Audi TT 65 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive
Edition 08.2008
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - front differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT01520
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, gearbox allocation, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Notes on the direct shift gearbox 02E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Safety functions of gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Notes on tow-starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.1 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Exploded view - servicing multiple clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Removing and installing multiple clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Exploded view - selector lever handle with interlock button (side), selector lever display
illumination bulb L101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Removing and installing selector lever handle with interlock button (side) . . . . . . . . . . . . 30
3 Exploded view - selector lever handle with interlock button (front), selector lever display
illumination bulb L101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Removing and installing selector lever handle with interlock button (front) . . . . . . . . . . . . 33
3.2 Detaching selector lever boot from selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3 Moving interlock button on selector lever handle into installation position . . . . . . . . . . . . . . 37
4 Removing and installing selector lever display illumination bulb L101 . . . . . . . . . . . . . . . . 39
5 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 Manual release of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2 Checking selector mechanism and ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . 43
5.3 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.4 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.5 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.6 Removing and installing tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8 Checking connectors on selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Overview - removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1 Removing gearbox - vehicles with 2.0 ltr. TFSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2 Installing gearbox - vehicles with 2.0 ltr. TFSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.3 Removing gearbox - vehicles with 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.4 Installing gearbox - vehicles with 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7 Transporting the direct shift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8 Securing gearbox to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.1 Removing and installing gearbox mounting and gearbox support - vehicles with 2.0 ltr. TFSI
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2 Removing and installing gearbox mounting and gearbox support - vehicles with 3.2 ltr. MPI
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.3 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Contents i
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10.1 Checking gear oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10.2 Draining gear oil and filling up after repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
11 Exploded view - gear oil cooler and gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
12 Overview - removing and installing bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
12.1 Removing and installing bevel box - vehicles with 2.0 ltr. TFSI engine . . . . . . . . . . . . . . . . 107
12.2 Removing and installing bevel box - vehicles with 3.2 ltr. MPI engine . . . . . . . . . . . . . . . . 110
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1 Exploded view - oil pan, mechatronic unit, gear oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.2 Removing and installing mechatronic unit for dual clutch gearbox J743 . . . . . . . . . . . . . . 121
1.3 Removing and installing gearbox input speed sender G182 and clutch temperature sender
G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.4 Removing and installing gear oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 Exploded view - flange shaft and oil seals on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Renewing oil seal for flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.3 Renewing oil seal between bevel box and gearbox (on gearbox) . . . . . . . . . . . . . . . . . . . . 131
1.4 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2 Exploded view - flange shaft, oil seals and bracket on bevel box . . . . . . . . . . . . . . . . . . . . 136
2.1 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Renewing flange shaft oil seal (right-side) at bevel box (outer seal) . . . . . . . . . . . . . . . . . . 139
2.3 Renewing needle bearings (polygon bearings) for flange shaft (right-side) . . . . . . . . . . . . 141
2.4 Renewing oil seal between gearbox and bevel box (on bevel box) . . . . . . . . . . . . . . . . . . 142
2.5 Renewing oil seal for output flange on bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3 Overview - gear oil in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.1 Checking gear oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.2 Draining gear oil and filling up after repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5 Rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
ii Contents
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.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
00 – Technical data
1 Gearbox identification
The “6-speed direct shift gearbox 02E (four-wheel drive)” is in‐
stalled in the Audi TT 2007 ▸. Allocation ⇒ page 2 .
Audi TT 2007 ➤
The gearbox code is located on the top of the gearbox, near the
gearbox oil cooler.
Example:
♦ GKF = gearbox code
♦ 10.05.2 = date of production: 10th May 2002
♦ The other figures are production-related.
Note
The gearbox code letters are also given on the vehicle data stick‐
ers.
1. Gearbox identification 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
2 Code letters, gearbox allocation, ratios, equipment
Direct shift gearbox 02E four-wheel drive
Gearbox Code letters HXZ JFP JPZ
Allocation Model
Ratios Final drive I
Z2 : Z
1
Overall ratio
i
in top gear
ov.
Allocation: rear
final drive
Direct shift gearbox 02E four-wheel drive
Gearbox Code letters JUQ JYX KDE
Allocation Model
Ratios Final drive I
Z2 : Z
1
Overall ratio
i
in top gear
ov.
Manufac‐
tured
fro
m
05.06 05.08 11.06
to
Engine
Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
3.2 ltr. - 184 kW
6-cyl. MPI
2.0 ltr. - 147 kW
4-cyl. TFSI
72 : 15 = 4.800 69 : 17 = 4.059 72 : 15 = 4.800
for 1st to 4th gear
Final drive II
72 : 20 = 3.600 69 : 22 = 3.136 72 : 20 = 3.600
for 5th/6th gear
and reverse gear
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
gear
44 : 15 = 2.933 45 : 13 = 3.462 44 : 15 = 2.933
44 : 24 = 1.833 43 : 20 = 2.150 44 : 24 = 1.833
39 : 30 = 1.300 41 : 28 = 1.464 39 : 30 = 1.300
39 : 40 = 0.975 41 : 38 = 1.079 39 : 40 = 0.975
34 : 33 = 1.030 35 : 32 = 1.093 34 : 33 = 1.030
33 : 40 = 0.825 35 : 38 = 0.921 33 : 40 = 0.825
22 : 14 x 32 : 15 =
3.352
22 : 14 x 33 : 13 =
3.352
2.970 2.888 2.970
Designation Rear final drive 02D and 0AV
Manufac‐
tured
fro
m
11.06 11.06 09.07
to
Engine
Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
3.2 ltr. - 184 kW
6-cyl. MPI
3.2 ltr. - 184 kW
6-cyl. MPI
72 : 15 = 4.800 72 : 15 = 4.800 72 : 15 = 4.800
for 1st to 4th gear
Final drive II
72 : 20 = 3.600 72 : 20 = 3.600 72 : 20 = 3.600
for 5th/6th gear
and reverse gear
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
gear
44 : 15 = 2.933 44 : 15 = 2.933 44 : 15 = 2.933
44 : 24 = 1.833 44 : 24 = 1.833 44 : 24 = 1.833
39 : 30 = 1.300 39 : 30 = 1.300 39 : 30 = 1.300
39 : 40 = 0.975 39 : 40 = 0.975 39 : 40 = 0.975
34 : 33 = 1.030 34 : 33 = 1.030 34 : 33 = 1.030
33 : 40 = 0.825 33 : 40 = 0.825 33 : 40 = 0.825
22 : 14 x 32 : 15 =
3.352
22 : 14 x 32 : 15 =
3.352
2.970 2.970 2.970
3.2 ltr. - 184 kW
6-cyl. MPI
22 : 14 x 32 : 15 =
3.352
3.2 ltr. - 184 kW
6-cyl. MPI
22 : 14 x 32 : 15 =
3.352
2 Rep. Gr.00 - Technical data
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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
Direct shift gearbox 02E four-wheel drive
Allocation: rear
Designation Rear final drive 02D and 0AV
final drive
Direct shift gearbox 02E four-wheel drive
Gearbox Code letters KNL KNN KQA
Manufac‐
tured
fro
m
11.07 05.08 05.08
to
Allocation Model
Engine
Ratios Final drive I
Audi TT 2007 ▸ Audi TT 2007 ▸ Audi TT 2007 ▸
3.2 ltr. - 184 kW
6-cyl. MPI
2.0 ltr. - 195, 199 kW
4-cyl. TFSI
3.2 ltr. - 184 kW
6-cyl. MPI
72 : 15 = 4.800 62 : 13 = 4.769 72 : 15 = 4.800
for 1st to 4th gear
Z2 : Z
1
Final drive II
72 : 20 = 3.600 62 : 18 = 3.444 72 : 20 = 3.600
for 5th/6th gear
and reverse gear
Overall ratio
i
in top gear
ov.
Allocation: rear
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
gear
Designation Rear final drive 02D and 0AV
44 : 15 = 2.933 38 : 13 = 2.923 44 : 15 = 2.933
44 : 24 = 1.833 45 : 23 = 1.957 44 : 24 = 1.833
39 : 30 = 1.300 35 : 25 = 1.400 39 : 30 = 1.300
39 : 40 = 0.975 32 : 31 = 1.032 39 : 40 = 0.975
34 : 33 = 1.030 28 : 26 = 1.077 34 : 33 = 1.030
33 : 40 = 0.825 27 : 31 = 0.871 33 : 40 = 0.825
22 : 14 x 32 : 15 =
3.352
22 : 14 x 27 : 13 =
3.264
22 : 14 x 32 : 15 =
3.352
2.970 3.000 2.970
final drive
Direct shift gearbox 02E four-wheel drive
Gearbox Code letters KRF LME
Manufac‐
tured
fro
m
01.08 01.08
to
Allocation Model
Engine
Ratios Final drive I
Audi TT 2007 ▸ Audi TT 2007 ▸
2.0 ltr. - 195, 200 kW
4-cyl. TFSI
62 : 13 = 4.769 62 : 13 = 4.769
2.0 ltr. - 155 kW
4-cyl. TFSI
for 1st to 4th gear
Z2 : Z
1
Final drive II
62 : 18 = 3.444 62 : 18 = 3.444
for 5th/6th gear
and reverse gear
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
gear
38 : 13 = 2.923 38 : 13 = 2.923
45 : 23 = 1.957 43 : 24 = 1.792
35 : 25 = 1.400 32 : 27 = 1.185
32 : 31 = 1.032 29 : 35 = 0.829
28 : 26 = 1.077 25 : 29 = 0.862
27 : 31 = 0.871 24 : 35 = 0.686
22 : 14 x 27 : 13 =
3.264
22 : 14 x 27 : 13 =
3.264
2. Code letters, gearbox allocation, ratios, equipment 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 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
Direct shift gearbox 02E four-wheel drive
Overall ratio
i
in top gear
ov.
Allocation: rear
3.000 2.362
Designation Rear final drive 02D and 0AV
final drive
2.1 Calculating ratio “i”
Example:
6th gear Final drive
Drive gear ZG1 = 40 ZA1 = 20
Driven gear ZG2 = 33 ZA2 = 72
i = Z2 : Z1 (Z1 = number of teeth on drive gear, Z2 = number of
teeth on driven gear)
iG = gear ratio = ZG2 : ZG1 = 33 : 40 = 0.825
iA = axle ratio = ZA2 : ZA1 = 72 : 20 = 3.6
iov = overall ratio = iG x iA = 0.825 x 3.6 = 2.97
4 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
3 Capacities
Gearbox capacity
Capacities Direct shift gearbox 02E, four-wheel
drive
Initial filling 6.9 ltr.
Oil change approx. 5.5 ltr.
Change interval ⇒ Maintenance tables
Lubricant Gear oil for direct shift gearbox 02E
⇒ Electronic parts catalogue
Note
♦
Use only the correct type of gear oil for the direct shift gearbox
02E (available as a replacement part). Other types of lubricant
cause malfunctions and/or failure of the gearbox.
♦
You must also renew the gear oil filter when you change the
gear oil ⇒ page 105 .
Audi TT 2007 ➤
– Checking gear oil level and topping up ⇒ page 94
– Filling up with gear oil after repair ⇒ page 100
Bevel box capacity
Capacities Bevel box
Initial filling 0.9 ltr.
Oil change Filled for life, no change
Lubricant Gear oil ⇒ Electronic parts cata‐
logue .
Note
Use only the correct type of gear oil (available as a replacement
part) for the bevel box. Other types of oil cause malfunctions and/
or failure of the bevel box.
– Checking gear oil level and topping up ⇒ page 149
– Filling up with gear oil after repair ⇒ page 150
3. Capacities 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
4 Safety precautions
Observe the following precautions if tests have to be performed
with the engine running.
WARNING
Accidents can be caused if a gear is inadvertently engaged
while the engine is running.
♦ Before working on the vehicle while the engine is running,
shift the selector lever into position “P” and apply the
handbrake.
Danger from toxic fumes!
♦ When the engine is running, the exhaust system must al‐
ways be connected to the exhaust gas extractor.
6 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
Observe the following precautions if test equipment has to be
used while road-testing the vehicle:
WARNING
Accidents can be caused if the driver is distracted by test
equipment while road-testing, or if test equipment is not se‐
cured.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
TT Coupé:
Always secure testing equipment to the rear seat with a strap
and have them operated from there by a second person.
TT Roadster:
♦ Move the passenger's seat to the rearmost position.
♦ Use only vehicle diagnosis and service information sys‐
tem -VAS 5052- or diagnosis system -VAS 5053- .
♦ Test equipment may only be operated by the passenger;
the tester -1- must be placed flat on the passenger's lap
as illustrated.
Audi TT 2007 ➤
Observe the following precautions to avoid possible injury and/or
damage to electrical and electronic components:
♦ Switch off ignition before disconnecting and connecting test
equipment.
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.
♦ Always switch off the ignition before disconnecting the
battery.
4. Safety precautions 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
5 Notes on the direct shift gearbox 02E
5.1 General notes
Gearbox
The direct shift gearbox 02E is a dual-clutch gearbox, also refer‐
red to as “S tronic”. It has the same basic construction as a 6speed manual gearbox. The engine torque is transferred to the
gearbox via the dual-mass flywheel. The two multi-plate "wet"
clutches are controlled hydraulically and actuated alternately so
that the gearbox is operated like an automatic gearbox, in other
words the gears are engaged automatically (but can also be se‐
lected manually via the tiptronic function). There is no clutch
pedal. For further information please refer to ⇒ Self-study pro‐
gramme No. 308 ; Direct shift gearbox 02E .
Selector mechanism
In selector lever position “P” the selector lever cable is used to
engage the parking lock mechanically. All other gearshift com‐
mands and selector lever positions are transmitted via the CAN
data bus from the selector lever -E313- (selector mechanism) to
the mechatronic unit for dual clutch gearbox -J743- .
Gear oil (gearbox and final drive)
The direct shift gearbox and front final drive have a common filling
of gear oil ⇒ page 94 .
Note
Use only the correct type of gear oil for the direct shift gearbox
02E (available as a replacement part). Other types of oil will cause
malfunctions and/or failure of the gearbox; for Part No. refer to ⇒
Electronic parts catalogue .
The bevel box has a separate oil filling ⇒ page 149 .
Note
Use only the correct type of gear oil (available as a replacement
part) for the bevel box. Other types of oil will cause malfunctions
and/or failure of the bevel box; for Part No. refer to ⇒ Electronic
parts catalogue .
Regulations for the disposal of oil
Drained oil must be disposed of properly.
♦ Improper disposal of used oil endangers the environment.
♦ It must not be mixed with solvents, brake fluid, coolant or sim‐
ilar.
♦ Please observe the information shown on the packaging of the
oil.
Variation of gear-change points for gradients
Additional gear-change maps automatically select the gearchange points for gradients according to accelerator pedal posi‐
tion and road speed.
• The gear-change map for extreme uphill gradients is matched
to the engine power.
8 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
• The gear-change map for extreme downhill gradients is
matched to the engine braking effect.
• By selecting a gear directly via the tiptronic mode, it is possible
to make use of the engine braking effect available in a partic‐
ular gear, for instance when driving downhill with a trailer.
5.2 Safety functions of gearbox control unit
In the event of a failure of one or more components or sensors,
the control unit J743 will activate appropriate backup functions.
This enables the gearbox to continue operating without damage,
but will impair the operation and smoothness of the gearshifts.
Faults detected by the gearbox are classified in four different cat‐
egories.
1 - The fault is stored in the memory and one of the backup
programs is activated. The gear selection indicator in the
instrument cluster will continue to show the currently en‐
gaged selector lever position in the normal way. The driver
can continue to drive the vehicle (with certain restrictions),
and the condition is not critical to the safety of the vehicle or
to the gearbox itself. If at all, the driver will only notice the
fault if he experiences driveability problems, and will then
automatically contact an Audi Service Partner.
2 - Certain positions on the gear selection indicator in the in‐
strument cluster start to flash. This is to inform the driver that
this particular selector lever position is currently not availa‐
ble. Example: position "D" will start flashing if the selector
lever is moved from position "R" to position "D" while the
vehicle is still rolling backwards. To avoid damage to the
gearbox, the mechatronic unit for dual clutch gearbox -J743prevents 1st gear from being engaged while the vehicle is
moving backwards. 1st gear will only be engaged when the
vehicle comes to a standstill.
3 - The complete gear selection indicator lights up and flashes;
the currently engaged selector lever position is highlighted.
This shows the driver that a temporary critical fault in the
gearbox has been detected. Example: the gearbox has
been overloaded or overheated, for instance by towing an
excessively heavy load. The driver can continue to drive the
vehicle when the gearbox has cooled off, but will need to
avoid placing a heavy load on the transmission.
4 - The gear selection indicator flashes; the currently engaged
selector lever position is no longer indicated. This shows the
driver that a critical and permanent fault in the gearbox has
been detected. It may no longer be possible to use all gears,
so this condition is critical to the safety of the vehicle and to
the gearbox itself. This display is intended to warn the driver
that he should contact an Audi Service Partner.
Audi TT 2007 ➤
5. Notes on the direct shift gearbox 02E 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
6 Notes on tow-starting and towing
Caution
Risk of damage to the gearbox.
♦ The selector lever must be in position “N” when the vehicle
is towed.
♦ The vehicle must not be towed further than 50 km or at a
speed in excess of 50 km/h.
Note
It is not possible to start the engine by tow-starting, for instance
if the battery is discharged or if the starter is not working.
10 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
7 Repair instructions
Proper tools and the maximum possible care and cleanliness are
essential for satisfactory gearbox repairs. The usual basic safety
precautions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various re‐
pair procedures are summarised here. They apply to the work
described in this Manual.
Guided fault finding, vehicle self-diagnosis and testing system
♦ Before servicing the gearbox, the exact cause of the failure
must be determined using the functions “Guided Fault Find‐
ing”, “Vehicle Self-diagnosis” and “Test Instruments” ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
Special tools
For a complete list of special tools used in this Workshop Manual
⇒ "Workshop equipment and special tools" .
Gearbox
♦ Do not run the engine or tow the vehicle with the oil pan re‐
moved or when there is no gear oil in the gearbox.
♦ When installing a replacement gearbox, check the gear oil
level and top up as required ⇒ page 94 : capacities
⇒ page 5 ; specification ⇒ Electronic parts catalogue .
♦ When installing gearbox, ensure that dowel sleeves are fitted
correctly.
Audi TT 2007 ➤
7. Repair instructions 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
O-rings, oil seals and gaskets
♦ Renew O-rings, oil seals and gaskets.
♦ After removing gaskets and seals, always inspect the contact
surface on the housing or shaft for burrs resulting from removal
or for other signs of damage.
♦ Renew gaskets: completely remove the old gasket and clean
the sealing surfaces thoroughly.
♦ Lightly lubricate O-rings with gear oil before installation to pre‐
vent them being trapped and damaged during assembly.
♦ Lightly oil the outer circumference of oil seals and pack the
space between the sealing lips -arrow- about half-full with
sealing grease; for sealing grease refer to ⇒ Electronic parts
catalogue .
♦ Do not use any other lubricants where gear oil is specified.
Otherwise, there is a risk of problems occurring in the gearbox
hydraulics.
♦ The open side of the oil seal should face the side containing
the fluid.
♦ Observe rules for cleanliness ⇒ page 14 .
♦ After installation, check gear oil level and top up as required
⇒ page 94 and ⇒ page 149 .
Locking elements
♦ Do not overstretch circlips; renew if necessary.
♦ Circlips must be properly seated in the base of the groove.
Nuts, bolts
♦ Slacken 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.
♦ Use a wire brush to clean the threads of bolts which are se‐
cured with locking fluid. Then install bolts with locking fluid; for
locking fluid refer to ⇒ Electronic parts catalogue .
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Where instructions specify a torque setting plus an additional
angle, these bolts must be tightened to the specified torque
and then turned through the specified angle, e.g. 40 Nm + 90°
(90° = a quarter turn).
7.1 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 .
12 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
Please note:
♦ Use only genuine spare parts: these have been fully tested
and are compatible with aluminium.
♦ We recommend the use of accessories approved by Audi.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
Audi TT 2007 ➤
7. Repair instructions 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
8 Rules for cleanliness
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open lines and connections with clean plugs or sealing
caps immediately.
♦ Place removed parts on a clean surface and cover them over.
Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
completed immediately.
♦ Only install clean components: do not remove replacement
parts from packaging until just before installation.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
14 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
30 – Clutch
1 Exploded view - servicing multiple clutch
♦ The clutch in the direct shift gearbox 02E consists of two sets
of plates, or clutch packs, and is therefore referred to as a
“multiple clutch”. The larger clutch pack (located on the out‐
side) is designated “K 1” (clutch 1), and controls the torque
flow for reverse gear and gears “1”, “3” and “5”. The smaller
set of plates (on the inside) is designated “K 2” (clutch 2), and
controls the torque flow for gears “2”, “4” and “6”.
♦ Any work performed on the multiple clutch requires extra care
because all the parts are balanced and matched together in
production. If the components are rotated out of their original
positions when repairing, this will cause imbalance and impair
the smoothness of the gear-changes and reduce the service
life of the unit.
Replacement parts
1 - Multiple clutch
❑ With circlip
Audi TT 2007 ➤
Caution
The clutch plates can slip
out of position inside the
multiple clutch unit.
♦The multiple clutch unit
must not be dismantled
at present.
♦If the drive plate (which
forms the upper section
of the multiple clutch unit)
becomes detached from
the splines in the outer
plate carrier, the clutch
plates can slip out of po‐
sition in the clutch. It will
then no longer be possi‐
ble to adjust the clutch
correctly.
♦The drive plate included
with the replacement part
is not secured with the
large circlip; it is only a
close fit inside the clutch.
❑ Removing and installing
⇒ page 17
2 - Circlips
❑ 10x, with different thick‐
nesses for adjusting
multiple clutch
❑ Determining correct
thickness when instal‐
ling multiple clutch
⇒ page 22
3 - Clutch end cover
4 - Corrugated ring
1. Exploded view - servicing multiple clutch 15
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
Component parts of dismantled multiple clutch
Caution
The clutch plates can slip out of position inside the multiple
clutch unit.
♦ This diagram showing the components of the multiple
clutch is for information only. The multiple clutch unit must
not be dismantled at present.
♦ If the drive plate becomes detached from the splines in the
outer plate carrier, the clutch plates can slip out of position
in the multiple clutch. It will then no longer be possible to
adjust the clutch correctly.
1 - Outer plate carrier with
clutch housing.
2 - Oil seals
❑ 4x
3 - Inner plate carrier
Caution
The clutch plates can slip
out of position.
♦If the inner plate carrier is
lifted or taken out, the
plates can slip out of po‐
sition inside the clutch. It
will then no longer be
possible to adjust the
clutch correctly.
4 - Outer plates
❑ 4x
5 - Inner plates
❑ 4x
6 - Thrust washer
7 - Circlip
❑ Fit a new circlip of the
same thickness if the
original circlip is re‐
moved in order to re-in‐
stall the clutch plates.
8 - Circlip
❑ Determining correct
thickness when instal‐
ling multiple clutch
⇒ page 22
9 - Drive plate
10 - Circlip
❑ Renew
16 Rep. Gr.30 - Clutch
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
1.1 Removing and installing multiple clutch
Special tools and workshop equipment required
♦ Assembly sleeve -T10302-
♦ Retaining pin -T10303-
Audi TT 2007 ➤
Note
Assembly sleeve -T10302- must be cleaned before use; do not
use an assembly sleeve if it is scratched.
Removing
– Drain off gear oil ⇒ page 100 .
– Remove direct shift gearbox: vehicles with 2.0 ltr. TFSI engine
⇒ page 53 , vehicles with 3.2 ltr. MPI engine ⇒ page 66 .
– Secure direct shift gearbox to engine and gearbox support in
vertical position ⇒ page 81 .
– Renew gear oil filter ⇒ page 105 .
1. Exploded view - servicing multiple clutch 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Pry out and detach corrugated ring -2- for clutch end cover
using a screwdriver -1- -arrow-.
– Working through aperture for starter motor, pry out and detach
clutch end cover -2- using a screwdriver -1- or other suitable
lever -arrow-.
– Pry out circlip -2- for drive plate using a screwdriver -1-
-arrow-.
18 Rep. Gr.30 - Clutch
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Detach drive plate -arrows-.
– Pry out circlip -arrow- using a screwdriver or long-nose pliers.
Audi TT 2007 ➤
– Take multiple clutch out of gearbox.
– After removing multiple clutch, check whether clutch bell hous‐
ing was damaged during removal.
– Pull out pump shaft -A- and place to one side.
1. Exploded view - servicing multiple clutch 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
Installing
Caution
The clutch plates can slip out of position inside the multiple
clutch unit.
♦ If the drive plate becomes detached from the splines in the
outer plate carrier, the clutch plates can slip out of position
in the multiple clutch. It will then no longer be possible to
adjust the clutch correctly.
♦ To prevent the clutch plates from slipping inside the mul‐
tiple clutch unit, keep the drive plate pressed into the outer
plate carrier with both thumbs during all following steps.
Note
The circlip for the drive plate that is supplied with the replacement
parts is fitted at a later stage.
– Take new circlip for drive plate out of packaging and place to
one side.
– Take multiple clutch out of packaging, holding drive plate in
position.
– First fit old circlip -A- for drive plate from removed multiple
clutch.
• Installation position: the lug on the drive plate and the colourmarked splines on the outer plate carrier must be located
between the ends of the circlip.
– Using a screwdriver, check that circlip is fully engaged.
– Check that the 4 oil seals on the hub on the underside of the
multiple clutch are correctly seated; engage in position if nec‐
essary.
• Installation position: joints of seals should be offset
20 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Apply retaining pin -T10303- to seat of clutch end cover as
illustrated.
– Install multiple clutch in clutch bell housing (turn and move up
and down as required), at the same time keeping the drive
plate pressed into the outer plate carrier with both thumbs
-arrows-.
Note
Do not allow the multiple clutch to drop into the inner plate carrier.
Audi TT 2007 ➤
– Have a second mechanic hold the retaining pin -T10303- as
illustrated until the clutch end cover is installed.
Note
The multiple clutch must not be turned from this point onwards,
as this would turn the retaining pin -T10303- out of position.
– Check whether the projecting lug -arrow- on the drive plate is
positioned between the colour-marked splines on the outer
plate carrier.
– If no marking is provided, use waterproof pen to mark position
of drive plate in relation to outer rim of outer plate carrier as
illustrated so it can be re-fitted in the same position.
Note
When re-assembling, the lug on the drive plate must be located
again at this marked position.
1. Exploded view - servicing multiple clutch 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Pry out old circlip -2- using a screwdriver -1- -arrow-.
Caution
The clutch plates can slip out of position inside the multiple
clutch unit.
♦ If the inner plate carrier is taken out or lifted, the plates can
slip out of position inside the clutch. It will then no longer
be possible to adjust the clutch correctly.
– Lift out drive plate -arrows-; if necessary lever it carefully out
of splines on outer plate carrier using a screwdriver.
– Place drive plate to one side.
Adjusting multiple clutch (determining thickness of circlip)
– Select the 2 mm thick circlip from the circlips supplied with the
unit.
Note
The 2 mm circlip is fitted provisionally for measurement purposes
and will be replaced later with the final circlip of the required thick‐
ness.
– Fit circlip of 2 mm thickness -arrow-.
22 Rep. Gr.30 - Clutch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Secure universal dial gauge bracket -VW 387- to gearbox
flange.
– For 1st measurement, apply tip of dial gauge to end of input
shaft as shown in illustration.
– Preload dial gauge to 2 mm and set to “0”.
– Lift up multiple clutch as far as it will go.
– Note reading on dial gauge (= axial clearance of input shaft).
– For 2nd measurement, apply tip of dial gauge to hub of inner
plate carrier as shown in illustration.
Audi TT 2007 ➤
Note
The tip of the dial gauge must not contact the circlip.
– Preload dial gauge to 2 mm and set to “0”.
– Lift up multiple clutch as far as it will go.
– Take reading and note down measured value.
The thickness of the new circlip is calculated according to the fol‐
lowing formula:
Circlip = 2nd measured value – 1st measured value + 1.85 (=
constant value)
The thickness of the new circlips is graduated in steps of 0.1 mm.
When selecting the required circlip, round up or down to the near‐
est 10th of a millimetre as required. In other words, values up to
0.049 are rounded down and values of 0.050 and above are roun‐
ded up.
Example:
♦ Calculated value for new circlip is 2.27 mm: round up to the
nearest 10th and select circlip with a thickness of 2.3 mm.
♦ Calculated value for new circlip is 2.24 mm: round down to the
nearest 10th and select circlip with a thickness of 2.2 mm.
Note
If the calculated thickness of the new circlip is exactly 2.0 mm, the
circlip fitted previously for taking the measurement does not have
to be removed.
1. Exploded view - servicing multiple clutch 23
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Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Remove provisionally fitted circlip (2 mm) and fit new circlip
with thickness as calculated above.
Note
♦
Circlips must not be used more than once.
♦
The removed (provisional) circlip and all remaining circlips
should be disposed of.
– Install pump shaft. When installing, lift the shaft and turn it
slightly -arrow- so that it slides in and engages fully in the
splines.
– Install drive plate in multiple clutch.
• The projecting lug -arrow- on the drive plate must be posi‐
tioned between the colour-marked splines on the outer plate
carrier, or the marks made earlier in this procedure.
24 Rep. Gr.30 - Clutch
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Fit new circlip for drive plate.
• Installation position: the lug on the drive plate and the colourmarked splines on the outer plate carrier (or the corresponding
marks made previously) must be located between the ends of
the circlip.
– Using a screwdriver, check that circlip is fully engaged.
– Take out retaining pin -T10303- between multiple clutch and
housing.
Audi TT 2007 ➤
Caution
Leakage can occur at the contact surface of the clutch end
cover.
♦ Thoroughly degrease running surface -arrow- on drive
plate for internal seal of clutch end cover.
– Clean the contact surface for the outer seal of the clutch end
cover.
Caution
Leakage can occur at the internal seal for the clutch end cover.
♦ To ensure that the internal seal remains absolutely free of
grease, do not touch the seal with your hands.
– Take the clutch end cover out of its packaging, only taking hold
of it on the outside as illustrated.
– Clean end of gearbox shaft.
Note
♦
Using gear oil, lightly lubricate the outer seal for the clutch end
cover only.
♦
If there are any stickers on the inside or the outside of the
clutch end cover, remove them thoroughly.
1. Exploded view - servicing multiple clutch 25
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, four-wheel drive - Edition 08.2008
– Place assembly sleeve -T10302- on a flat surface.
– The internal seal in the new clutch end cover must be pre-
formed before installation; this is done by guiding the clutch
end cover, with the outside downwards, horizontally and uni‐
formly over the assembly sleeve -T10302- .
– Lift assembly sleeve -T10302- out of clutch end cover.
– Fit assembly sleeve -T10302- over end of multiple clutch shaft.
Caution
Clutch end cover can be damaged.
♦ Do not attempt to drive on the clutch end cover with a
hammer.
– Guide clutch end cover with the outside upwards horizontally
over assembly sleeve -T10302- and press cover uniformly on‐
to its seat.
– If necessary use a screwdriver to lever the clutch end cover
carefully into its seat as illustrated -arrow- so that the corru‐
gated ring can be fitted.
– Install corrugated ring for clutch end cover in gearbox housing,
always holding the ring in place on the opposite side so that it
remains in its groove.
– Using a screwdriver, check that corrugated ring is fully engag‐
ed.
– Install gearbox: vehicles with 2.0 ltr. TFSI engine
⇒ page 61 , vehicles with 3.2 ltr. MPI engine ⇒ page 74 .
– Fill up with gear oil for direct shift gearbox ⇒ page 100 .
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
– Perform basic setting.
26 Rep. Gr.30 - Clutch
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