

3 - Clip

4 - Gate relay lever

❑ Installation position

⇒ page 55

❑ Detaching and securing

gate relay lever at gear‐ box selector lever

⇒ page 56

5 - Cable end-piece

❑ Secures gate selector

cable to gate relay lever ❑ Allocation ⇒ page 55 ❑ Lever off to remove

⇒ page 57

❑ Pressing on

⇒ page 57

❑ Release to adjust selec‐

tor mechanism

⇒ page 59

6 - Slide block

7 - Nut

❑ 23 Nm ❑ Self-locking ❑ Renew

8 - Securing clip

❑ Renew

9 - Cable end-piece

❑ Secures gear selector cable to gearbox selector lever ❑ Allocation ⇒ page 55 ❑ Release to adjust selector mechanism ⇒ page 59

10 - Oil seal

❑ Renewing ⇒ page 118

54 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

11 - Locking pin

❑ For adjusting selector mechanism ⇒ page 58

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-

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

5. Exploded view - gearbox selector lever and gate relay lever 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 0A6, four-wheel drive - Edition 06.2009

Releasing cable end-piece from gate selector cable

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

turn to left -arrow 2- to lock.

– Press gate relay lever forwards -arrow 3- and pull gate selector

cable out of cable end-piece.

Detaching and securing gear selector cable at gearbox selector lever

Detaching

– Lift up tab and detach securing clip -1- for gear selector cable

from gearbox selector lever -2-.

– Pull gear selector cable 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 onto gearbox selector lever -2- and

secure with securing clip -1-.

Detaching and securing gate relay lever at gearbox selector lever

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.

56 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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-.

Audi TT 2007 ➤

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

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

– Ensure that components engage securely.

Note

-Arrow 1- can be disregarded.

5. Exploded view - gearbox selector lever and gate relay lever 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 0A6, four-wheel drive - Edition 06.2009

6 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.

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

2nd gear gate.

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

locking pin -T10027 A- .

Note

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

58 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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

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

– Push locking sleeve forwards onto stop -arrow 1- and turn fully

clockwise -arrow 2- so that it engages.

• It should now be possible to move the selector cable in the cable end-piece.

Audi TT 2007 ➤

Lock selector shaft as follows:

– Pull up selector shaft -arrow 1-.

– Press locking pin -A- inwards towards selector shaft

-arrow 2- and at the same time turn upwards -arrow 3- so it engages in selector shaft.

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

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

– Release locking sleeve -arrow 1- and let it slide onto stop

-arrow 2-.

• Cable adjustment is now complete.

6. Adjusting selector mechanism 59

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Turn locking pin -A- back to initial position -arrow 2- and pull

out of gearbox -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.

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

– Fit gear lever boot and trim panel for centre console.

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

60 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

7 Removing and installing gearbox

General view

♦ ⇒ “7.1 Removing gearbox - vehicles with 2.5 ltr. TFSI engine”,

page 61

♦ ⇒ “7.2 Installing gearbox”, page 70

7.1 Removing gearbox - vehicles with 2.5 ltr. TFSI engine

Audi TT 2007 ➤

Special tools and workshop equipment required

♦ Support bracket -10 - 222 A-

♦ Hose clamps, up to 25 mm -3094-

♦ Gearbox support -3282-

♦ Pin -3282/34-

♦ Adjustment plate -3282/60-

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

7. Removing and installing gearbox 61

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

♦ Engine bung set -VAS 6122-

♦ Grease -G 000 450 02-

♦ Grease for clutch plate splines -G 000 100-

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.

– With ignition switched off, disconnect battery earth cable

-arrow- ⇒ Rep. Gr. 27 .

– Remove starter ⇒ Rep. Gr. 27 .

– Remove nuts -1- and detach heat shield for drive shaft (right-

side).

– Remove drive shafts on both sides ⇒ Rep. Gr. 40 .

62 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Remove steering box with subframe ⇒ Rep. Gr. 48 .

– Remove coolant pipe (left-side) ⇒ Rep. Gr. 19 .

Audi TT 2007 ➤

– Remove vibration damper ⇒ Rep. Gr. 13 .

7. Removing and installing gearbox 63

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Release hose clip -2-.

Note

-Items 1 and 3- can be disregarded.

– Remove bolt -4- for earth wire.

– Unplug electrical connector -3- for reversing light switch -F4- .

Note

-Items 1 and 2- can be disregarded.

• To avoid damage to the gate selector cable, the cable endpiece must be separated from the gate selector cable before removal.

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

turn to left -arrow 2- to lock.

– Press gate relay lever forwards -arrow 3- and pull gate selector

cable out of cable end-piece.

– Detach securing clip -1- for gear selector cable from gearbox

selector lever -2- and pull selector cable off pin -arrow-.

64 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Unscrew bolts -arrows-, remove cable support bracket from

gearbox and tie up on left side.

– If a plastic pipe is installed between clutch master cylinder and

slave cylinder, clamp off supply hose to clutch master cylinder using hose clamp -3094- .

Audi TT 2007 ➤

– If a pipe/hose assembly is installed between clutch master

cylinder and slave cylinder, clamp off hose -A- using hose clamp -3094- .

Note

♦

-Arrow- can be disregarded.

♦

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 or pipe/hose assembly -A- out of bleeder con‐

nection for clutch slave cylinder.

– Seal off open lines and connections with clean plugs from en‐

gine bung set -VAS 6122- .

Note

-Item B- can be disregarded.

Caution

Catch escaping brake fluid.

♦ Do not operate clutch pedal after detaching pipe from

bleeder connection for clutch slave cylinder.

7. Removing and installing gearbox 65

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Set up support bracket -10 - 222 A- on body flanges using the

following equipment:

♦ Rack -10 - 222 A /1- (2x)

♦ Adapter -10 - 222 A /3-

♦ 2x spindle -10 - 222 A /11-

♦ Adapter -10 - 222 A /20-

• One spindle -10 - 222 A /11- faces forward, the other to the rear.

WARNING

Risk of accident.

♦ The hook attachment and locating pin on the lifting tackle

must be secured with a locking pin -arrows-.

– Hook front spindle -10 - 222 A /11- with adapter -10 - 222 A /

20- onto engine lifting eye (front left).

– Hook rear spindle -10 - 222 A /11- onto engine lifting eye (rear

left).

– Remove bolts -1- securing gearbox to engine.

– Remove bolts -arrows- from gearbox mounting.

66 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Detach air intake grille -1- from bumper cover in direction of

-arrow-.

– Unscrew bolt -1- and detach air duct.

Note

-Item 2- can be disregarded.

Audi TT 2007 ➤

– Remove bolt -1-.

– Release hose clip -2- and detach air pipe.

– Mark position of flexible coupling relative to bevel box flange

for re-installation.

– Engage a gear and remove bolts -arrow- for flexible coupling

on propshaft.

7. Removing and installing gearbox 67

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

Caution

Risk of damage to seal -arrow- in propshaft flange.

♦ Push propshaft as far back as possible, while keeping it

horizontal.

Note

If seal is damaged propshaft must be renewed.

– Remove bolts -1- and -2- and detach bracket for starter cata‐

lytic converter.

Note

-Item 3- can be disregarded.

– Remove bolts -1- and -2-.

– Release hose clips -arrows- and detach air pipe.

– Remove bolts -1, 2, 3- and detach bracket for bevel box.

68 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Adjust spindles of support bracket -10 - 222 A- to lower gear‐

box by distance -a-.

• Dimension -a- = 80 mm

Set up gearbox support -3282- with adjustment plate -3282/60to remove gearbox “0A6”.

– Insert gearbox support -3282- in engine and gearbox jack -

V.A.G 1383 A- .

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

ment plate.

– Screw in support elements -A-, as illustrated on adjustment

plate -3282/60- .

– In place of support element -C-, screw in bolt -3282/34- .

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

vehicle.

• Arrow symbol -B- on adjustment plate points to front of vehicle.

– Align adjustment plate and gearbox parallel to one another.

Audi TT 2007 ➤

– Screw pin -3282/34- into hole for bolt securing pendulum sup‐

port to gearbox.

7. Removing and installing gearbox 69

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Remove remaining engine/gearbox securing bolts.

– Push gearbox off dowel sleeves -A, B-.

– Tilt gearbox to left using spindles of gearbox support -3282- .

– Lower gearbox carefully, observing longitudinal member.

Note

Pay attention to all pipes/hoses/wiring when lowering gearbox.

7.2 Installing gearbox

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.

♦

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 installing a new gearbox, the gear selector lever and gate relay lever must be transferred to the new unit.

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

threaded holes which will accommodate self-locking bolts.

– If no dowel sleeves -A, B- for centralising engine/gearbox are

in the cylinder block, install dowel sleeves.

– Check centring of clutch plate ⇒ page 33 .

– Check release bearing for wear; if necessary, renew clutch

slave cylinder with release bearing ⇒ page 30 .

– Raise gearbox carefully using gearbox support -3282- .

– Align gearbox with engine and install.

Note

Pay attention to all pipes/hoses/wiring when installing the gear‐ box.

– Screw in and tighten bottom engine/gearbox securing bolts

-1 … 5- first, then remaining securing bolts ⇒ page 72 .

70 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

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

spindles of support bracket -10 - 222 A- until gearbox makes contact with gearbox mounting.

Note

The gearbox mounting must be parallel with the gearbox to avoid causing damage to the threads in the gearbox.

– Install gearbox mounting ⇒ page 75 .

Note

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

Caution

Risk of accident.

Audi TT 2007 ➤

♦ Do not remove support bracket -10 - 222 A- until all bolts

securing the left-hand engine/gearbox mounting have been tightened to the specified torque.

– Install bracket for bevel box ⇒ page 73 .

– Install drive shafts (left and right) ⇒ Rep. Gr. 40 .

– Install heat shield for drive shaft (right-side) ⇒ page 73 .

Caution

Risk of damage to seal -arrow- in propshaft flange.

♦ Push propshaft as far back as possible, while keeping it

horizontal.

Note

If seal is damaged propshaft must be renewed.

– Press engine/gearbox assembly towards bulkhead, guiding

pin on bevel box carefully into propshaft flange.

7. Removing and installing gearbox 71

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Bolt flexible coupling on propshaft onto bevel box flange

-arrows- ⇒ Rear final drive 02D, 0AV, 0BR and 0BY; Rep. Gr. 39 .

– Install pendulum support ⇒ page 75 .

– Install vibration damper ⇒ Rep. Gr. 13 .

– Install coolant pipe (left-side) ⇒ Rep. Gr. 19 .

– Install steering box with subframe ⇒ Rep. Gr. 48 .

– Install drive shafts ⇒ Rep. Gr. 40 .

– Install exhaust system and cross piece ⇒ Rep. Gr. 26 .

– Install radiator cowl ⇒ Rep. Gr. 19 .

– Install starter ⇒ Rep. Gr. 27 .

– Install pipe/hose assembly or plastic pipe ⇒ page 25 .

– Bleed clutch system ⇒ page 28 .

– Install cable support bracket ⇒ page 51 .

– Secure gear selector cable to gearbox selector lever

⇒ page 56 .

– Insert gate selector cable in cable end-piece.

– Adjust selector mechanism ⇒ page 58 .

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

– Observe correct procedure after connecting battery ⇒ Rep.

Gr. 27 .

– Install front sections of wheel housing liners ⇒ Rep. Gr. 66 .

– Install noise insulation frame ⇒ Rep. Gr. 50 .

– Install noise insulation ⇒ Rep. Gr. 66 .

– Fit wheels ⇒ Rep. Gr. 44 .

– Check gear oil level in gearbox ⇒ page 85 .

– Check gear oil level in bevel box ⇒ page 86 .

Tightening torques (installing gearbox)

Note

♦

Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.

♦

Additional lubricant such as engine or gear oil may be used, but do not use graphite lubricant.

♦

Do not use parts which have been degreased.

♦

Tolerance for tightening torques ±15%.

72 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

Engine/gearbox securing bolts

Item Bolt Nm

1 M12x65 80

2

1)

M12x180 80

3 M10x65 40 4 M10x75 40

5

2)

M12x95 80

A, B Dowel sleeves for centralising

1)

•

Bolt with stud M8.

2)

•

Screwed into gearbox from engine side.

Bracket for bevel box - tightening torque and sequence

– Tighten bolts in 5 stages as follows:

1. Screw in bolts -1 ... 3- (hand-tight).

2. Pre-tighten bolts -2- to 8 Nm.

Audi TT 2007 ➤

3. Tighten bolts -1- and -3- initially to 8 Nm.

4. Tighten bolts -2- to 40 Nm.

5. Tighten bolts -1- and -3- to 40 Nm.

Heat shield for drive shaft (right-side) - tightening torque

– Tighten nuts -1- to 25 Nm.

7. Removing and installing gearbox 73

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

8 Transporting gearbox

Special tools and workshop equipment required

♦ Shackle -10-222A/12-

♦ Hook -10-222A/2-

♦ Workshop hoist -VAS 6100-

Shackle -10-222A/12- may be used in conjunction with hook

-10-222A/2- and a workshop hoist to transport the gearbox and

to set up gearbox support -3282- .

– Secure shackle -10-222A/12- to gearbox housing.

– Lift gearbox using workshop hoist and hook -10-222A/2- .

74 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

9 Exploded view - assembly mountings

1 - Bolt

❑ Engine mounting to en‐

gine

❑ Tightening torque ⇒

Rep. Gr. 10

2 - Bolt

❑ Engine mounting to en‐

gine

❑ Tightening torque ⇒

Rep. Gr. 10

3 - Bolt

❑ Engine mounting to

body

❑ Tightening torque ⇒

Rep. Gr. 10

4 - Bracket

❑ For activated charcoal

filter

5 - Bolt

❑ Tightening torque ⇒

Rep. Gr. 10

6 - Nut

❑ Tightening torque ⇒

Rep. Gr. 10

7 - Engine mounting

❑ Checking adjustment ⇒

Rep. Gr. 10 ❑ Adjusting ⇒ Rep. Gr. 10 ❑ Removing and installing

⇒ Rep. Gr. 10

8 - Connecting bracket

9 - Bolt

❑ Connecting bracket to body ❑ Tightening torque ⇒ Rep. Gr. 10

10 - Bolt

❑ Connecting bracket to engine mounting ❑ Tightening torque ⇒ Rep. Gr. 10

11 - Bolt

❑ Engine mounting to body ❑ Tightening torque ⇒ Rep. Gr. 10

Audi TT 2007 ➤

12 - Pendulum support

❑ Removing and installing ⇒ page 79

13 - Bolt

❑ Pendulum support to subframe ❑ 100 Nm + 90° ❑ Always renew

9. Exploded view - assembly mountings 75

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

14 - Bolt

❑ Pendulum support to gearbox ❑ 60 Nm +90° ❑ Always renew

15 - Bolt

❑ Pendulum support to gearbox ❑ 60 Nm +90° ❑ Always renew

16 - Bolt

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

17 - Bolt

❑ Gearbox mounting to body ❑ 40 Nm +90° ❑ Always renew

18 - Gearbox mounting

❑ Checking adjustment ⇒ Rep. Gr. 10 ❑ Adjusting ⇒ Rep. Gr. 10 ❑ Removing and installing ⇒ page 76

9.1 Removing and installing gearbox mounting

Special tools and workshop equipment required

♦ Support bracket -10-222 A-

♦ Hooks -10 - 222 A /20-

76 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

Removing

– Lift off engine cover panel -1- -arrows-.

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

Audi TT 2007 ➤

– Open retainers for wiring duct -arrows-.

– Cut through cable tie and press electrical wiring to one side.

– Unclip wiring duct.

9. Exploded view - assembly mountings 77

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Set up support bracket -10 - 222 A- on body flanges using the

following equipment:

♦ Rack -10 - 222 A /1- (2x)

♦ Adapter -10 - 222 A /3-

♦ 2x spindle -10 - 222 A /11-

♦ Hooks -10 - 222 A /20-

• One spindle -10 - 222 A /11- faces forward, the other to the

rear.

WARNING

Risk of accident.

♦ The hook attachments and locating pins on the lifting tack‐

le must be secured with a locking pin -arrows-.

– Hook front spindle -10 - 222 A /11- with hook -10 - 222 A /20-

onto engine lifting eye (front left).

– Hook rear spindle -10 - 222 A /11- onto engine lifting eye (rear

left).

– Apply light tension to spindles.

– Remove bolts -arrows- from gearbox mounting.

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

Installing

• Tightening torques

⇒ “9 Exploded view - assembly mountings”, page 75

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

– Adjust assembly mountings ⇒ Rep. Gr. 10 .

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

78 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

9.2 Removing and installing pendulum sup‐ port

Removing

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

– Remove bolts -1, 2, 3- and detach pendulum support.

Audi TT 2007 ➤

Installing

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

• Tightening torques

⇒ “9 Exploded view - assembly mountings”, page 75

Note

Renew securing bolts for pendulum support.

– First tighten bolts -2, 3- securing pendulum support to gear‐

box, then bolt -1- at subframe.

9. Exploded view - assembly mountings 79

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

10 Removing and installing bevel box

(gearbox installed)

Special tools and workshop equipment required

♦ Socket and extended bit -T10107 A-

♦ Counterhold tool -T10371-

♦ Cap -T10381-

Removing

– Remove nuts -1- and detach heat shield for drive shaft (right-

side).

– Remove drive shaft (right-side) ⇒ Rep. Gr. 40 .

– Remove catalytic converters ⇒ Rep. Gr. 26 .

80 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Mark position of flexible coupling relative to bevel box flange

for re-installation.

– Engage a gear and remove bolts -arrows- securung propshaft

flexible coupling to bevel box.

Caution

Risk of damage to seal -arrow- in propshaft flange.

♦ Push propshaft as far back as possible, while keeping it

horizontal.

Audi TT 2007 ➤

Note

If seal is damaged propshaft must be renewed.

– Remove bolts -2, 3- for pendulum support.

Note

-Item 1- can be disregarded.

– Remove bolts -1- and -2- and detach bracket for starter cata‐

lytic converter.

Note

-Item 3- can be disregarded.

10. Removing and installing bevel box (gearbox installed) 81

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Remove bolts -1, 2, 3- and detach bracket for bevel box.

– Remove circlip -arrow A- and O-ring -arrow B- from stub shaft

(right-side).

– Remove countersunk bolt for stub shaft (right-side).

– Remove top bolts -arrows- for bevel box.

82 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Remove bottom bolts -arrows- for bevel box.

– Press bevel box carefully off gearbox.

– Push engine/gearbox assembly forwards in order to remove

bevel box.

– Guide bevel box past engine -B- using recess -A- in subframe.

• Stub shaft -C- faces downwards.

Audi TT 2007 ➤

– Fit cap -T10381- in gearbox.

Installing bevel box

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

Note

Renew O-rings and circlip.

Caution

The oil seal between the bevel box and the gearbox can be damaged.

♦ Turn stub shaft clockwise when fitting bevel box onto

gearbox.

– Push bevel box fully onto gearbox, ensuring that splines of

bevel box input shaft and differential are centred when brought together.

– If the teeth are correctly positioned and the components are

located centrally, the bevel box will slide against the gearbox onto the stop.

– Bolt bevel box to gearbox. Tightening torque

⇒ Item 15 (page 186)

Note

Do not use the securing bolts to pull the bevel box onto the gear‐ box. This could cause the bevel box to tilt and the securing eyes may break off.

10. Removing and installing bevel box (gearbox installed) 83

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Tighten countersunk bolt for stub shaft (right-side). Tightening

torque ⇒ Item 12 (page 185)

– Install bracket for bevel box ⇒ page 73 .

– Install oil return line for turbocharger ⇒ Rep. Gr. 21 .

– Install catalytic converters ⇒ Rep. Gr. 26 .

– Install drive shaft (right-side) ⇒ Rep. Gr. 40 .

– Install heat shield for drive shaft (right-side) ⇒ page 73 .

Caution

Risk of damage to seal -arrow- in propshaft flange.

♦ Push propshaft as far back as possible, while keeping it

horizontal.

Note

If seal is damaged propshaft must be renewed.

– Press engine/gearbox assembly towards bulkhead, guiding

pin on bevel box carefully into propshaft flange.

– Bolt flexible coupling on propshaft onto bevel box flange

-arrows- ⇒ Rear final drive 02D, 0AV, 0BR and 0BY; Rep. Gr. 39 .

– Install pendulum support ⇒ page 79 .

– Check gear oil level in bevel box ⇒ page 86 .

– Check gear oil level in gearbox ⇒ page 85 .

84 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

11 Checking oil level in manual gearbox

Note

♦

The manual gearbox and bevel box have separate oil fillings.

♦

Checking gear oil level in bevel box ⇒ page 86

♦

For gear oil specification, refer to ⇒ Electronic parts cata‐ logue .

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Audi TT 2007 ➤

Procedure

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

– Remove gear oil inspection plug -arrow-.

• Specification: oil level up to bottom lip of filler hole

– Top up gear oil if necessary.

– Screw in plug -arrow- with new seal. Tightening torque

⇒ Item 3 (page 110)

– Install noise insulation ⇒ Rep. Gr. 66 .

11. Checking oil level in manual gearbox 85

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

12 Overview - gear oil in bevel box

Note

♦

The bevel box is bolted to the side of the gearbox and has its own oil supply.

♦

Checking gear oil level ⇒ page 85

♦

For gear oil specification, refer to ⇒ Electronic parts cata‐ logue .

Oil filler plug - tightening torque

Note

Renew oil filler plug -arrow-.

– Tighten oil filler plug to 15 Nm.

12.1 Checking gear oil level in bevel box

Note

♦

The bevel box is secured to the side of the gearbox and has a separate oil filling.

♦

For gear oil specifications, refer to ⇒ Electronic parts cata‐ logue .

Special tools and workshop equipment required

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

Procedure

• Vehicle must be standing on level surface.

• Bevel box must be in installation position.

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

– Place used oil collection and extraction unit -V.A.G 1782- be‐

low bevel box.

86 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Remove oil filler plug -arrow- in bevel box.

• Specification: oil level up to bottom lip of filler hole

– Top up gear oil if necessary

⇒ “12.2 Topping up gear oil in bevel box”, page 87

Note

Carefully remove any traces of escaped oil on bevel box.

– Tighten new oil filler plug. Tightening torque ⇒ page 86

– Install noise insulation ⇒ Rep. Gr. 66 .

12.2 Topping up gear oil in bevel box

• The bevel box is secured to the side of the gearbox and has

a separate oil filling.

• Vehicle must be standing on level surface.

• Bevel box must be in installation position.

Special tools and workshop equipment required

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

Audi TT 2007 ➤

♦ Charging device for Haldex coupling -VAS 6291-

♦ Adapter -VAS 6291/2-

12. Overview - gear oil in bevel box 87

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

Procedure

– Run hose of charging device -VAS 6291- behind right drive

shaft and through right wheel housing to outside.

Note

Cover area beneath oil filler plug -arrow- with a cloth.

– Place used oil collection and extraction unit -V.A.G 1782- be‐

low bevel box.

– Remove oil filler plug -arrow- in bevel box.

– Disconnect adapter -A- and elbow joint -B-.

– Screw adapter -A- in onto stop.

– A hexagon key can be used for this.

-Arrow- = hexagon key, 5 mm, commercially available.

– Engage elbow joint -B- in adapter -A- (⇒ previous illustration).

• The hose must not hang down.

88 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Please make sure that valve -arrow- is closed.

– Screw oil reservoir -A- onto charging device -VAS 6291- .

– Now open valve -arrow- and hold oil reservoir as shown in il‐

lustration.

The bevel box will now be filled.

• When bevel box is filled correctly oil will emerge at adapter

-A-.

• If no oil has emerged, continue filling procedure.

– After oil has escaped from adapter -A-, place the reservoir at

a lower position to enable part of the excess oil to drain back from the hose into the reservoir.

Audi TT 2007 ➤

– As soon as oil stops flowing back into the reservoir, remove

charging device by pressing catch in direction of -arrow-.

– Unscrew adapter -VAS 6291/2- .

– Fit new oil filler plug and tighten. Tightening torque

⇒ page 86

Note

Carefully remove any traces of escaped oil on bevel box.

– Install noise insulation ⇒ Rep. Gr. 66 .

12. Overview - gear oil in bevel box 89

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

13 Securing gearbox to engine and

gearbox support

Special tools and workshop equipment required

♦ Support plate -VW 309-

♦ Gearbox support -VW 353-

♦ Engine and gearbox support -VAS 6095-

– Secure gearbox to gearbox support -VW 353- with bolts

-arrows-.

90 Rep. Gr.34 - Controls, housing

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6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

– Use holes -1- and -2- for this purpose.

Audi TT 2007 ➤

13. Securing gearbox to engine and gearbox support 91

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

14 Dismantling and assembling gearbox

14.1 General layout of gearbox

1 - Clutch housing

2 - Output shaft for reverse gear

3 - Output shaft for 1st/2nd gear

4 - Slave cylinder with release bearing

5 - Input shaft

❑ With 5th and 6th speed

selector gears

6 - Output shaft for 3rd – 6th gear

7 - Differential

8 - Bevel box

9 - Stub shaft (right-side)

10 - Bevel gear with input shaft

11 - Shaft bevel gear

12 - Output flange

13 - Stub shaft (left-side)

14 - Gearbox housing

15 - 4th speed selector gear

16 - 3rd speed selector gear

17 - 6th speed selector gear

18 - 5th speed selector gear

19 - 2nd speed selector gear

20 - 1st speed selector gear

21 - Reverse selector gear

14.2 Exploded view

Sequence for dismantling and assembling ⇒ page 97

92 Rep. Gr.34 - Controls, housing

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I - Removing and installing gearbox housing and selector unit ⇒ page 94

II - Removing and installing in‐ put shaft, output shafts, differ‐ ential, selector rods and bevel box ⇒ page 95

Audi TT 2007 ➤

6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

14. Dismantling and assembling gearbox 93

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

14.3 Exploded view - removing and installing gearbox housing and selector unit

1 - Countersunk bolt

❑ Tightening torque

⇒ Item 30 (page 187)

2 - Stub shaft (left-side) with spring

❑ Removing and installing

⇒ page 162

❑ Assembling

⇒ page 185

3 - Circlip

❑ For grooved ball bearing

on input shaft

4 - Sealing cap

5 - Bolt

❑ 5 Nm

6 - Locking plate

❑ Depending on version,

sealing cap is secured with either locking plate or retainer

⇒ Item 7 (page 94) ⇒ page 108

7 - Retainer

❑ Depending on version,

sealing cap is secured with either retainer or locking plate

⇒ Item 6 (page 94) ⇒ page 108

8 - Bolt

❑ 20 Nm

9 - Hexagon nut

❑ 20 Nm and turn 90° further

10 - Reversing light switch -F4-

❑ 20 Nm ❑ With captive seal ⇒ Item 11 (page 94)

11 - Seal

12 - Hexagon bolt

❑ 8 Nm and turn 120° further ❑ Always renew

13 - O-ring

❑ Always renew

14 - Selector unit

❑ Servicing ⇒ page 117

15 - Bolt

❑ 25 Nm ❑ Always renew

94 Rep. Gr.34 - Controls, housing

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Audi TT 2007 ➤

6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

16 - Clutch housing

❑ Servicing ⇒ page 113

17 - Gearbox housing

❑ Servicing ⇒ page 109

18 - Seal

❑ Always renew

19 - Oil drain plug

❑ 45 Nm

14.4 Exploded view - removing and installing input shaft, output shafts, differen‐ tial, selector rods and bevel box

1 - Output shaft for reverse gear ⇒ page 151

❑ Installation position

⇒ page 96

2 - Selector fork for reverse gear

❑ Installation position

⇒ page 96

3 - Output shaft for 1st and 2nd gears ⇒ page 128

❑ Installation position

⇒ page 96

4 - Selector rod with selector fork for 1st and 2nd gear

❑ Installation position

⇒ page 96

5 - Output shaft for 3rd – 6th gear ⇒ page 140

❑ Installation position

⇒ page 96

6 - Selector rod with selector fork for 3rd and 4th gear

❑ Note installation posi‐

tion ⇒ page 105

7 - Input shaft ⇒ page 121

❑ With 5th and 6th speed

selector gears

❑ Installation position

⇒ page 96

❑ Always renew grooved

ball bearing on input shaft

⇒ Item 16 (page 122)

8 - Selector rod with selector fork for 5th and 6th gear

❑ Installation position ⇒ page 96

9 - Bleeder connection

❑ Connect to slave cylinder ⇒ Item 13 (page 96)

10 - Clutch housing

❑ Servicing ⇒ page 113

14. Dismantling and assembling gearbox 95

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Audi TT 2007 ➤ 6-speed manual gearbox 0A6, four-wheel drive - Edition 06.2009

11 - O-ring

❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing

12 - Bolt

❑ 3x ❑ Tightening torque ⇒ Item 4 (page 30) ❑ Removing and installing ⇒ page 31

13 - Slave cylinder with release bearing

❑ Removing and installing ⇒ page 31

14 - Input shaft oil seal

❑ Removing ⇒ page 116 ❑ Driving in ⇒ page 116

15 - Countersunk bolt

❑ Tightening torque ⇒ Item 12 (page 185)

16 - Bolt

❑ Tightening torque ⇒ Item 15 (page 186) ❑ 4x ❑ Always renew

17 - Bevel box

❑ Removing and installing (with gearbox installed) ⇒ page 80 ❑ Removing and installing (with gearbox removed) ⇒ page 97

18 - Differential ⇒ page 185

Installation position of shafts and selector rods in gearbox

1 - Output shaft for reverse gear

2 - Output shaft for 1st/2nd gear

3 - Input shaft

4 - Output shaft for 3rd – 6th gear

A - Reverse gear selector fork

B - Selector rod for 1st and 2nd gear

C - Selector rod for 5th and 6th gear

D - Selector rod for 3rd and 4th gear

96 Rep. Gr.34 - Controls, housing