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Service
Workshop Manual
Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive
Edition 10.2009
Service Department. Technical Information
Page 2
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
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.
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.
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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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with respect to the correctness of information in this document. Copyright by AUDI AG.
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The 6-speed manual gearbox 02Q, 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 02Q, four-wheel drive -arrow 2-
Manual gearbox 02Q, four-wheel drive -arrow-
Audi TT 2007 ➤
Code letters and date of manufacture of gearbox -arrow-
Example:GUM04083
Additional data identify the factory where the unit was built.
Note
IIII
Code letters DayMonth Year of manufac‐
ture (2003)
The code letters for the gearbox are also given on the vehicle data
stickers.
1. Gearbox identification 1
Page 8
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Reverse gear 34 : 23 x 14 : 14 = 3.99034 : 23 x 14 : 14 =
34 : 23 x 14 : 14 =
3.990
3.990
Capacity of manual gearbox2.3 litres
Capacity of bevel box0.9 litres
Clutch actuationHydraulic
The following data can be found in the ⇒ Electronic parts catalogue .
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Reverse gear 34 : 23 x 14 : 14 = 3.99034 : 23 x 14 : 14 =
3.990
Overall ratio i
in top gear2.9852.9852.826
ov.
Capacity of manual gearbox2.3 litres
Capacity of bevel box0.9 litres
Clutch actuationHydraulic
The following data can be found in the ⇒ Electronic parts catalogue .
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The following data can be found in the ⇒ Electronic parts catalogue .
♦ Gear oil specification
♦ Bevel box gear oil specification
♦ Allocation of drive shaft flange type
♦ Allocation of clutch type
♦ Rear final drive identification
4 Rep. Gr.00 - Technical data
Page 11
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iov = overall ratio = iG x iA = 0.912 x 3.273 = 2.985
1) Z1 = No. of teeth on drive gear, Z2 = No. of teeth on driven gear
6 Rep. Gr.00 - Technical data
Page 13
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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.
4.1Contact corrosion!
Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Rubber or plastic parts and adhesives also consist of non-con‐
ductive materials.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ The gearbox casing is made of a magnesium alloy.
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
Audi TT 2007 ➤
Caution
Damage caused by contact corrosion is not covered under
warranty.
4.2Repair instructions
Special tools
♦ For a complete list of special tools used in this Workshop
Manual ⇒ Workshop equipment and special tools .
Gearbox
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing the gearbox, ensure that the dowel sleeves
between the engine and the gearbox are correctly located.
♦ For allocation of bolts and other components, refer to ⇒ Elec‐
tronic parts catalogue .
♦ Clean contact surfaces when assembling mounting brackets
and waxed components. The contact surfaces must be free of
wax and grease.
♦ After installing a replacement gearbox with bevel box, check
oil level in gearbox ⇒ page 138 and bevel box ⇒ page 150 .
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♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrowabout half full with grease -G 052 128 A1- .
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal in the housing
so that the sealing lip does not contact the shaft in the same
place as the old seal (make use of installation depth toleran‐
ces).
♦ Lightly lubricate O-rings with oil before installation to prevent
them being trapped during assembly.
♦ After installing new gaskets, O-rings and oil seals, check oil
level in manual gearbox ⇒ page 138 and bevel box
⇒ page 150 .
Sealants
♦ Thoroughly clean joint surfaces on gearbox housing etc. be‐
fore applying sealing paste.
♦ Apply sealing paste -AMV 188 200 03- evenly and not too
thick.
♦ Breather holes must remain free of sealing paste.
Locking elements
♦ Do not over-stretch circlips.
♦ 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-.
8 Rep. Gr.00 - Technical data
Page 15
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♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Renew self-locking nuts and bolts.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
♦ For all threaded connections, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with
wax until after assembly is completed.
Bearings
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Lubricate all bearings (except tapered roller bearings) with
gear oil before installing in gearbox.
♦ Use inductive heater -VAS 6414- to heat inner races of tapered
roller bearings to approx. 100°C before installing. Press home
onto stop when installing so there is no axial clearance.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ If required, renew the tapered roller bearings on one shaft to‐
gether and use new bearings from a single manufacturer.
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
Audi TT 2007 ➤
Shims
♦ Use a micrometer to measure the shims at several points.
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.
♦ Install only shims which are in perfect condition.
4. General repair instructions 9
Page 16
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♦ 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
♦ Clean before pressing on.
♦ Use inductive heater -VAS 6414- to heat to approx. 100°C be‐
fore installing. Press home onto stop when installing so there
is no axial clearance.
Selector gears and locking collars
♦ After installing, check 1st to 6th speed selector gears for min‐
imal axial play and freedom of movement.
♦ Abnormal wear on synchro-ring or selector gear:
A - Worn chamfer on dog teeth of synchro-ring or selector gear.
♦ In comparison: intact synchro-ring or selector gear:
B - Intact chamfer on dog teeth of synchro-ring or selector gear.
10 Rep. Gr.00 - Technical data
Page 17
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C - Worn chamfer on internal splines of locking collar.
♦ In comparison: intact locking collar:
D - Intact chamfer on internal splines of locking collar.
Clutch actuation, clutch
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures ⇒ page 12 ).
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts consecutively in steps of 90°.
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.
♦ Only blow out dual-mass flywheel with compressed air.
♦ Clutch pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the
clutch plate, the pressure plate must not be cleaned. Other‐
wise the service life of the clutch will be considerably reduced.
♦ The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
Audi TT 2007 ➤
4. General repair instructions 11
Page 18
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If you suspect a defective clutch master cylinder or clutch slave
cylinder, pay attention to
⇒ “1.1 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 12 and perform
⇒ “1.2 Function check for clutch master cylinder and slave cylin‐
der”, page 13 prior to renewing.
⇒ “2.1 Removing and installing
over-centre spring”, page 16
⇒ “2.2 Removing and installing
clutch pedal”, page 18
⇒ “2.3 Removing and installing
mounting bracket”, page 21
⇒ “2.4 Removing and installing
clutch position sender G476 ”,
page 23
⇒ “2.5 Removing and installing
clutch master cylinder”,
page 24
II -
⇒ “3 Exploded view - hydraul‐
ics (LHD)”, page 27
⇒ “3.1 Removing and installing
pipe/hose assembly or plastic
pipe”, page 29
⇒ “3.2 Bleeding clutch sys‐
tem”, page 31
III -
⇒ “4 Exploded view - hydraul‐
ics (RHD)”, page 33
1.1Notes on removing and installing clutch
master cylinder and slave cylinder
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective you must first carry out
a function check
12 Rep. Gr.30 - Clutch
Page 19
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⇒ “1.2 Function check for clutch master cylinder and slave
cylinder”, page 13 .
♦ If slave cylinder is removed from gearbox with pipe/hose as‐
sembly still attached, make sure you do not press clutch pedal.
Otherwise, the piston will be pressed out of the slave cylinder
and be destroyed.
♦ After installing the slave cylinder, carefully press the clutch
pedal. If you feel an unusually strong point of resistance when
depressing the clutch pedal, you must not press it down fur‐
ther. The plunger of the slave cylinder is likely to have been
guided past the clutch release lever. The slave cylinder would
then be destroyed once pedal force exceeds approx. 300 N.
1.2Function check for clutch master cylin‐
der and slave cylinder
Before you renew the clutch master cylinder or slave cylinder you
must - in the case of the following faults - first carry out the ap‐
propriate checks.
Noises when operating the clutch:
♦ First check the over-centre spring / clutch pedal switch for
noise.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains depressed / does not
return to its initial position.
♦ Check whether the clutch pedal returns all the way to its initial
position, thereby uncovering the vent opening in the master
cylinder.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside.
♦ The vent opening must be uncovered, otherwise the perma‐
nent self-bleeding function for the hydraulic clutch system will
no longer be effective.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time. This could
impair the self-bleeding function of the clutch system as the
vent opening in the master cylinder can no longer function.
♦ The self-bleeding function of the clutch system can be im‐
paired if the footwell trim or floor mats get trapped, if the clutch
pedal switch jams or if the driver rests his foot on the clutch
pedal for long periods of time.
Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks
(visual inspection).
Audi TT 2007 ➤
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 12 .
Pedal forces:
♦ approx. 140 N for complete service life of the clutch
1. Overview - clutch mechanism 13
Page 20
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♦ Mechanical fault on pressure plate/clutch plate ⇒ page 39 or
⇒ page 45
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 12 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines
(due to corrosion or dirt, etc.)
♦ Foreign body in clutch system
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 39 or
⇒ page 45
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate or dowel
sleeves).
14 Rep. Gr.30 - Clutch
Page 21
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❑ Made of rubber or plastic, depending on version
❑ Plastic supply hose with additional seals ⇒ page 28
15 - Nut
❑ For securing mounting bracket to bulkhead
❑ 20 Nm
❑ 3x
❑ Self-locking
❑ Renew
16 - Nut
❑ 25 Nm
❑ Self-locking
❑ Renew
17 - Stop
❑ For clutch pedal
Crash bar - tightening torque
– Fit crash bar -2- and tighten 1 or 2 bolts (depending on version)
-arrows B-.
•M6 10 Nm
•M8 20 Nm
Renewing pedal rubber for clutch pedal
– Cut new clutch pedal rubber to size as illustrated.
•Dimension -x- = 20 mm
2.1Removing and installing over-centre
spring
Special tools and workshop equipment required
16 Rep. Gr.30 - Clutch
Page 23
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Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nut.
♦
Lubricate all bearings and contact surfaces with grease -G 000
450 02- .
– Fit over-centre spring -2- into mounting bracket from above
while holding end of spring in correct position with assembly
tool -T10178- .
•Socket -arrow- of over-centre spring must be in vertical posi‐
tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press clutch pedal slightly, push bolt through and tighten self-
locking nut.
– Install crash bar ⇒ page 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2.2Removing and installing clutch pedal
Special tools and workshop equipment required
♦ Pliers -T10005-
18 Rep. Gr.30 - Clutch
Page 25
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– Release retaining clip for operating rod on master cylinder us‐
ing pliers -T10005- .
– Remove clutch pedal.
Installing
•Tightening torque ⇒ page 15
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew self-locking nut.
♦
Lubricate all bearings and contact surfaces with grease -G 000
450 02- .
– Install retaining clip -2- on operating rod -1- of master cylinder.
– Press retaining clip into mounting on clutch pedal so that it
snaps into place.
– Fit over-centre spring -2- into mounting bracket from above
while holding end of spring in correct position with assembly
tool -T10178- .
20 Rep. Gr.30 - Clutch
Page 27
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•Socket -arrow- of over-centre spring must be in vertical posi‐
tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press top of clutch pedal forwards against spring pressure of
over-centre spring, push through bolt and tighten self-locking
nut.
Note
It is easier to press the clutch pedal against the spring if you pull
back the bottom of the pedal carefully as you bring the top of the
pedal into installation position.
– Install crash bar ⇒ page 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
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In the following steps make sure that no brake fluid escapes onto
the longitudinal member or onto the gearbox below. If this does
happen, clean the affected area thoroughly.
– Use hose clamp -3094- to clamp off supply hose to clutch
master cylinder.
– Disconnect supply hose at clutch master cylinder (if necessa‐
– Release retaining clip -2- with a screwdriver and disconnect
pipe/hose assembly -1- or plastic pipe from clutch master cyl‐
inder.
– Unclip and detach clutch position sender -G476- from clutch
master cylinder -arrow-. Electrical connector -4- can remain
connected.
– Move driver's seat to rear as far as possible and move steering
wheel into uppermost position.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
22 Rep. Gr.30 - Clutch
Page 29
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– Fit clutch position sender -G476- at clutch master cylinder and
engage -arrow-.
– Attach electrical connector -4-.
2.5Removing and installing clutch master
cylinder
Special tools and workshop equipment required
♦ Pliers -T10005-
Removing
Note
♦
If you suspect a defective clutch master cylinder, perform
function test prior to renewing
⇒ “1.1 Notes on removing and installing clutch master cylinder
and slave cylinder”, page 12 .
♦
When working in the footwell, put cloths on the floor covering
to protect it from possible brake fluid spills.
24 Rep. Gr.30 - Clutch
Page 31
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– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.
•
Length of spacer = approx. 40 mm (e.g. 1/2” socket)
– Secure master cylinder on mounting bracket -arrow 1- and
-arrow 2-.
– Press operating rod -1- for master cylinder in direction of
-arrow- so that retaining clip -2- snaps into place in clutch ped‐
al.
– Install mounting bracket ⇒ page 21 .
26 Rep. Gr.30 - Clutch
Page 33
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pipe/hose assembly,
pull out clip as far as it
will go
6 - Seal or O-ring
❑ Renew damaged seals
or O-rings
❑ Push onto pipe connec‐
tion
❑ Lubricate with brake flu‐
id before installing
❑ Whether a seal or an O-
ring is used depends on
the type of connection
⇒ page 28
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
7 - Retaining clip
❑ To remove and install retaining clip first detach clutch master cylinder from clutch pedal ⇒ page 18
8 - Clutch pedal
❑ Removing and installing ⇒ page 18
9 - Nut
❑ For securing mounting bracket to bulkhead
❑ Tightening torque ⇒ Item 15 (page 16)
10 - Pipe/hose assembly
❑ Removing and installing ⇒ page 29
❑ Different types depending on gearbox version
❑ For correct version, refer to ⇒ Electronic parts catalogue
11 - Bracket
❑ For pipe/hose assembly ⇒ Item 10 (page 27)
❑ Secured on body
❑ Identification of brackets ⇒ page 29
12 - Plastic pipe
❑ Removing and installing ⇒ page 29
3. Exploded view - hydraulics (LHD) 27
Page 34
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❑ Different types depending on gearbox version
❑ For correct version, refer to ⇒ Electronic parts catalogue
13 - Bracket
❑ For plastic pipe ⇒ Item 12 (page 27)
❑ Secured on body
❑ Identification of brackets ⇒ page 29
14 - Seal or O-ring
❑ Renew damaged seals or O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 28
❑ For correct version, refer to ⇒ Electronic parts catalogue
15 - Bleeder connection
16 - Clip
❑ To remove and install pipe/hose assembly or bleeder connection, pull out clip as far as it will go.
17 - Bleeder screw
❑ 4.5 Nm
❑ Bleeding clutch system ⇒ page 31
18 - Dust cap
19 - Clutch slave cylinder with release bearing
❑ Can only be renewed after removing gearbox
20 - Gearbox
O-ring or seal for pipe/hose assembly or plastic pipe
1 - O-ring
♦ Connection with annular groove -arrow 1-
♦ Check O-ring for damage and renew if necessary
2 - Seal
♦ Connection with shoulder -arrow 2-
♦ Position seal -2- onto connection -arrow 2- before fitting
Vehicles with plastic supply hose -1-
•Seals -2- must be fitted in supply hose.
28 Rep. Gr.30 - Clutch
Page 35
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24 .
– Use hose clamp -3094- to clamp off supply hose to clutch
master cylinder.
3. Exploded view - hydraulics (LHD) 29
Page 36
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
In the following steps make sure that no brake fluid escapes
onto the longitudinal member or onto the gearbox below. If this
does happen, clean the affected area thoroughly.
♦
Place a cloth underneath to catch escaping brake fluid.
– To detach at clutch master cylinder, release retaining clip -3-
with a screwdriver.
– Pull off pipe/hose assembly -1- or plastic pipe with O-ring -2-
and detach from bracket.
Caution
Do not depress clutch pedal after removing pipe/hose assem‐
bly or plastic pipe.
Note
Place a cloth underneath to catch escaping brake fluid.
– To detach at bleeder connection, release retaining clip -2- with
a screwdriver and pull pipe/hose assembly -4- or plastic pipe
with O-ring -3- off bleeder connection -1-.
Installing
Installation is carried out in reverse sequence; note the following:
Note
For distinction between O-rings -2- and seals, refer to
⇒ page 28
– Check O-ring -2- for damage and renew if necessary.
– Press pipe/hose assembly -1- or plastic pipe onto connection
on clutch master cylinder -4- so that retaining clip -3- snaps
into place.
– Pull on pipe to check it is secure.
30 Rep. Gr.30 - Clutch
Page 37
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– Check O-ring -3- for damage and renew if necessary.
– Press pipe/hose assembly -4- or plastic pipe onto bleeder
connection so that retaining clip -2- snaps into place.
– Pull on pipe to check it is secure.
– Bleed clutch system ⇒ page 31 .
3.2Bleeding clutch system
Note
♦
The clutch system must be bled after performing work on the
hydraulic clutch mechanism.
♦
In the following steps make sure that no brake fluid escapes
onto the longitudinal member or onto the gearbox below.
♦
Before bleeding clutch system, top up brake fluid reservoir to
“max.” marking with brake fluid.
Audi TT 2007 ➤
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-
♦ Brake fluid specification ⇒ Rep. Gr. 47.
Procedure
•Tightening torque ⇒ page 27
– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24 .
3. Exploded view - hydraulics (LHD) 31
Page 38
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– Pull clutch pedal back to its normal rest position.
– Connect brake filling and bleeding equipment -VAS 5234- to
brake fluid reservoir.
– Remove protective cap from bleeder screw -arrow- and con‐
nect hose -A- from bleeder bottle to bleeder screw.
– Switch on bleeding equipment.
•Operating pressure 2.0 bar
–
Now open bleeder screw approx 1/4 turn and allow 100 cm
3
of brake fluid to run out.
– With bleeder screw open, pump clutch pedal rapidly all the way
in and out by hand 15 to 20 times (approx. 2 times per second).
– Close bleeder screw.
– Switch off brake filling and bleeding equipment -VAS 5234-
and relieve pressure from bleeding equipment.
– Now press clutch pedal slowly all the way in and out 10 times.
– Check that clutch system is functioning properly.
– Disconnect bleeder hose and fit protective cap.
– Remove brake filling and bleeding equipment -VAS 5234-
from brake fluid reservoir.
– Install air cleaner housing ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .
32 Rep. Gr.30 - Clutch
Page 39
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❑ For plastic supply hose
❑ Seals must be fitted in
supply hose.
3 - Supply hose
❑ Made of rubber or plas‐
tic, depending on ver‐
sion
❑ Plastic supply hose with
additional seals
⇒ Item 2 (page 33)
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 24
5 - Clip
❑ To remove and install
pipe, pull out clip as far
as it will go
6 - Seal or O-ring
❑ Matched to type of con‐
nection ⇒ page 28
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
❑ Renew damaged seals
or O-rings
❑ Push onto pipe connec‐
tion
❑ Lubricate with brake flu‐
id before installing
7 - Retaining clip
❑ To remove and install retaining clip first detach master cylinder from clutch pedal ⇒ page 18
8 - Clutch pedal
9 - Nut
❑ For securing mounting bracket to bulkhead
❑ 20 Nm
10 - Bracket
❑ Secured on body
11 - Pipe
❑ For correct version, refer to ⇒ Electronic parts catalogue
Audi TT 2007 ➤
12 - Seal or O-ring
❑ Matched to type of connection ⇒ page 28
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Renew damaged seals or O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
4. Exploded view - hydraulics (RHD) 33
Page 40
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with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For correct version, refer to ⇒ Electronic parts catalogue
14 - Bracket
❑ Secured to bracket for ABS/EDL
15 - Seal or O-ring
❑ Matched to type of connection ⇒ page 28
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Renew damaged seals or O-rings
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
16 - Clip
❑ To remove and install pipe/hose assembly or bleeder connection, pull out clip as far as it will go.
17 - Bleeder screw
❑ Bleeding clutch system ⇒ page 31
❑ 4.5 Nm
18 - Dust cap
19 - Bleeder connection
20 - Clutch slave cylinder with release bearing
❑ Can only be renewed after removing gearbox
❑ Removing and installing ⇒ page 36
21 - Gearbox
34 Rep. Gr.30 - Clutch
Page 41
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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.
5.1Removing and installing clutch slave
cylinder together with release bearing
Note
Slave cylinder and release bearing are one unit and can only be
renewed together.
Removing
•Gearbox removed ⇒ page 82 .
– Release retaining clip -2- with a screwdriver and pull bleeder
connection -4- off slave cylinder -1-.
– Remove bolts -arrows-.
– Take off slave cylinder together with release bearing -A-.
Installing
•Tightening torque ⇒ page 35
Installation is carried out in reverse sequence; note the following:
Caution
Tighten securing bolts for slave cylinder in small steps. Other‐
wise mounting lugs -arrows- can be damaged.
– Secure clutch slave cylinder with release bearing -arrows-.
– Check O-ring -3- for damage and renew if necessary.
– Press bleeder connection -4- onto connection on clutch slave
cylinder -1- so that retaining clip -2- snaps into place.
– Pull on bleeder connection to check it is secure.
– Bleed clutch system ⇒ page 31 .
36 Rep. Gr.30 - Clutch
Page 43
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The clutch fitted in the vehicle is supplied by either “Sachs” or
“LuK”.
With gearbox installed, the clutch version fitted can be distin‐
guished as follows:
– Release fasteners -1 ... 4- and remove centre noise insulation.
Audi TT 2007 ➤
A number of recesses -arrows- are located in lower area of sump
between engine -A- and gearbox -B-.
– Check the contour of the flywheel visible through the recesses.
A - round contour -arrows- = Sachs version clutch
Exploded view - Sachs version clutch ⇒ page 39
B - square contour -arrows 1- and annular groove -arrow 2- = LuK
version clutch
Exploded view - LuK version clutch ⇒ page 45
6. Clutch identification 37
Page 44
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Round contour -arrows 1- and annular groove -arrow 2- = LuK
version clutch
Exploded view - LuK version clutch ⇒ page 45
38 Rep. Gr.30 - Clutch
Page 45
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with respect to the correctness of information in this document. Copyright by AUDI AG.
The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another
manufacturer must not be installed on the same vehicle.
1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
❑ Observe instructions for
removal ⇒ page 41
2 - Clutch plate
❑ Removing and installing
⇒ page 41
❑ Always renew pressure
plate as well
❑ Installation position
⇒ page 44
❑ For diameter of clutch
plate, refer to ⇒ Elec‐
tronic parts catalogue
3 - Pressure plate
❑ With adjustment mech‐
anism
❑ Identification
⇒ page 40
❑ Removing and installing
⇒ page 41
❑ Checking ends of dia‐
phragm spring
⇒ page 40
❑ Checking springs and
riveting ⇒ page 40
❑ Checking wire ring or
sheet-metal ring ⇒ page 41
❑ Always renew clutch plate as well
❑ For correct version, refer to ⇒ Electronic parts catalogue
❑ Contact surface for clutch lining must be free of grooves, oil and grease
4 - Bolt
❑ M6 - 13 Nm
❑ M7 - 20 Nm
❑ Loosen and tighten bolts consecutively in steps of 90°
7. Exploded view - Sachs version clutch 39
Page 46
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Identification of self-adjusting Sachs version clutch
♦ Pressure plate with stop mechanism (position sensor)
-arrow-.
Checking ends of diaphragm spring
•Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.
Checking springs and riveting
I - Springs OK
•Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
•Renew pressure plate if springs are broken or badly bent
-arrow B-.
40 Rep. Gr.30 - Clutch
Page 47
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– Check that rivets -arrows B- are secure at all springs
-arrows A-.
•Renew pressure plate if rivets -arrows B- are loose.
Checking wire ring or sheet-metal ring
– Check wire ring or sheet-metal ring -arrow- in pressure plate
for damage.
•Renew pressure plate if wire ring or sheet-metal ring is broken.
Audi TT 2007 ➤
Instructions for removing dual-mass flywheel
Note
Do not use an impact wrench or pneumatic wrench to remove
bolts -B-: this would severely damage the dual-mass flywheel.
The bolts must always be removed by hand.
– Rotate dual-mass flywheel -A- so that the bolts are aligned
centrally behind the holes -arrows-.
– When removing the bolts, make sure that none of the bolt
heads contacts the dual-mass flywheel, as this would damage
the flywheel when the bolts are unscrewed further.
7.1Removing and installing clutch (Sachs
version)
Special tools and workshop equipment required
♦ Counterhold tool -3067-
7. Exploded view - Sachs version clutch 41
Page 48
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always adhere to the
following procedure when unbolting the pressure plate:
– Apply counter-hold tool -3067- in order to loosen bolts.
– Working clockwise, loosen all six bolts consecutively in steps
of 90° (1/4 turn) until the pressure plate is released.
•Stop -2- with pin -1- should come loose when the bolts are
slackened.
– If the stop does not come loose, push the pin towards the dual-
mass flywheel.
– Take off pressure plate and clutch plate.
Installing
•Tightening torque ⇒ page 39
Installation is carried out in reverse sequence; note the following:
Audi TT 2007 ➤
Note
♦
The dual-mass flywheel, pressure plate and clutch plate are
matched together; components from another manufacturer
must not be installed on the same vehicle.
♦
Always renew clutch plate and pressure plate together and
select the correct parts according to engine code ⇒ Electronic
parts catalogue .
♦
If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.
♦
Clean input shaft splines and (in the case of a used clutch
plate) the hub splines. Remove corrosion and apply only a very
thin coating of grease -G 000 100- to the splines. Then move
clutch plate backwards and forwards on input shaft until hub
moves freely on shaft. It is important to remove excess grease.
♦
Clutch pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the
clutch plate, the pressure plate must not be cleaned. Other‐
wise the service life of the clutch will be considerably reduced.
♦
Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert bolts.
♦
Only blow out dual-mass flywheel with compressed air.
♦
The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
♦
Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block; install if necessary.
♦
If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).
7. Exploded view - Sachs version clutch 43
Page 50
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with respect to the correctness of information in this document. Copyright by AUDI AG.
•Marking “Getriebeseite” (gearbox side) and the protruding
spring cage face towards gearbox.
– 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:
– Make sure that the stop pin (position sensor) -arrow- is free to
move.
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with pressure plate.
– Working clockwise, tighten all six bolts consecutively in steps
of 90° (1/4 turn) until the housing makes contact with the fly‐
wheel.
•The stop pin -arrow- should then lift away from the pressure
plate.
– Working clockwise, tighten all 6 bolts to final torque consecu‐
tively. Tightening torque ⇒ Item 4 (page 39)
44 Rep. Gr.30 - Clutch
Page 51
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The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another
manufacturer must not be installed on the same vehicle.
1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
❑ Observe instructions for
removal ⇒ page 47
2 - Clutch plate
❑ Removing and installing
⇒ page 47
❑ Always renew SAC
pressure plate as well
❑ Installation position:
marking
“Getriebeseite” (gear‐
box side) faces towards
gearbox
❑ For diameter of clutch
plate, refer to ⇒ Elec‐
tronic parts catalogue
3 - SAC pressure plate
❑ “SAC” = self adjusting
clutch
❑ Always renew clutch
plate as well
❑ Removing and installing
⇒ page 47
❑ Checking position of ad‐
juster ring on new SAC
pressure plate
⇒ page 49
❑ Checking ends of diaphragm spring ⇒ page 40
❑ Checking spring connection and rivets ⇒ page 46
❑ Checking metal ring ⇒ page 46
❑ Contact surface for clutch lining must be free of grooves, oil and grease
4 - Bolt
❑ M6 - 13 Nm
❑ M7 - 20 Nm
❑ Loosen and tighten bolts consecutively in steps of 90°
8. Exploded view - LuK version clutch 45
Page 52
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with respect to the correctness of information in this document. Copyright by AUDI AG.
•Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.
Checking springs and riveting
I - Springs OK
•Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
•Renew pressure plate if springs are broken or badly bent
-arrow B-.
– Check that rivets -arrows B- are secure at all springs
-arrows A-.
•Renew pressure plate if rivets -arrows B- are loose.
Checking metal ring
– Check metal ring -arrow- in pressure plate for damage.
•Renew pressure plate if metal ring is broken.
46 Rep. Gr.30 - Clutch
Page 53
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Do not use an impact wrench or pneumatic wrench to remove
bolts -B-: this would severely damage the dual-mass flywheel.
The bolts must always be removed by hand.
– Rotate dual-mass flywheel -A- so that the bolts are aligned
centrally behind the holes -arrows-.
– When removing the bolts, make sure that none of the bolt
heads contacts the dual-mass flywheel, as this would damage
the flywheel when the bolts are unscrewed further.
8.1Removing and installing clutch (LuK ver‐
sion)
Special tools and workshop equipment required
♦ Counterhold tool -3067-
Audi TT 2007 ➤
♦ Centring mandrel -T10097-
♦ Grease for clutch plate splines -G 000 100-
8. Exploded view - LuK version clutch 47
Page 54
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Apply counter-hold tool -3067- in order to loosen bolts.
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always adhere to the
following procedure when unbolting the pressure plate:
– Working clockwise, loosen all six bolts consecutively in steps
of 90° (1/4 turn) until the pressure plate is released.
– Take off pressure plate and clutch plate.
Installing
•Tightening torque ⇒ page 45
Installation is carried out in reverse sequence; note the following:
Note
♦
The dual-mass flywheel, pressure plate and clutch plate are
matched together; components from another manufacturer
must not be installed on the same vehicle.
♦
Always renew clutch plate and pressure plate together and
select the correct parts according to engine code ⇒ Electronic
parts catalogue .
♦
Checking position of adjuster ring on new pressure plate
⇒ page 49
♦
If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.
♦
Clean input shaft splines and (in the case of a used clutch
plate) the hub splines. Remove corrosion and apply only a very
thin coating of grease -G 000 100- to the splines. Then move
clutch plate backwards and forwards on input shaft until hub
moves freely on shaft. It is important to remove excess grease.
♦
Clutch pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the
clutch plate, the pressure plate must not be cleaned. Other‐
wise the service life of the clutch will be considerably reduced.
♦
Pressure plate contact surface and clutch plate lining must
make full contact with flywheel. Only then insert bolts.
♦
Only blow out dual-mass flywheel with compressed air.
♦
The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
♦
Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block; install if necessary.
♦
If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).
48 Rep. Gr.30 - Clutch
Page 55
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Checking position of adjustment mechanism (new SAC pressure
plates only)
•The two edges -A- of the adjuster ring should be located be‐
tween the two notches -arrows B-.
•If the adjuster ring is in a different position on a new pressure
plate, the pressure plate and clutch plate must not be installed.
•The position of the adjuster ring can be outside the notches
on used clutches.
Installation position of clutch plate:
•The marking “Getriebeseite” (gearbox side) faces towards the
gearbox
Audi TT 2007 ➤
– Use 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 45)
8. Exploded view - LuK version clutch 49
Page 56
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with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ ⇒ “6.3 Removing and installing gear selector cable and gate
selector cable”, page 77
♦ ⇒ “7 Adjusting selector mechanism”, page 79
-Arrow A- gear selection movement
-Arrow B- gate selection movement
50 Rep. Gr.34 - Controls, housing
Page 57
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with respect to the correctness of information in this document. Copyright by AUDI AG.
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from each other
❑ Renew together
❑ Removing and installing
⇒ page 53
❑ Detaching from trim
panel for centre console
⇒ page 53
❑ Disconnecting from se‐
curing frame
⇒ page 53
2 - Clip
❑ Secures gear knob to
gear lever
❑ Secure with hose clip
pliers -V.A.G 1275-
3 - Trim panel for centre con‐
sole
❑ Remove and install to‐
gether with gear knob
⇒ page 53
❑ Detaching from gear
lever boot ⇒ page 53
4 - Securing frame
❑ Detaching from trim
panel for centre console
⇒ page 53
❑ Detaching from gear
lever boot ⇒ page 53
5 - Washer
❑ 4x
6 - Bolt
❑ 1.5 Nm
❑ 4x
7 - Noise insulation plate
8 - Noise insulation
9 - Gear lever
❑ Adjusting selector mechanism ⇒ page 79
52 Rep. Gr.34 - Controls, housing
Page 59
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Detaching trim panel for centre console and securing frame for
gear lever boot
– Remove bolts -arrows-.
– Detach trim panel from securing frame
Detaching securing frame and gear lever boot
– Carefully release tabs -arrows- and lift off securing frame -1-
from gear lever boot -2-.
Audi TT 2007 ➤
2.1Removing 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-
2. Exploded view - gear knob and covers 53
Page 60
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Carefully lever off trim panel from centre console -arrows-.
– Unplug electrical connector on trim panel.
– Pull trim panel -3- up and over gear knob.
– Open clip -1- and pull off gear knob -2- together with gear lever
boot and trim panel -3-.
– Detach gear lever boot and trim panel for centre console -3-
⇒ page 53 .
Installing
Installation is carried out in reverse sequence; note the following:
– Push gear knob onto gear lever until it contacts stop.
– Secure gear knob to gear lever with a new clip -1-, using hose
clip pliers -V.A.G 1275- .
54 Rep. Gr.34 - Controls, housing
Page 61
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3Exploded view - gear lever and selector housing for vehicles with ve‐
hicle ID No. up to 8J-7-013000
Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Securing clip
❑ Removing and installing
⇒ page 57
2 - Bush
3 - Spring
4 - Bush
5 - Bolt
❑ 6 Nm
6 - Cover
7 - Damper
❑ For spring
⇒ Item 18 (page 55)
8 - Damper
9 - Ball socket
10 - Gear lever guide
11 - Damping washer
12 - Gasket
❑ Between selector hous‐
ing and floor
❑ Self-adhesive
❑ Glue onto selector
housing
13 - Gear lever
14 - Selector housing
15 - Bearing bush
16 - Pivot pin
17 - Guide bush
❑ Press onto selector housing
18 - Spring
❑ Installing ⇒ page 57
19 - Gate selector lever
20 - Bolt
❑ 5 Nm
21 - Gasket
❑ Renew
22 - Floor plate
❑ Bend tabs open to remove
❑ Renew
3. Exploded view - gear lever and selector housing for vehicles with vehicle ID No. up to 8J-7-013000 55
Page 62
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Detaching securing clip for gear selector cable -A- and gate se‐
lector cable -B-
– Use screwdriver to lift tab -arrow 1- and lever off securing clip
-arrow 2-.
56 Rep. Gr.34 - Controls, housing
Page 63
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– Press spacer bush -3- in direction indicated -arrow-.
– Take off securing clip -1-.
Installing spring
– Insert arm -A- of spring in guide -1- from above.
– Pull down arm -B- of spring and insert it in the guide from be‐
low.
Audi TT 2007 ➤
Note
The gate selector lever is removed to give a better illustration.
3. Exploded view - gear lever and selector housing for vehicles with vehicle ID No. up to 8J-7-013000 57
Page 64
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with respect to the correctness of information in this document. Copyright by AUDI AG.
4Exploded view - gear lever and selector housing for vehicles with ve‐
hicle ID No. from 8J-7-013001 onwards
Note
♦
Lubricate bearings and moving surfaces with grease -G 000 450 02- .
♦
Dismantling and assembling selector mechanism ⇒ page 59
1 - Floor plate
❑ Bend tabs open to re‐
move
❑ Always renew
2 - Gasket
❑ Renew
3 - Gear lever
❑ Can be removed and in‐
stalled without removing
gear lever guide
⇒ Item 15 (page 59)
4 - Damping washer
❑ Push onto gear lever as
far as stop -arrow-
5 - Retaining clip
❑ Take care not to dam‐
age selector cables
when removing.
❑ Renew
6 - Gate selector cable
❑ Lever off gate selector
lever
❑ Press onto gate selector
lever inside selector
mechanism
❑ Installation position
⇒ page 50
7 - Bush
8 - Gear selector cable
❑ Lever off gear lever
guide
❑ Press onto gear lever
guide inside selector mechanism
❑ Installation position ⇒ page 50
9 - Damper
10 - Ball socket
❑ Will be damaged during removal
❑ Renew
11 - Bush
12 - Securing clip
❑ Removing and installing ⇒ page 57
58 Rep. Gr.34 - Controls, housing
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❑ Between selector housing and floor
❑ Self-adhesive
❑ Glue onto selector housing
18 - Selector housing
❑ With spring and gate selector lever
❑ Spring and gate selector lever cannot be removed
4.1Dismantling and assembling selector
mechanism
Audi TT 2007 ➤
Special tools and workshop equipment required
♦ Thrust block -T10083-
Dismantling
– Remove selector mechanism ⇒ page 64
– Using a screwdriver, bend open tabs -arrows- on all sides of
floor plate and remove floor plate.
– Remove gasket from selector housing.
– Remove gear selector cable and gate selector cable from se‐
lector housing ⇒ page 58 .
4. Exploded view - gear lever and selector housing for vehicles with vehicle ID No. from 8J-7-013001 onwards 59
Page 66
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Lift top spring arm -A- over tab on gate selector lever.
– Using a screwdriver, press lugs -arrows- on ball socket to‐
wards ball on gear lever guide; if necessary, break off lugs.
– Prise ball socket -A- out of selector housing together with gear
lever guide and gear lever -B-.
– Then press ball socket off ball on gear lever guide and remove.
Note
♦
Note guides -A- when performing the following steps.
♦
They must not be allowed to break off.
– Swivel bottom spring arm -arrow 1- onto stop on shoulder of
gate selector lever.
Caution
During the following steps, the bottom spring arm (-arrow 1-)
can become dislodged and snap downwards off the shoulder
of the gate selector lever.
– Pull gear lever guide upwards as far as stop and at the same
time pull ball-head pin -arrow 2- out of gate selector lever.
– Press spring -arrow 1- carefully off the shoulder of the gate
selector lever.
The spring arms will then compress “diagonally”.
60 Rep. Gr.34 - Controls, housing
Page 67
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– Then turn gear lever guide in direction of -arrow 1-.
•The pin -arrow 2- should be positioned in the recess on the
selector housing.
– Next, swivel gear lever guide out in direction of -arrow 3- to‐
gether with gear lever.
Assembling selector mechanism
– Release spring arms -A- and -B-.
•Spring arms -A- and -B- must point in opposite directions.
(Shown here with gear lever guide installed.)
Audi TT 2007 ➤
– Insert gear lever guide into selector housing together with gear
lever.
•Pin -arrow 1- should be positioned just inside recess on se‐
lector housing.
– Turn gear lever guide in direction of -arrow 2- until ball-head
pin -A- is above recess on selector housing.
– Position selector housing with gear lever guide onto thrust
block -T10083- .
•The gear lever guide rests in the larger recess -arrow- in the
thrust block -T10083- .
•The gear lever guide should protrude out of the selector hous‐
ing as far as the stop.
4. Exploded view - gear lever and selector housing for vehicles with vehicle ID No. from 8J-7-013001 onwards 61
Page 68
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pull arm -B- of spring downwards and insert it next to the guide
(towards ball head).
Note
For illustration purposes, only part of the gate selector lever is
shown.
– Carefully take selector housing off thrust block -T10083- to‐
gether with gear lever guide.
– Move gate selector lever rearwards as far as stop in direction
of -arrow 1-.
– Grease ball-head pin.
– Press ball-head pin into gate selector lever -arrow 2-.
•Guides -A- and tabs -B- must not be damaged.
– Now insert gear lever guide (which is now fitted in selector
housing) into larger recess -arrow- in thrust block -T10083again.
•The gear lever guide should protrude out of the selector hous‐
ing as far as the stop.
– Lift top spring arm -A- over pin on gate selector lever.
•Use a new ball socket -B-.
– Grease ball socket and ball of gear lever guide.
– Press ball socket onto ball of gear lever guide as far as stop.
– Remove selector housing from thrust block -T10083- .
– Press ball socket into selector housing in direction of
-arrows-.
62 Rep. Gr.34 - Controls, housing
Page 69
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Lift top spring arm -A- over pin on gate selector lever into
guide.
– Insert bottom spring arm into guide.
– Fit gear lever, gear selector cable, gate selector cable and
floor plate ⇒ page 58 .
– Install selector mechanism ⇒ page 64 .
Audi TT 2007 ➤
4. Exploded view - gear lever and selector housing for vehicles with vehicle ID No. from 8J-7-013001 onwards 63
Page 70
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24 .
– Detach securing clip -1- for gear selector cable and pull cable
off pin.
Metal gate relay lever:
– Detach securing clip -2- for gate selector cable from gate relay
lever and pull cable off pin.
Plastic gate relay lever:
•To prevent damage to gate selector cable, cable end-piece
must be detached from gate selector cable before removing
relay lever.
– Pull locking mechanism forwards in direction of -arrow 1- onto
stop and then turn to left in direction of -arrow 2- to lock.
– Then press gate relay lever forwards (in direction of
-arrow 3-).
•Detach cable end-piece only when gate relay lever is removed
⇒ page 76 .
64 Rep. Gr.34 - Controls, housing
Page 71
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove two bolts and one flange nut -arrows- and detach ca‐
ble support bracket from gearbox.
Vehicles with V6 engine:
– Remove three bolts -arrows- and detach cable support bracket
from gearbox.
Continued for all vehicles:
Audi TT 2007 ➤
– Remove propshaft ⇒ Rear final drive 02D, 0AV, 0BR and 0BY;
Rep. Gr. 39 .
– Loosen fasteners -arrows- and detach heat shield towards
rear of vehicle.
– Swing selector housing down and remove with selector ca‐
bles.
5. Removing and installing selector mechanism 65
Page 72
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Installation is carried out in reverse sequence; note the following:
– Install selector mechanism and tighten nuts -arrows-. Tight‐
ening torque ⇒ Item 16 (page 59)
– Route cables -1- from selector mechanism -2- to gearbox as
follows:
•The cables must run parallel and must not be crossed.
•The cables must be routed in the slot provided in heat shield
-3-.
Note
The enlargement shows the heat shield from above.
The cables and heat shield are held in the correct positions by
clip -A-.
66 Rep. Gr.34 - Controls, housing
Page 73
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– Attach cable support bracket to gearbox -arrows-. Tightening
torque ⇒ page 68
– Spread a small amount of grease -G 000 450 02- onto pins
-arrows- of gearbox selector lever -1- and, if necessary, gate
relay lever -2-.
•If they are removed, always renew securing clip -3- and, on
vehicles with metal gate relay lever, securing clip -4-.
– Fit gear selector cable and secure with securing clip -3-.
Metal gate relay lever:
– Fit gate selector cable and secure with securing clip -4-.
Plastic gate relay lever
– Insert gate selector cable in cable end-piece.
Continued for all vehicles:
– Adjust selector mechanism ⇒ page 79 .
– Install propshaft ⇒ Rear final drive 02D, 0AV, 0BR and 0BY;
Rep. Gr. 39 .
– Fit noise insulation above selector mechanism and install cen‐
tre console ⇒ Rep. Gr. 68 .
– Install gear knob together with boot ⇒ page 53 .
– Install air cleaner housing ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .
Audi TT 2007 ➤
5. Removing and installing selector mechanism 67
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with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 20 Nm
❑ 2x on vehicles with 4-cylinder engine
❑ 3x on vehicles with 6-cylinder engine
68 Rep. Gr.34 - Controls, housing
Page 75
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with respect to the correctness of information in this document. Copyright by AUDI AG.
The holes in the cable end-pieces have different diameters.
Cable end-piece for:Dimension “a”
1. - Gear selector cable to gearbox selector lev‐
8.5 mm
er from 06.06 onwards
2. - Gear selector cable to gearbox selector lev‐
10 mm
er up to 05.06
2. - Gate selector cable to metal gate relay lever8 mm
Audi TT 2007 ➤
From 06.06 onwards: smaller diameter of mounting pin for cable
end-piece (on gear selector cable)
Mounting pin for cable end-piece (on gear se‐
Dimension “a”
lector cable)
Up to 05.0610 mm
From 06.06 onwards8.5 mm
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 69
Page 76
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with respect to the correctness of information in this document. Copyright by AUDI AG.
6.1Exploded view - gearbox selector lever and gate relay lever up to model
year 2007
Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Selector mechanism cover
❑ Removing and installing
(with gearbox installed)
⇒ page 203
2 - Selector shaft
❑ Removing and installing
(with gearbox installed)
⇒ page 203
3 - Bush
4 - Securing clip
❑ Removing ⇒ page 71
5 - Oil seal
❑ Renewing ⇒ page 201
6 - Securing clip
7 - Cable end-piece
❑ Secures gear selector
cable to gearbox selec‐
tor lever
⇒ Item 4 (page 68)
❑ Allocation ⇒ page 69
8 - Nut
❑ 23 Nm
❑ Self-locking
❑ Renew
9 - Gearbox selector lever
❑ With damper weight
❑ Install so that gap in
splines aligns with se‐
lector shaft
⇒ page 71
❑ Installation position
⇒ page 71
❑ Different diameters of mounting pin for cable end-piece ⇒ page 69
10 - Securing clip
11 - Cable end-piece
❑ Secures gate selector cable to gate relay lever ⇒ Item 2 (page 68)
❑ Allocation ⇒ page 69
❑ Release to adjust selector mechanism ⇒ page 80
12 - Gate relay lever
❑ Installation position ⇒ page 71
70 Rep. Gr.34 - Controls, housing
Page 77
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– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow Bon the selector shaft.
Audi TT 2007 ➤
Installation position: gearbox selector lever/gate relay lever
1 - Gearbox selector lever with damper weight
2 - Gate relay lever locates in guide rail of gearbox selector lever
via slide block -arrow-.
– Coat guide rail and slide block -arrow- with grease -G 000 450
02- .
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 71
Page 78
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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.
❑ 20 Nm
❑ 2x on vehicles with 4-cylinder engine
❑ 3x on vehicles with 6-cylinder engine
15 - Grommet
16 - Bush
17 - Nut
❑ 20 Nm
❑ Only on vehicles with 4-cylinder engine
18 - Gate relay lever
❑ Made of plastic
❑ Different versions available; for correct version refer to ⇒ Electronic parts catalogue
❑ Installation position ⇒ page 74
❑ Detaching and securing gate relay lever (with detent catch) at gearbox selector lever ⇒ page 75
❑ Detaching and securing gate relay lever (with clip) at gearbox selector lever ⇒ page 76
19 - Slide block
❑ Installation position ⇒ page 74
20 - Cable end-piece
❑ Secures gate selector cable to gate relay lever
❑ Allocation ⇒ page 69
❑ Detaching from gate selector cable ⇒ page 74
21 - Angled rod
❑ For adjusting selector mechanism ⇒ page 79
Identification of cable end-pieces
The holes in the cable end-pieces have different diameters.
Cable end-piece for:Dimension “a”
-1- Gear selector cable to gearbox selector lever8.5 mm
-2- Gate selector cable to gate relay lever10 mm
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 73
Page 80
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow Bon the selector shaft.
Installation position: gearbox selector lever/gate relay lever
1 - Gearbox selector lever
2 - Clip or detent catch (depending on version)
3 - Gate relay lever locates in guide rail of gearbox selector lever
via slide block -arrow B-.
– Coat guide rail and slide block -arrow- with grease -G 000 450
02- .
Detaching cable end-pieces from gear selector cable and gate
selector cable
– Pull locking mechanism forwards -arrow 1- onto stop and then
turn to left -arrow 2- to lock.
– Take cable -B- out of cable end-piece -A-.
74 Rep. Gr.34 - Controls, housing
Page 81
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Insert gate relay lever with cable end-piece as far as stop.
•Gate relay lever is secured by detent -arrow 1-.
•Cable end-piece is secured by detent -arrow 2-.
•Ensure that components engage securely.
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 75
Page 82
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Detaching and securing gate relay lever (with clip) at gearbox se‐
lector lever -arrow 1-
Detaching
– Remove clip -arrow 1- and take off gate relay lever together
with cable end-piece.
Securing
Note
Lubricate all bearings and moving surfaces with grease -G 000
450 02- .
– Insert gate relay lever with cable end-piece as far as stop.
– Press on clip -arrow 1-, making sure it engages securely.
Note
-Arrow 2- can be disregarded.
Levering cable end-piece for gate selector cable off gate relay
lever
•Gate relay lever removed
– Apply plain slot screwdriver -A- between bush -B- and gate
relay lever.
Pressing cable end-piece for gate selector cable onto gate relay
lever
•Gate relay lever removed
•Press on cable end-piece only at bush -arrow-.
•Cable end-piece must move freely on gate relay lever.
•Cable end-piece must be behind detent.
– Ensure that components engage securely.
76 Rep. Gr.34 - Controls, housing
Page 83
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with respect to the correctness of information in this document. Copyright by AUDI AG.
6.3Removing and installing gear selector
cable and gate selector cable
Removing
– Remove selector mechanism ⇒ page 64 .
– Using a screwdriver, bend open tabs -arrows- for selector
mechanism on floor plate and remove floor plate.
– Remove gasket.
Vehicles with vehicle ID No. up to 8J-7-013000:
– Detach securing clips -1- and -4- and pull both cables off pins.
Vehicles with vehicle ID No. from 8J-7-013001 onwards:
– Prise gear selector cable and gate selector cable off pins.
Continued for all vehicles:
– Take off securing clips -2 ... 3- and detach gear selector cable
and gate selector cable from selector housing.
Audi TT 2007 ➤
Release cable end-pieces -A- for gate selector cable and gear
selector cable -B- as follows:
– Push sleeve forwards onto stop -arrow 1-.
– Turn sleeve clockwise onto stop -arrow 2- so that it engages.
– Detach cable end-pieces from cables.
– Pull off securing clips -1- and -2-.
– Detach cable support bracket from cables.
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 77
Page 84
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Fit new gasket and secure new floor plate to selector mecha‐
nism by bending over tabs -arrows-.
– Install selector mechanism ⇒ page 64 .
– Adjust selector mechanism ⇒ page 79 .
78 Rep. Gr.34 - Controls, housing
Page 85
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with respect to the correctness of information in this document. Copyright by AUDI AG.
•Gear selector linkage must be in proper condition and undam‐
aged.
•Selector mechanism must move freely.
•Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
•Gearbox in neutral.
Adjusting
– Open ashtray.
– Carefully lever off trim panel from centre console -arrows-.
– Pull trim panel up and over gear knob.
Audi TT 2007 ➤
7. Adjusting selector mechanism 79
Page 86
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– With gearbox in neutral, guide gear lever to the left into 1st/
2nd gear gate.
– Lift noise insulation plate.
– Then guide locking pin -T10027A- through hole -A- and into
hole -B-.
Note
The noise insulation panels are removed to give a better illustra‐
tion.
– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24 .
Release cable end-pieces -A- for gate selector cable and gear
selector cable -B- as follows:
– Push sleeve forwards onto stop -arrow 1-.
– Turn sleeve clockwise onto stop -arrow 2- so that it engages.
Note
It should be possible to move selector cable -B- in the cable endpiece.
•Gearbox in neutral.
Lock the selector shaft as follows:
– Press down gearbox selector lever -1- in direction of arrow
-A-.
– At the same time press and turn angled rod -2- in direction of
arrow -B- and -C- until it engages.
The selector shaft is then locked and can no longer be moved.
– Check that gate selector cable and gear selector cable -B- are
located in cable end-pieces -A- without tension.
– Release locking sleeve -arrow 1-.
– Allow locking sleeve to slide onto stop -arrow 2-.
Cable adjustment is now complete.
80 Rep. Gr.34 - Controls, housing
Page 87
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– Turn angled rod -A- back to initial position in direction of
-arrow 2- and pull out of gearbox in direction of -arrow 1-.
– Pull locking pin -T10027 A- out of selector mechanism.
Checking gear lever setting
•With the gearbox in neutral, the gear lever should rest in the
3rd/4th gear gate.
– Depress clutch.
– Select all gears several times. Pay particular attention to the
operation of the reverse gear locking mechanism.
•The gear lever should return by itself from the reverse gear
gate to the 3rd/4th gear gate.
If the gear lever sticks or baulks repeatedly when engaging a
gear, perform the adjustment procedure again.
– Fit cover and trim panel for centre console.
– Install air cleaner housing ⇒ Rep. Gr. 23 or ⇒ Rep. Gr. 24 .
Audi TT 2007 ➤
7. Adjusting selector mechanism 81
Page 88
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with respect to the correctness of information in this document. Copyright by AUDI AG.
8.1Removing gearbox - vehicles with 2.0 ltr. TFSI engine
Special tools and workshop
equipment required
♦ Support bracket -10 - 222
A-
♦ Hose clamps, up to Ø 25
mm -3094-
♦ Gearbox support -3282-
♦ Adapter -VW 771/40-
♦ Engine and gearbox jack -
V.A.G 1383 A-
82 Rep. Gr.34 - Controls, housing
Page 89
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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 engine cover panel -arrows-.
8. Removing and installing gearbox 83
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove air cleaner housing completely ⇒ Rep. Gr. 24 .
– Remove bolts -arrows- and detach bracket for air cleaner
housing.
– Detach securing clip -1- and pull cable end-piece off pin.
Metal gate relay lever:
– Detach securing clip -2- and pull cable end-piece off gate relay
lever.
Plastic gate relay lever:
•To prevent damage to gate selector cable, cable end-piece
must be detached from gate selector cable before removing
relay lever.
– Pull locking mechanism forwards in direction of -arrow 1- onto
stop and then turn to left in direction of -arrow 2- to lock.
– Then press gate relay lever forwards (in direction of
-arrow 3-).
•Detach cable end-piece only when gate relay lever is removed
⇒ page 76 .
Continued for all vehicles:
– Detach cable support bracket from gearbox -arrows-; then
move to one side and tie up together with selector cables.
84 Rep. Gr.34 - Controls, housing
Page 91
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew top engine/gearbox securing bolts -arrows-.
– Remove the two top bolts on radiator cowl -top arrows-.
Audi TT 2007 ➤
– Set up support bracket -10 - 222 A- together with racks -10 -
222 A /1- on wing mounting flanges.
– Engage hook of spindle -10 - 222 A /11- in engine lifting eye
(left-side).
– Partly take up weight of engine with spindle, but do not lift.
– With vehicle still standing on its wheels, slacken off front left
flange bolt -2- 90° (maximum). Do not slacken further, as this
would damage the wheel bearing.
– Remove both front wheels.
8. Removing and installing gearbox 85
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
– Remove nut -1- and detach bracket from stud together with
electrical wiring.
– Move bracket and wiring clear to the side.
– Remove bottom bolt securing starter -1-.
– Unscrew bolts -1 ... 3- and remove pendulum support.
8. Removing and installing gearbox 87
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Release hose clips -1- and -2- and remove air intake pipe.
– Detach electrical connector -1-.
– Remove remaining bolts -bottom arrows- and take out radiator
cowl from below.
– Remove nuts -arrows-.
– Detach catalytic converter from turbocharger and secure cat‐
alytic converter to prevent it from falling.
Note
-Item 1- and -item 2- can be disregarded.
– Unbolt heat shield for drive shaft (right-side) from bevel box
-arrows-.
– Unbolt drive shaft (left-side) from flange shaft on gearbox.
– Unbolt drive shaft (right-side) from flange shaft on bevel box.
88 Rep. Gr.34 - Controls, housing
Page 95
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Mark position of flexible coupling and bevel box flange in re‐
lation to one another.
– Unbolt propshaft with flexible coupling from bevel box
-arrows- (counterhold triangular flange with suitable lever).
Audi TT 2007 ➤
– Push engine/gearbox assembly forward slightly (towards front
end) and then pull propshaft off bevel box.
Caution
The seal -arrow- in the propshaft flange can be damaged.
♦ Push propshaft towards the rear and to the right as far as
possible.
Note
If seal is damaged propshaft must be renewed.
– If a plastic pipe is installed between clutch master cylinder and
slave cylinder, clamp off supply hose to clutch master cylinder
using hose clamp up to 25 mm -3094- .
Note
♦
In the following steps make sure that no brake fluid escapes
onto the starter or onto the gearbox below. If this does happen,
clean the affected area thoroughly.
♦
Seal off open lines and connections with clean plugs or sealing
caps to prevent dirt from entering.
8. Removing and installing gearbox 89
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– If a pipe/hose assembly is installed between clutch master
cylinder and slave cylinder, clamp off hose -A- using hose
clamp up to 25 mm -3094- .
Note
-Arrow- can be disregarded.
– 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 and seal end of pipe.
Caution
Do not operate clutch pedal after disconnecting pipe/hose as‐
sembly.
– Remove nut -B-.
– Detach earth cable and remove top securing bolt for starter.
– Place starter to side onto longitudinal member.
– Remove bolts on gearbox mounting -arrows-.
– By adjusting spindles on support bracket -10 - 222 A- , lower
gearbox by distance -a-.
•Dimension -a- = 60 mm.
90 Rep. Gr.34 - Controls, housing
Page 97
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The wheel bearing must not be subjected to load after the bolt
-2- securing the drive shaft has been slackened.
– Remove engine/gearbox connecting bolts (bottom) -4- and
-5-.
•Leave connecting bolt -3- screwed in.
To remove gearbox “02Q” set up gearbox support -3282- with
adjustment plate -3282/33- .
– 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 .
8. Removing and installing gearbox 91
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Bolt on support elements -A-, as illustrated on adjustment
plate .
– Screw in pin -3282/29- instead of support element -C-.
– Place engine and gearbox jack -V.A.G 1383 A- under vehicle;
arrow symbol -B- on adjustment plate points to front of vehicle.
– Align adjustment plate and gearbox parallel to one another.
– Secure adapter -VW 771/40- in tapped hole of gearbox hous‐
ing, as shown in illustration.
– Screw pin -3282/29- into hole for bolt securing pendulum sup‐
port to gearbox.
– Secure gearbox to gearbox support -3282- with bolt M10x20
-item A-.
•Make sure pin -B- is flush at bottom with guide of gearbox
support -3282- -arrow-.
– Unscrew last engine/gearbox securing bolt -C-.
– Press gearbox off dowel sleeves.
– Now remove bracket -A- for bevel box.
– Turn gearbox upwards at differential end. Guide output flange
-C- on gearbox past propshaft -A- and front exhaust pipe -B-.
Rotate output flange if necessary.
Note
Also pay attention to area between bevel box and intermediate
plate on engine.
– Then tilt gearbox to the left by turning spindles of gearbox
support -3282- .
– Guide gearbox past suspension bracket for wishbone, then
push gearbox forwards slightly and lower out carefully.
92 Rep. Gr.34 - Controls, housing
Page 99
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
8.2Removing gearbox - vehicles with 3.2 ltr. MPI engine
Special tools and workshop
equipment required
♦ Support bracket -10 - 222
A-
♦ Hooks -10 - 222 A /10-
♦ Hose clamps, up to Ø 25
mm -3094-
♦ Gearbox support -3282-
♦ Pin -3282/29-
♦ Adjustment plate -3282/33-
Audi TT 2007 ➤
8. Removing and installing gearbox 93
Page 100
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.