Audi TT 63 User Manual

Page 1
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Workshop Manual
Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive
Edition 10.2009
Service Department. Technical Information
Page 2
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.
List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT01620
Page 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, allocation, transmission ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Overview - clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Notes on removing and installing clutch master cylinder and slave cylinder . . . . . . . . . . . . 12
1.2 Function check for clutch master cylinder and slave cylinder . . . . . . . . . . . . . . . . . . . . . . 13
2 Exploded view - pedal cluster, clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Exploded view - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Removing and installing pipe/hose assembly or plastic pipe . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Exploded view - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Exploded view - clutch release mechanism, slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 36
6 Clutch identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7 Exploded view - Sachs version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1 Removing and installing clutch (Sachs version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 Exploded view - LuK version clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1 Removing and installing clutch (LuK version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Exploded view - gear knob and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Removing and installing gear knob with gear lever boot . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Exploded view - gear lever and selector housing for vehicles with vehicle ID No. up to
8J-7-013000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4 Exploded view - gear lever and selector housing for vehicles with vehicle ID No. from
8J-7-013001 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6 Exploded view - gear selector cable and gate selector cable up to model year 2007 . . . . 68
6.1 Exploded view - gearbox selector lever and gate relay lever up to model year 2007 . . . . 70
6.2 Exploded view - gear selector cable and gate selector cable from model year 2008
onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.3 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 77
7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.1 Removing gearbox - vehicles with 2.0 ltr. TFSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.2 Removing gearbox - vehicles with 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Contents i
Page 4
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
8.3 Removing gearbox - vehicles with 2.0 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.4 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.1 Removing gearbox mounting - vehicles with 2.0 ltr. TFSI engine . . . . . . . . . . . . . . . . . . . . 128
11.2 Removing gearbox mounting - vehicles with 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . 130
11.3 Removing gearbox mounting - vehicles with 2.0 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . 133
11.4 Installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
12.1 Checking oil level in manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
13 Removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
13.1 Removing bevel box - vehicles with 2.0 ltr. TFSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . 141
13.2 Removing bevel box - vehicles with 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
13.3 Removing bevel box - vehicles with 2.0 ltr. TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
13.4 Installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
14.1 Checking gear oil level in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
14.2 Topping up gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
15 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
15.1 General layout of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
15.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
15.3 Exploded view - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . 156
15.4 Exploded view - input shaft, output shafts, differential, bevel box and selector rods . . . . . . 158
15.5 Dismantling and assembling gearbox (version without circlip A for input shaft sealing cap)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
15.6 Dismantling and assembling gearbox (version with circlip A for input shaft sealing cap) . . 172
16 Exploded view - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
16.1 Servicing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
17 Exploded view - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
17.1 Servicing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
17.2 Renewing input shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
18 Exploded view - selector mechanism in gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
18.1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
18.2 Removing and installing selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
19 Exploded view - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
19.1 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.2 Modifications in area of grooved ball bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2 Exploded view - output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.1 Dismantling and assembling output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . 220
2.2 Adjusting output shaft for 1st - 4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3 Exploded view - output shaft for 5th, 6th and reverse gear . . . . . . . . . . . . . . . . . . . . . . . . 235
3.1 Dismantling and assembling output shaft for 5th, 6th and reverse gear . . . . . . . . . . . . . . 237
3.2 Adjusting output shaft for 5th, 6th and reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1 Exploded view - flange shaft and oil seals on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.1 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.2 Renewing oil seal for flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
ii Contents
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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
1.3 Renewing oil seal for bevel box with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2 Exploded view - flange shaft and oil seals on bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.1 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.2 Renewing flange shaft oil seal (right-side) at bevel box (outer seal) . . . . . . . . . . . . . . . . . . 258
2.3 Renewing needle bearings (polygon bearings) for flange shaft (right-side) . . . . . . . . . . . . 259
2.4 Renewing oil seal between gearbox and bevel box (on bevel box) . . . . . . . . . . . . . . . . . . 260
2.5 Renewing oil seal for output flange on bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3 Exploded view - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.2 Table of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5 Rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Contents iii
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
iv Contents
Page 7
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

00 – Technical data

1 Gearbox identification

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: GUM 04 08 3
Additional data identify the factory where the unit was built.
Note
I I I I
Code letters Day Month 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

2 Code letters, allocation, transmission ratios, capacities

Manual gearbox Code letters
JLV JYV KDP
Manufactured from 04.06 11.06 06.07
to 11.06 05.07 02.08
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
Ratio Final drive I
Engine 3.2 ltr. MPI - 184 kW 3.2 ltr. MPI - 184 kW 3.2 ltr. MPI - 184 kW
72 : 17 = 4.235 72 : 17 = 4.235 72 : 17 = 4.235
for 1st to 4th
gear
i = Z2 : Z
1
Final drive II
72 : 22 = 3.273 72 : 22 = 3.273 72 : 22 = 3.273
for 5th/6th gear
and reverse
gear
Overall ratio i
in top gear 2.985 2.985 2.985
ov.
1st gear 47 : 14 = 3.357 47 : 14 = 3.357 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469 47 : 32 = 1.469 47 : 32 = 1.469
4th gear 37 : 34 = 1.088 37 : 34 = 1.088 37 : 34 = 1.088 5th gear 41 : 37 = 1.108 41 : 37 = 1.108 41 : 37 = 1.108 6th gear 31 : 34 = 0.912 31 : 34 = 0.912 31 : 34 = 0.912
Reverse gear 34 : 23 x 14 : 14 = 3.990 34 : 23 x 14 : 14 =
34 : 23 x 14 : 14 =
3.990
3.990
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 .
♦ Gear oil specification
♦ Bevel box gear oil specification
♦ Allocation of drive shaft flange type
♦ Allocation of clutch type
♦ Rear final drive identification
Manual gearbox Code letters
KNT KNZ KNW
Manufactured from 01.08 05.08 06.08
to 12.09 06.09 06.09
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
Engine 3.2 ltr. MPI - 184 kW 2.0 ltr. TFSI - 199 kW 2.0 ltr. TDI CR - 125
kW
Ratio Final drive I
72 : 17 = 4.235 72 : 17 = 4.235 62 : 16 = 3.875
for 1st to 4th
gear
i = Z2 : Z
1
Final drive II
72 : 22 = 3.273 72 : 22 = 3.273 62 : 20 = 3.100
for 5th/6th gear
and reverse
gear
1st gear 47 : 14 = 3.357 47 : 14 = 3.357 49 : 13 = 3.769
2 Rep. Gr.00 - Technical data
Page 9
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Manual gearbox Code letters
KNT KNZ KNW
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469 47 : 32 = 1.469 45 : 34 = 1.324
4th gear 37 : 34 = 1.088 37 : 34 = 1.088 34 : 37 = 0.919 5th gear 41 : 37 = 1.108 34 : 31 = 1.097 37 : 41 = 0.902 6th gear 31 : 34 = 0.912 31 : 34 = 0.912 28 : 37 = 0.757
Reverse gear 34 : 23 x 14 : 14 = 3.990 34 : 23 x 14 : 14 =
3.990
Overall ratio i
in top gear 2.985 2.985 2.826
ov. 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 .
♦ Gear oil specification
♦ Bevel box gear oil specification
♦ Allocation of drive shaft flange type
♦ Allocation of clutch type
♦ Rear final drive identification
36 : 23 x 13 : 14 =
4.549
Manual gearbox Code letters
KXY KZN KZV
Manufactured from 06.09 12.09 06.09
to
Allocation Model Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
Ratio Final drive I
Engine 2.0 ltr. TDI CR - 125 kW 3.2 ltr. MPI - 184 kW 2.0 ltr. TFSI - 199 kW
62 : 16 = 3.875 72 : 17 = 4.235 72 : 17 = 4.235
for 1st to 4th
gear
i = Z2 : Z
1
Final drive II
62 : 20 = 3.100 72 : 22 = 3.273 72 : 22 = 3.273
for 5th/6th gear
and reverse
gear
Overall ratio i
in top gear 2.826 2.985 2.985
ov.
1st gear 49 : 13 = 3.769 47 : 14 = 3.357 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 45 : 34 = 1.324 47 : 32 = 1.469 47 : 32 = 1.469
4th gear 34 : 37 = 0.919 37 : 34 = 1.088 37 : 34 = 1.088 5th gear 37 : 41 = 0.902 41 : 37 = 1.108 34 : 31 = 1.097 6th gear 28 : 37 = 0.757 31 : 34 = 0.912 31 : 34 = 0.912
Reverse gear 36 : 23 x 13 : 14 = 4.549 34 : 23 x 14 : 14 =
34 : 23 x 14 : 14 =
3.990
3.990
Capacity of manual gearbox 2.3 litres Capacity of bevel box 0.9 litres Clutch actuation Hydraulic
2. Code letters, allocation, transmission ratios, capacities 3
Page 10
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Manual gearbox Code letters
KXY KZN KZV
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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

3 Transmission layout

Identification
Arrows point in direction of travel
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft II for 5th, 6th and reverse gear
6 - Output shaft I for 1st - 4th gear
7 - Differential
8 - Bevel box
9 - Propshaft
10 - Haldex coupling
11 - Rear final drive
12 - Differential
Audi TT 2007 ➤
Ratio
Arrows point in direction of travel
3. Transmission layout 5
Page 12
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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

3.1 Calculating ratio “i”

Example:
6th gear Final drive
Drive gear ZG1 = 34 ZA1 = 22
Driven gear ZG2 = 31 ZA2 = 72
i = ZG2 : ZG1
1)
iG = gear ratio = ZG2 : ZG1 = 31 : 34 = 0.912
iA = axle ratio = ZA2 : ZA1 = 72 : 22 = 3.273
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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

4 General repair instructions

Proper tools and the maximum possible care and cleanliness are essential for satisfactory gearbox repairs. The usual basic safety precautions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various re‐ pair procedures - which were previously repeated at numerous places in the Workshop Manual - are summarised here. They ap‐ ply to the work described in this Manual.

4.1 Contact corrosion!

Contact corrosion can occur if non-approved fasteners are used on the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating are fitted.
Rubber or plastic parts and adhesives also consist of non-con‐ ductive materials.
If you are not sure whether used parts can be re-installed, always fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ The gearbox casing is made of a magnesium alloy.
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
Audi TT 2007 ➤
Caution
Damage caused by contact corrosion is not covered under warranty.

4.2 Repair instructions

Special tools
♦ For a complete list of special tools used in this Workshop
Manual ⇒ Workshop equipment and special tools .
Gearbox
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before dismantling.
♦ When installing the gearbox, ensure that the dowel sleeves
between the engine and the gearbox are correctly located.
♦ For allocation of bolts and other components, refer to ⇒ Elec‐
tronic parts catalogue .
♦ Clean contact surfaces when assembling mounting brackets
and waxed components. The contact surfaces must be free of wax and grease.
♦ After installing a replacement gearbox with bevel box, check
oil level in gearbox ⇒ page 138 and bevel box ⇒ page 150 .
♦ Capacities ⇒ page 2 , specifications ⇒ Electronic parts cata‐
logue .
4. General repair instructions 7
Page 14
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Oil seals, seals, O-rings and gaskets
♦ Always renew oil seals, O-rings and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow­about half full with grease -G 052 128 A1- .
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal in the housing
so that the sealing lip does not contact the shaft in the same place as the old seal (make use of installation depth toleran‐ ces).
♦ Lightly lubricate O-rings with oil before installation to prevent
them being trapped during assembly.
♦ 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Nuts, bolts
♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified.
♦ Renew self-locking nuts and bolts.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐ erwise there is a danger of the bolts shearing off the next time they are removed.
♦ For all threaded connections, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with wax until after assembly is completed.
Bearings
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Lubricate all bearings (except tapered roller bearings) with
gear oil before installing in gearbox.
♦ Use inductive heater -VAS 6414- to heat inner races of tapered
roller bearings to approx. 100°C before installing. Press home onto stop when installing so there is no axial clearance.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ If required, renew the tapered roller bearings on one shaft to‐
gether and use new bearings from a single manufacturer.
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
Audi TT 2007 ➤
Shims
♦ Use a micrometer to measure the shims at several points.
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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Synchro-rings
♦ Do not interchange synchro-rings. When reusing always fit to
the same selector gear.
♦ Check for wear; renew if necessary.
♦ Check the grooves -arrow 1- on synchro-ring -A- and on inner
ring for wear (flattened sections in grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is fitted, check the outer contact
surface -arrow 2- and inner contact surface -arrow 3- of the intermediate ring for “scoring”, “visible traces of wear” and “blue discolouration (caused by overheating)”.
♦ Check chamfer on selector gear for scoring and visible traces
of wear.
♦ Lubricate 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
♦ Abnormal wear on locking collar:
C - Worn chamfer on internal splines of locking collar.
♦ In comparison: intact locking collar:
D - Intact chamfer on internal splines of locking collar.
Clutch actuation, clutch
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the clutch system (further measures ⇒ page 12 ).
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts consecutively in steps of 90°.
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox in order to prevent odours.
♦ Only blow out dual-mass flywheel with compressed air.
♦ Clutch pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the clutch plate, the pressure plate must not be cleaned. Other‐ wise the service life of the clutch will be considerably reduced.
♦ The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
Audi TT 2007 ➤
4. General repair instructions 11
Page 18
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

30 – Clutch

1 Overview - clutch mechanism

Note
If you suspect a defective clutch master cylinder or clutch slave cylinder, pay attention to
⇒ “1.1 Notes on removing and installing clutch master cylinder and slave cylinder”, page 12 and perform ⇒ “1.2 Function check for clutch master cylinder and slave cylin‐ der”, page 13 prior to renewing.
I -
⇒ “2 Exploded view - pedal cluster, clutch master cylin‐ der”, page 15
⇒ “2.1 Removing and installing over-centre spring”, page 16
⇒ “2.2 Removing and installing clutch pedal”, page 18
⇒ “2.3 Removing and installing mounting bracket”, page 21
⇒ “2.4 Removing and installing clutch position sender G476 ”, page 23
⇒ “2.5 Removing and installing clutch master cylinder”, page 24
II -
⇒ “3 Exploded view - hydraul‐ ics (LHD)”, page 27
⇒ “3.1 Removing and installing pipe/hose assembly or plastic pipe”, page 29
⇒ “3.2 Bleeding clutch sys‐ tem”, page 31
III -
⇒ “4 Exploded view - hydraul‐ ics (RHD)”, page 33

1.1 Notes on removing and installing clutch master cylinder and slave cylinder

♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective you must first carry out a function check
12 Rep. Gr.30 - Clutch
Page 19
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
⇒ “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.
1.2 Function check for clutch master cylin‐ der and slave cylinder
Before you renew the clutch master cylinder or slave cylinder you must - in the case of the following faults - first carry out the ap‐ propriate checks.
Noises when operating the clutch:
♦ First check the over-centre spring / clutch pedal switch for
noise.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains depressed / does not return to its initial position.
♦ Check whether the clutch pedal returns all the way to its initial
position, thereby uncovering the vent opening in the master cylinder.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside.
♦ The vent opening must be uncovered, otherwise the perma‐
nent self-bleeding function for the hydraulic clutch system will no longer be effective.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time. This could impair the self-bleeding function of the clutch system as the vent opening in the master cylinder can no longer function.
♦ The self-bleeding function of the clutch system can be im‐
paired if the footwell trim or floor mats get trapped, if the clutch pedal switch jams or if the driver rests his foot on the clutch pedal for long periods of time.
Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks (visual inspection).
Audi TT 2007 ➤
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 12 .
Pedal forces:
♦ approx. 140 N for complete service life of the clutch
1. Overview - clutch mechanism 13
Page 20
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
High pedal force:
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 39 or
⇒ page 45
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 12 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines
(due to corrosion or dirt, etc.)
♦ Foreign body in clutch system
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 39 or
⇒ page 45
♦ Wrong components used or components forgotten when car‐
rying out repair work (e.g. intermediate plate or dowel sleeves).
14 Rep. Gr.30 - Clutch
Page 21
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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

2 Exploded view - pedal cluster, clutch master cylinder

Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
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 21
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
⇒ page 16
6 - Bearing bush
7 - Pivot pin
8 - Clutch pedal
❑ Removing and installing
⇒ page 18
❑ If fitting new pedal rub‐
ber, cut to required size
as described
⇒ page 16
9 - Retaining clip
❑ For operating rod on
clutch master cylinder
10 - Seal
❑ Renew ❑ Between master cylinder and mounting bracket
11 - Clutch master cylinder
❑ Removing and installing ⇒ page 24
12 - Clutch position sender -G476-
❑ Removing and installing ⇒ page 23 ❑ Checking in “Guided Fault Finding” ⇒ Vehicle diagnosis, testing and information system VAS 5051
13 - Retaining clip
❑ To remove and install pipe/hose assembly, pull out clip as far as it will go
14 - Supply hose
❑ To brake fluid reservoir
2. Exploded view - pedal cluster, clutch master cylinder 15
Page 22
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
❑ 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

2.1 Removing and installing over-centre spring

Special tools and workshop equipment required
16 Rep. Gr.30 - Clutch
Page 23
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
♦ Assembly tool -T10178-
♦ Grease -G 000 450 02-
Removing
Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
Audi TT 2007 ➤
– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,
remove nut -2- and pull out bolt -5-.
Note
The clutch pedal does not have to be detached from the operating rod on the clutch master cylinder.
– Pivot clutch pedal down slightly and and take over-centre
spring -4- out of mounting bracket.
2. Exploded view - pedal cluster, clutch master cylinder 17
Page 24
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Installing
Tightening torque ⇒ page 15
Installation is carried out in reverse sequence; note the following:
Note
Renew self-locking nut.
Lubricate all bearings and contact surfaces with grease -G 000 450 02- .
– Fit over-centre spring -2- into mounting bracket from above
while holding end of spring in correct position with assembly tool -T10178- .
Socket -arrow- of over-centre spring must be in vertical posi‐
tion.
– Fit actuator on clutch pedal -A- into corresponding socket in
over-centre spring -arrow-.
– Press clutch pedal slightly, push bolt through and tighten self-
locking nut.
– Install crash bar ⇒ page 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .

2.2 Removing and installing clutch pedal

Special tools and workshop equipment required
♦ Pliers -T10005-
18 Rep. Gr.30 - Clutch
Page 25
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
♦ Assembly tool -T10178-
♦ Grease -G 000 450 02-
Removing
Clutch pedal mounting bracket fitted in vehicle
– Move driver's seat away from pedals.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
Audi TT 2007 ➤
– Unbolt clutch pedal -1- from mounting bracket -3-. To do this,
remove nut -2- and pull out bolt -5-.
– Pivot clutch pedal down slightly and and take over-centre
spring -4- out of mounting bracket.
2. Exploded view - pedal cluster, clutch master cylinder 19
Page 26
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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 top of clutch pedal forwards against spring pressure of
over-centre spring, push through bolt and tighten self-locking nut.
Note
It is easier to press the clutch pedal against the spring if you pull back the bottom of the pedal carefully as you bring the top of the pedal into installation position.
– Install crash bar ⇒ page 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2.3 Removing and installing mounting
bracket
Audi TT 2007 ➤
Special tools and workshop equipment required
♦ Hose clamp, up to Ø 25 mm -3094-
♦ Hose clip pliers -VAS 6340-
2. Exploded view - pedal cluster, clutch master cylinder 21
Page 28
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Removing
Note
In the following steps make sure that no brake fluid escapes onto the longitudinal member or onto the gearbox below. If this does happen, clean the affected area thoroughly.
– Use hose clamp -3094- to clamp off supply hose to clutch
master cylinder.
– Disconnect supply hose at clutch master cylinder (if necessa‐
ry, release spring-type clip -3- using hose clip pliers -VAS 6340- ).
– Release retaining clip -2- with a screwdriver and disconnect
pipe/hose assembly -1- or plastic pipe from clutch master cyl‐ inder.
– Unclip and detach clutch position sender -G476- from clutch
master cylinder -arrow-. Electrical connector -4- can remain connected.
– Move driver's seat to rear as far as possible and move steering
wheel into uppermost position.
– Remove storage compartment on driver's side ⇒ Rep. Gr.
68 .
– Unscrew bolt -arrow A- and remove footwell air outlet (front
left) -1-.
– Unclip wiring harness at rear of footwell air outlet -1- and move
clear to one side.
– Unbolt crash bar -2- (secured by one or two bolts -arrows B-,
depending on version).
22 Rep. Gr.30 - Clutch
Page 29
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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 15
Installation is carried out in reverse sequence; note the following:
Note
Renew self-locking nuts.
Secure all hose connections with the correct hose clips (as original equipment); refer to ⇒ Electronic parts catalogue .
Audi TT 2007 ➤
– Fit mounting bracket -1- and tighten nuts -2-.
– Install pipe/hose assembly or plastic pipe ⇒ page 29 .
– Bleed clutch system ⇒ page 31 .
– Install crash bar ⇒ page 16 .
– Install front footwell vent (left-side) ⇒ Rep. Gr. 80 .
– Install storage compartment on driver's side ⇒ Rep. Gr. 68 .
2.4 Removing and installing clutch position
sender -G476-
Removing
– Unplug electrical connector -4-.
– Unclip clutch position sender -G476- at clutch master cylinder
in direction of -arrow- and remove.
Note
-Items 1, 2 and 3- can be disregarded.
2. Exploded view - pedal cluster, clutch master cylinder 23
Page 30
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Installing
– Fit clutch position sender -G476- at clutch master cylinder and
engage -arrow-.
– Attach electrical connector -4-.

2.5 Removing and installing clutch master cylinder

Special tools and workshop equipment required
♦ Pliers -T10005-
Removing
Note
If you suspect a defective clutch master cylinder, perform function test prior to renewing
⇒ “1.1 Notes on removing and installing clutch master cylinder and slave cylinder”, page 12 .
When working in the footwell, put cloths on the floor covering to protect it from possible brake fluid spills.
24 Rep. Gr.30 - Clutch
Page 31
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Remove mounting bracket ⇒ page 21 .
– Release retaining clip for operating rod on clutch pedal using
pliers -T10005- .
– Insert a spacer -A- between clutch pedal and stop, and press
clutch pedal forward.
Length of spacer = approx. 40 mm (e.g. 1/2” socket)
– Release retainer clip -B- and pull master cylinder out of mount‐
ing bracket -arrow 1- and -arrow 2-.
Audi TT 2007 ➤
Installing
Move clutch pedal back as far as stop until it is in normal po‐ sition.
– Install retaining clip -2- on operating rod -1- for clutch master
cylinder.
2. Exploded view - pedal cluster, clutch master cylinder 25
Page 32
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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)
– 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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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

3 Exploded view - hydraulics (LHD)

1 - Brake fluid reservoir
2 - Hose clip (spring-type clip)
❑ Not fitted in all vehicles
3 - Supply hose
❑ Made of rubber or plas‐
tic, depending on ver‐ sion
❑ Plastic supply hose with
additional seals
⇒ page 28
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 24
5 - Clip
❑ To remove and install
pipe/hose assembly, pull out clip as far as it will go
6 - Seal or O-ring
❑ Renew damaged seals
or O-rings
❑ Push onto pipe connec‐
tion
❑ Lubricate with brake flu‐
id before installing
❑ Whether a seal or an O-
ring is used depends on the type of connection
⇒ page 28
❑ For correct version, re‐
fer to ⇒ Electronic parts catalogue
7 - Retaining clip
❑ To remove and install retaining clip first detach clutch master cylinder from clutch pedal ⇒ page 18
8 - Clutch pedal
❑ Removing and installing ⇒ page 18
9 - Nut
❑ For securing mounting bracket to 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
❑ 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Identification of brackets
Dimension “a” (mm) Pipe version
8 Plastic pipe 6 Pipe/hose assembly
3.1 Removing and installing pipe/hose as‐
sembly or plastic pipe
Special tools and workshop equipment required
♦ Hose clamps, up to Ø 25 mm -3094-
Audi TT 2007 ➤
Removing
– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24 .
– Use hose clamp -3094- to clamp off supply hose to clutch
master cylinder.
3. Exploded view - hydraulics (LHD) 29
Page 36
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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.
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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Check O-ring -3- for damage and renew if necessary.
– Press pipe/hose assembly -4- or plastic pipe onto bleeder
connection so that retaining clip -2- snaps into place.
– Pull on pipe to check it is secure.
– Bleed clutch system ⇒ page 31 .

3.2 Bleeding clutch system

Note
The clutch system must be bled after performing work on the hydraulic clutch mechanism.
In the following steps make sure that no brake fluid escapes onto the longitudinal member or onto the gearbox below.
Before bleeding clutch system, top up brake fluid reservoir to “max.” marking with brake fluid.
Audi TT 2007 ➤
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-
♦ Brake fluid specification ⇒ Rep. Gr. 47.
Procedure
Tightening torque ⇒ page 27
– Remove air cleaner housing completely ⇒ Rep. Gr. 23 or ⇒
Rep. Gr. 24 .
3. Exploded view - hydraulics (LHD) 31
Page 38
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

4 Exploded view - hydraulics (RHD)

1 - Brake fluid reservoir
2 - Seal
❑ For plastic supply hose ❑ Seals must be fitted in
supply hose.
3 - Supply hose
❑ Made of rubber or plas‐
tic, depending on ver‐ sion
❑ Plastic supply hose with
additional seals
⇒ Item 2 (page 33)
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 24
5 - Clip
❑ To remove and install
pipe, pull out clip as far as it will go
6 - Seal or O-ring
❑ Matched to type of con‐
nection ⇒ page 28
❑ For correct version, re‐
fer to ⇒ Electronic parts catalogue
❑ Renew damaged seals
or O-rings
❑ Push onto pipe connec‐
tion
❑ Lubricate with brake flu‐
id before installing
7 - Retaining clip
❑ To remove and install retaining clip first detach master cylinder from clutch pedal ⇒ page 18
8 - Clutch pedal
9 - Nut
❑ For securing mounting bracket to 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
13 - Pipe/hose assembly
❑ For correct version, refer to ⇒ Electronic parts catalogue
14 - Bracket
❑ Secured to bracket for ABS/EDL
15 - Seal or O-ring
❑ Matched to type of connection ⇒ page 28 ❑ For correct version, refer to ⇒ Electronic parts catalogue ❑ Renew damaged seals or O-rings ❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing
16 - Clip
❑ To remove and install pipe/hose assembly or bleeder connection, pull out clip as far as it will go.
17 - Bleeder screw
❑ Bleeding clutch system ⇒ page 31 ❑ 4.5 Nm
18 - Dust cap
19 - Bleeder connection
20 - 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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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

5 Exploded view - clutch release mechanism, slave cylinder

1 - Bolt
❑ 12 Nm for metal clutch
slave cylinder
❑ 15 Nm for plastic clutch
slave cylinder ❑ 3x ❑ Renew ❑ Tighten bolts carefully in
several small steps and
in diagonal sequence;
make sure that mount‐
ing lugs on slave cylin‐
der do not break off
2 - Clutch slave cylinder with release bearing
❑ Slave cylinder and re‐
lease bearing are one
unit and can only be re‐
newed together ❑ Do not wash out bear‐
ing; wipe clean only ❑ If bearing is noisy, re‐
new together with slave
cylinder ❑ Removing and installing
⇒ page 36
3 - O-ring
❑ Renew if damaged ❑ Push onto pipe connec‐
tion ❑ Lubricate with brake flu‐
id before installing
4 - Retaining clip
5 - Bleeder screw
❑ Tightening torque ⇒ Item 17 (page 28)
6 - Protective cap
7 - Retaining clip
8 - Pipe/hose assembly or plastic pipe
❑ To clutch master cylinder ❑ Removing and installing ⇒ page 29
9 - O-ring
❑ Renew if damaged ❑ Push onto pipe connection ❑ Lubricate with brake fluid before installing
10 - Bleeder connection
❑ Removing and installing
⇒ “5.1 Removing and installing clutch slave cylinder together with release bearing”, page 36
11 - Oil seal
❑ For input shaft
5. Exploded view - clutch release mechanism, slave cylinder 35
Page 42
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
❑ Removing and installing ⇒ page 198

5.1 Removing and installing clutch slave cylinder together with release bearing

Note
Slave cylinder and release bearing are one unit and can only be renewed together.
Removing
Gearbox removed ⇒ page 82 .
– Release retaining clip -2- with a screwdriver and pull bleeder
connection -4- off slave cylinder -1-.
– Remove bolts -arrows-.
– Take off slave cylinder together with release bearing -A-.
Installing
Tightening torque ⇒ page 35
Installation is carried out in reverse sequence; note the following:
Caution
Tighten securing bolts for slave cylinder in small steps. Other‐ wise mounting lugs -arrows- can be damaged.
– Secure clutch slave cylinder with release bearing -arrows-.
– Check O-ring -3- for damage and renew if necessary.
– Press bleeder connection -4- onto connection on clutch slave
cylinder -1- so that retaining clip -2- snaps into place.
– Pull on bleeder connection to check it is secure.
– Bleed clutch system ⇒ page 31 .
36 Rep. Gr.30 - Clutch
Page 43
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

6 Clutch identification

Note
The clutch fitted in the vehicle is supplied by either “Sachs” or “LuK”.
With gearbox installed, the clutch version fitted can be distin‐ guished as follows:
– Release fasteners -1 ... 4- and remove centre noise insulation.
Audi TT 2007 ➤
A number of recesses -arrows- are located in lower area of sump between engine -A- and gearbox -B-.
– Check the contour of the flywheel visible through the recesses.
A - round contour -arrows- = Sachs version clutch
Exploded view - Sachs version clutch ⇒ page 39
B - square contour -arrows 1- and annular groove -arrow 2- = LuK version clutch
Exploded view - LuK version clutch ⇒ page 45
6. Clutch identification 37
Page 44
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

7 Exploded view - Sachs version clutch

Note
The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.
1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be free of grooves, oil and grease
❑ Observe instructions for
removal ⇒ page 41
2 - Clutch plate
❑ Removing and installing
⇒ page 41
❑ Always renew pressure
plate as well
❑ Installation position
⇒ page 44
❑ For diameter of clutch
plate, refer to ⇒ Elec‐ tronic parts catalogue
3 - Pressure plate
❑ With adjustment mech‐
anism
❑ Identification
⇒ page 40
❑ Removing and installing
⇒ page 41
❑ Checking ends of dia‐
phragm spring
⇒ page 40
❑ Checking springs and
riveting ⇒ page 40
❑ Checking wire ring or
sheet-metal ring ⇒ page 41
❑ Always renew clutch plate as well ❑ For correct version, refer to ⇒ Electronic parts catalogue ❑ Contact surface for clutch lining must be free of grooves, oil and grease
4 - Bolt
❑ M6 - 13 Nm ❑ M7 - 20 Nm ❑ Loosen and tighten bolts consecutively in steps of 90°
7. Exploded view - Sachs version clutch 39
Page 46
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Check that rivets -arrows B- are secure at all springs
-arrows A-.
Renew pressure plate if rivets -arrows B- are loose.
Checking wire ring or sheet-metal ring
– Check wire ring or sheet-metal ring -arrow- in pressure plate
for damage.
Renew pressure plate if wire ring or sheet-metal ring is broken.
Audi TT 2007 ➤
Instructions for removing dual-mass flywheel
Note
Do not use an impact wrench or pneumatic wrench to remove bolts -B-: this would severely damage the dual-mass flywheel. The bolts must always be removed by hand.
– Rotate dual-mass flywheel -A- so that the bolts are aligned
centrally behind the holes -arrows-.
– When removing the bolts, make sure that none of the bolt
heads contacts the dual-mass flywheel, as this would damage the flywheel when the bolts are unscrewed further.

7.1 Removing and installing clutch (Sachs version)

Special tools and workshop equipment required
♦ Counterhold tool -3067-
7. Exploded view - Sachs version clutch 41
Page 48
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
♦ Centring mandrel -T10097-
♦ Grease for clutch plate splines -G 000 100-
42 Rep. Gr.30 - Clutch
Page 49
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Removing
Gearbox removed ⇒ page 82 .
To prevent the pressure plate from becoming distorted during re‐ moval (causes clutch grab when driving off), always adhere to the following procedure when unbolting the pressure plate:
– Apply counter-hold tool -3067- in order to loosen bolts.
– Working clockwise, loosen all six bolts consecutively in steps
of 90° (1/4 turn) until the pressure plate is released.
Stop -2- with pin -1- should come loose when the bolts are
slackened.
– If the stop does not come loose, push the pin towards the dual-
mass flywheel.
– Take off pressure plate and clutch plate.
Installing
Tightening torque ⇒ page 39
Installation is carried out in reverse sequence; note the following:
Audi TT 2007 ➤
Note
The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.
Always renew clutch plate and pressure plate together and select the correct parts according to engine code ⇒ Electronic parts catalogue .
If the clutch has burnt out, thoroughly clean the gearbox hous‐ ing in area of clutch and parts of the engine facing the gearbox in order to prevent odours.
Clean input shaft splines and (in the case of a used clutch plate) the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.
Clutch pressure plates have an anti-corrosion coating and are greased. With the exception of the friction surface for the clutch plate, the pressure plate must not be cleaned. Other‐ wise the service life of the clutch will be considerably reduced.
Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert bolts.
Only blow out dual-mass flywheel with compressed air.
The friction surface of the pressure plate and the dual-mass flywheel must be cleaned (degreased) thoroughly.
Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.
If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).
7. Exploded view - Sachs version clutch 43
Page 50
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Installation position of clutch plate
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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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

8 Exploded view - LuK version clutch

Note
The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.
1 - Dual-mass flywheel
❑ Removing and installing
⇒ Rep. Gr. 13
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch lining must be free of grooves, oil and grease
❑ Observe instructions for
removal ⇒ page 47
2 - Clutch plate
❑ Removing and installing
⇒ page 47
❑ Always renew SAC
pressure plate as well
❑ Installation position:
marking “Getriebeseite” (gear‐ box side) faces towards gearbox
❑ For diameter of clutch
plate, refer to ⇒ Elec‐ tronic parts catalogue
3 - SAC pressure plate
❑ “SAC” = self adjusting
clutch
❑ Always renew clutch
plate as well
❑ Removing and installing
⇒ page 47
❑ Checking position of ad‐
juster ring on new SAC pressure plate
⇒ page 49
❑ Checking ends of diaphragm spring ⇒ page 40 ❑ Checking spring connection and rivets ⇒ page 46 ❑ Checking metal ring ⇒ page 46 ❑ Contact surface for clutch lining must be free of grooves, oil and grease
4 - Bolt
❑ M6 - 13 Nm ❑ M7 - 20 Nm ❑ Loosen and tighten bolts consecutively in steps of 90°
8. Exploded view - LuK version clutch 45
Page 52
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Checking ends of diaphragm spring
Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.
Checking springs and riveting
I - Springs OK
Slight kinking on the outside -arrows A- is normal on produc‐ tion parts.
II - Springs damaged
Renew pressure plate if springs are broken or badly bent
-arrow B-.
– Check that rivets -arrows B- are secure at all springs
-arrows A-.
Renew pressure plate if rivets -arrows B- are loose.
Checking metal ring
– Check metal ring -arrow- in pressure plate for damage.
Renew pressure plate if metal ring is broken.
46 Rep. Gr.30 - Clutch
Page 53
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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.
8.1 Removing and installing clutch (LuK ver‐ sion)
Special tools and workshop equipment required
♦ Counterhold tool -3067-
Audi TT 2007 ➤
♦ Centring mandrel -T10097-
♦ Grease for clutch plate splines -G 000 100-
8. Exploded view - LuK version clutch 47
Page 54
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Removing
Gearbox removed ⇒ page 82 .
– Apply counter-hold tool -3067- in order to loosen bolts.
To prevent the pressure plate from becoming distorted during re‐ moval (causes clutch grab when driving off), always adhere to the following procedure when unbolting the pressure plate:
– Working clockwise, loosen all six bolts consecutively in steps
of 90° (1/4 turn) until the pressure plate is released.
– Take off pressure plate and clutch plate.
Installing
Tightening torque ⇒ page 45
Installation is carried out in reverse sequence; note the following:
Note
The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle.
Always renew clutch plate and pressure plate together and select the correct parts according to engine code ⇒ Electronic parts catalogue .
Checking position of adjuster ring on new pressure plate
⇒ page 49
If the clutch has burnt out, thoroughly clean the gearbox hous‐ ing in area of clutch and parts of the engine facing the gearbox in order to prevent odours.
Clean input shaft splines and (in the case of a used clutch plate) the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease.
Clutch pressure plates have an anti-corrosion coating and are greased. With the exception of the friction surface for the clutch plate, the pressure plate must not be cleaned. Other‐ wise the service life of the clutch will be considerably reduced.
Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert bolts.
Only blow out dual-mass flywheel with compressed air.
The friction surface of the pressure plate and the dual-mass flywheel must be cleaned (degreased) thoroughly.
Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.
If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).
48 Rep. Gr.30 - Clutch
Page 55
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

34 – Controls, housing

1 Overview - selector mechanism

⇒ “2 Exploded view - gear knob and covers”, page 52
⇒ “2.1 Removing and installing gear knob with gear lever boot
”, page 53
⇒ “3 Exploded view - gear lever and selector housing for ve‐
hicles with vehicle ID No. up to 8J-7-013000”, page 55
⇒ “4 Exploded view - gear lever and selector housing for ve‐
hicles with vehicle ID No. from 8J-7-013001 onwards”, page 58
⇒ “4.1 Dismantling and assembling selector mechanism”,
page 59
⇒ “5 Removing and installing selector mechanism”,
page 64
⇒ “6 Exploded view - gear selector cable and gate selector
cable up to model year 2007”, page 68
⇒ “6.1 Exploded view - gearbox selector lever and gate relay
lever up to model year 2007”, page 70
⇒ “6.2 Exploded view - gear selector cable and gate selector
cable from model year 2008 onwards”, page 72
⇒ “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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1 - Gear selector cable
2 - Gate selector cable
3 - Heat shield
❑ Detach before removing
selector mechanism
4 - Gate relay lever
5 - Gearbox selector lever
Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
1. Overview - selector mechanism 51
Page 58
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

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 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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 off securing frame -1-
from gear lever boot -2-.
Audi TT 2007 ➤

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-
2. Exploded view - gear knob and covers 53
Page 60
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
♦ Hose clip pliers -V.A.G 1275-
Removing
– Open ashtray.
– Carefully lever off trim panel from centre console -arrows-.
– Unplug electrical connector on trim panel.
– Pull trim panel -3- up and over gear knob.
– Open clip -1- and pull off gear knob -2- together with gear lever
boot and trim panel -3-.
– Detach gear lever boot and trim panel for centre console -3-
⇒ page 53 .
Installing
Installation is carried out in reverse sequence; note the following:
– Push gear knob onto gear lever until it contacts stop.
– Secure gear knob to gear lever with a new clip -1-, using hose
clip pliers -V.A.G 1275- .
54 Rep. Gr.34 - Controls, housing
Page 61
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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
3 Exploded 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
23 - Gate selector cable
❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79
24 - Gear selector cable
❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79
25 - Securing clip
❑ Renew ❑ Removing ⇒ page 56
26 - Nut
❑ 8 Nm ❑ 4x
27 - Bearing bush
❑ Only fits in one position
28 - Securing clip
❑ Renew
Detaching securing clip for gear selector cable -A- and gate se‐ lector cable -B-
– Use screwdriver to lift tab -arrow 1- and lever off securing clip
-arrow 2-.
56 Rep. Gr.34 - Controls, housing
Page 63
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Removing and installing securing clip
– Hold gear lever -2- in position.
– Press spacer bush -3- in direction indicated -arrow-.
– Take off securing clip -1-.
Installing spring
– Insert arm -A- of spring in guide -1- from above.
– Pull down arm -B- of spring and insert it in the guide from be‐
low.
Audi TT 2007 ➤
Note
The gate selector lever is removed to give a better illustration.
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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
4 Exploded 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
Page 65
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
13 - Spring
14 - Bush
15 - Gear lever guide
16 - Nut
❑ 4x
M6 - 8 Nm
M8 - 25 Nm
17 - Gasket
❑ Between selector housing and floor ❑ Self-adhesive ❑ Glue onto selector housing
18 - Selector housing
❑ With spring and gate selector lever ❑ Spring and gate selector lever cannot be removed

4.1 Dismantling 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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-.
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Insert arm -A- of spring in guide from above.
– Pull arm -B- of spring downwards and insert it next to the guide
(towards ball head).
Note
For illustration purposes, only part of the gate selector lever is shown.
– Carefully take selector housing off thrust block -T10083- to‐
gether with gear lever guide.
– Move gate selector lever rearwards as far as stop in direction
of -arrow 1-.
– Grease ball-head pin.
– Press ball-head pin into gate selector lever -arrow 2-.
Guides -A- and tabs -B- must not be damaged.
– Now insert gear lever guide (which is now fitted in selector
housing) into larger recess -arrow- in thrust block -T10083­again.
The gear lever guide should protrude out of the selector hous‐ ing as far as the stop.
– Lift top spring arm -A- over pin on gate selector lever.
Use a new ball socket -B-.
– Grease ball socket and ball of gear lever guide.
– Press ball socket onto ball of gear lever guide as far as stop.
– Remove selector housing from thrust block -T10083- .
– Press ball socket into selector housing in direction of
-arrows-.
62 Rep. Gr.34 - Controls, housing
Page 69
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
All four lugs -arrows- must engage.
– Lift top spring arm -A- over pin on gate selector lever into
guide.
– Insert bottom spring arm into guide.
– Fit gear lever, gear selector cable, gate selector cable and
floor plate ⇒ page 58 .
– Install selector mechanism ⇒ page 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
5 Removing and installing selector
mechanism
Removing
– Remove gear knob together with trim panel for centre console
⇒ page 53 .
– Remove centre console ⇒ Rep. Gr. 68 .
– Remove noise insulation panels above selector mechanism.
– Remove nuts -arrows-.
– Remove 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Vehicles with 4-cylinder engine:
– 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Installing
Installation is carried out in reverse sequence; note the following:
– Install selector mechanism and tighten nuts -arrows-. Tight‐
ening torque ⇒ Item 16 (page 59)
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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
Page 74
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
6 Exploded view - gear selector cable and gate selector cable up to
model year 2007
Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Securing clip
2 - Cable end-piece
❑ Secures gate selector
cable to gate relay lever ❑ Allocation ⇒ page 69 ❑ Release to adjust selec‐
tor mechanism
⇒ page 80
3 - Securing clip
4 - Cable end-piece
❑ Secures gear selector
cable to gearbox selec‐
tor lever ❑ Allocation ⇒ page 69 ❑ Release to adjust selec‐
tor mechanism
⇒ page 80
5 - Bush
6 - Grommet
7 - Gear selector cable
❑ Removing and installing
⇒ page 77
❑ From vehicle ID No.
8J-7-013001 onwards:
modified attachment on
gear lever inside selec‐
tor mechanism
⇒ Item 8 (page 58)
❑ Adjusting ⇒ page 79
8 - Securing clips
❑ Discontinued for vehicle
ID No. 8J-7-013001 on‐
wards ⇒ page 58
9 - Retaining clips
10 - Gate selector cable
❑ Removing and installing ⇒ page 77 ❑ From vehicle ID No. 8J-7-013001 onwards: modified attachment on gate selector lever inside selector
mechanism ⇒ Item 6 (page 58) ❑ Adjusting ⇒ page 79
11 - Bolt
❑ 20 Nm ❑ 2x 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
12 - Cable support bracket
13 - Nut
❑ 20 Nm ❑ Only on vehicles with 4-cylinder engine
Identification of cable end-pieces
The holes in the cable end-pieces have different diameters.
Cable end-piece for: Dimension “a”
1. - Gear selector cable to gearbox selector lev‐
8.5 mm
er from 06.06 onwards
2. - Gear selector cable to gearbox selector lev‐
10 mm
er up to 05.06
2. - Gate selector cable to metal gate relay lever 8 mm
Audi TT 2007 ➤
From 06.06 onwards: smaller diameter of mounting pin for cable
end-piece (on gear selector cable)
Mounting pin for cable end-piece (on gear se‐
Dimension “a”
lector cable)
Up to 05.06 10 mm From 06.06 onwards 8.5 mm
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 69
Page 76
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

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

Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Selector mechanism cover
❑ Removing and installing
(with gearbox installed)
⇒ page 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
13 - Slide block
14 - Bush
15 - Angled rod
❑ For adjusting selector mechanism ⇒ page 79
Removing securing clip for gate relay lever
– Lift clip -arrow-.
Installing gearbox selector lever
– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B­on the selector shaft.
Audi TT 2007 ➤
Installation position: gearbox selector lever/gate relay lever
1 - Gearbox selector lever with damper weight
2 - Gate relay lever locates in guide rail of gearbox selector lever via slide block -arrow-.
– Coat guide rail and slide block -arrow- with grease -G 000 450
02- .
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 71
Page 78
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

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

Note
Lubricate all bearings and moving surfaces with grease -G 000 450 02- .
1 - Gearbox
2 - Clip
❑ Not fitted on all versions ❑ For gate relay lever from
08.2008 onwards
❑ Detaching and fitting
⇒ page 76
3 - Gearbox selector lever
❑ Fitting ⇒ page 74 ❑ Installation position
⇒ page 74
❑ After installing, adjust
selector mechanism
⇒ page 79
4 - Cable end-piece
❑ Secures gear selector
cable to gearbox selec‐
tor lever ❑ Allocation ⇒ page 73 ❑ Detaching from gear se‐
lector cable
⇒ page 74
5 - Securing clip
❑ Removing ⇒ page 75 ❑ Renew
6 - Nut
❑ Self-locking ❑ Renew ❑ 23 Nm
7 - Retaining clip
❑ Renew
8 - Gear selector cable
❑ Detaching and securing at gearbox selector lever ⇒ page 75 ❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79
9 - Gate selector cable
❑ Removing and installing ⇒ page 77 ❑ Adjusting ⇒ page 79
10 - Selector housing
11 - Retaining clips
❑ Renew
72 Rep. Gr.34 - Controls, housing
Page 79
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Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
12 - Retaining clip
❑ Renew
13 - Cable support bracket
14 - Bolt
❑ 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 lever 8.5 mm
-2- Gate selector cable to gate relay lever 10 mm
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 73
Page 80
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Installing gearbox selector lever
– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B­on the selector shaft.
Installation position: gearbox selector lever/gate relay lever
1 - Gearbox selector lever
2 - Clip or detent catch (depending on version)
3 - Gate relay lever locates in guide rail of gearbox selector lever via slide block -arrow 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Detaching and securing gear selector cable at gearbox selector
lever
Detaching
– Lift up tab and detach securing clip -3- for gear selector cable
from gearbox selector lever -1-.
– Pull gear selector cable -2- off pin -arrow-.
Securing
Note
Renew securing clip for gear selector cable.
Apply a small quantity of grease -G 000 450 02- to the pin
-arrow-.
– Push gear selector cable -2- onto gearbox selector lever -1-
and secure with securing clip -3-.
Detaching and securing gate relay lever (with detent catch) at
gearbox selector lever -arrow 1-
Detaching
– Press in detent -arrow 1- as far as stop and remove gate relay
lever together with cable end-piece (move relay lever in nor‐ mal direction of operation).
Audi TT 2007 ➤
Note
-Arrow 2- can be disregarded.
Securing
Note
To install, lubricate bearings and moving surfaces with grease -
G 000 450 02- .
– Press cable end-piece onto gate relay lever ⇒ page 76 .
– Insert gate relay lever with cable end-piece as far as stop.
Gate relay lever is secured by detent -arrow 1-.
Cable end-piece is secured by detent -arrow 2-.
Ensure that components engage securely.
6. Exploded view - gear selector cable and gate selector cable up to model year 2007 75
Page 82
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

6.3 Removing 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
Installing
Installation is carried out in reverse sequence; note the following:
– Secure gear selector cable and gate selector cable to selector
housing with securing clips -1 ... 4-.
Vehicles with vehicle ID No. from 8J-7-013001 onwards:
– Press gear selector cable and gate selector cable onto pins.
Continued for all vehicles:
– Fit new gasket and secure new floor plate to selector mecha‐
nism by bending over tabs -arrows-.
– Install selector mechanism ⇒ page 64 .
– Adjust selector mechanism ⇒ page 79 .
78 Rep. Gr.34 - Controls, housing
Page 85
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

7 Adjusting selector mechanism

Special tools and workshop equipment required
♦ Locking pin -T10027 A-
Requirements for adjustment
Gear selector linkage must be in proper condition and undam‐
aged.
Selector mechanism must move freely.
Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
Gearbox in neutral.
Adjusting
– Open ashtray.
– Carefully lever off trim panel from centre console -arrows-.
– Pull trim panel up and over gear knob.
Audi TT 2007 ➤
7. Adjusting selector mechanism 79
Page 86
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

8 Removing and installing gearbox

General view
⇒ “8.1 Removing gearbox - vehicles with 2.0 ltr. TFSI engine”,
page 82
⇒ “8.2 Removing gearbox - vehicles with 3.2 ltr. MPI engine”,
page 93 .
⇒ “8.3 Removing gearbox - vehicles with 2.0 ltr. TDI engine”,
page 106
⇒ “8.4 Installing gearbox”, page 115

8.1 Removing 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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♦ Pin -3282/29-
♦ Adjustment plate -3282/33-
Audi TT 2007 ➤
6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
♦ Bolt M10x20
♦ 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 engine cover panel -arrows-.
8. Removing and installing gearbox 83
Page 90
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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
Page 92
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Remove noise insulation panels -1- and -2- ⇒ Rep. Gr. 66 .
– Remove noise insulation (left and right) -arrows-.
– Unscrew bolt -2- and disconnect air duct for gearbox cooling
-1- (-arrow-).
– Remove noise insulation frame -arrow- ⇒ Rep. Gr. 50 .
86 Rep. Gr.34 - Controls, housing
Page 93
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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Release retainers -arrows A- using a screwdriver.
– Detach air intake grille -1- (left-side) from bumper cover in di‐
rection of -arrow B-.
– Open flap -2- -arrow- and remove bolt -1-.
Audi TT 2007 ➤
– Unplug electrical connector -2- for reversing light switch -F4- .
– Remove nut -1- and detach bracket from stud together with
electrical wiring.
– Move bracket and wiring clear to the side.
– Remove bottom bolt securing starter -1-.
– Unscrew bolts -1 ... 3- and remove pendulum support.
8. Removing and installing gearbox 87
Page 94
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Slacken bolts -1- and remove bolts -2-.
– 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
Page 96
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– Unbolt gearbox bracket from gearbox -arrows-.
Metal gate relay lever -1-:
– Pull off securing clip -arrow- and remove gate relay lever -1-.
Plastic gate relay lever -1-:
– Removing gate relay lever (with detent catch) ⇒ page 75
– Removing gate relay lever (with clip) ⇒ page 75
Audi TT 2007 ➤
Continued for all vehicles:
– Remove flange bolt -2- and detach drive shaft (left-side) -1-.
Note
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
Page 98
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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
– 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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6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009

8.2 Removing 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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Audi TT 2007 ➤ 6-speed manual gearbox 02Q, four-wheel drive - Edition 10.2009
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Engine support bracket, ba‐
sic set -T40091-
♦ Engine support bracket,
supplementary set ­T40093-
♦ Adapter -VW 771/40-
94 Rep. Gr.34 - Controls, housing
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