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Service
Workshop Manual
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive
Edition 12.2006
Service Department. Technical Information
Page 2
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - 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 A005TT01220
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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, front-wheel drive - Edition 12.2006
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Code letters, gearbox allocation, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Calculating ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Notes on the direct shift gearbox 02E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Safety functions of gearbox control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Notes on tow-starting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Servicing multiple clutch - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing and installing multiple clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Selector lever handle, selector lever display illumination bulb L101 - exploded view . . . . 26
2.1 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Removing and installing selector lever display illumination bulb L101 . . . . . . . . . . . . . . . . 28
3 Servicing selector mechanism - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 Manual release of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Checking selector mechanism and ignition key removal lock . . . . . . . . . . . . . . . . . . . . . . 32
3.3 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.5 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6 Removing and installing tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.7 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 42
3.8 Checking connectors on selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1 Tightening torques (installing gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6 Transporting the direct shift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.1 Checking gear oil level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2 Changing gear oil or filling up after performing repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10 Gear oil cooler and gear oil filter - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.1 Removing and installing gear oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.2 Removing and installing gear oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1 Oil pan, mechatronic unit, gear oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.1 Oil pan, mechatronic unit, gear oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Contents i
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Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
1.3 Removing and installing mechatronic unit for direct shift gearbox J743 . . . . . . . . . . . . . . 85
1.4 Removing and installing gearbox input speed sender G182 and clutch temperature sender
G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.5 Removing and installing gear oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1 Flange shafts and oil seals - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.1 Removing and installing flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Removing and installing flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.3 Renewing oil seal for flange shaft (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.4 Renewing oil seal for flange shaft (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.5 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ii Contents
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Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
00 – Technical data
1 Gearbox identification
The “6-speed direct shift gearbox 02E (front-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 is also given on the vehicle data stickers.
1. Gearbox identification 1
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Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
2 Code letters, gearbox allocation, ratios, equipment
Direct shift gearbox 02E front-wheel drive
Gearbox Code letters HXW JPP
Allocation Model
Ratios Final drive I
Z2 : Z
1
Overall ratio
i
in top gear
ov.
Manufac‐
tured
Engine
for 1st to 4th gear
Final drive II
for 5th/6th gear
and reverse gear
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
gear
fro
m
to
05.06 11.06
Audi TT 2007 ▸ Audi TT 2007 ▸
2.0 ltr. - TFSI 147 kW
4 cylinders
69 : 17 = 4.059 69 : 17 = 4.059
69 : 22 = 3.136 69 : 22 = 3.136
45 : 13 = 3.461 45 : 13 = 3.461
43 : 20 = 2.150 43 : 20 = 2.150
41 : 28 = 1.464 41 : 28 = 1.464
41 : 38 = 1.078 41 : 38 = 1.078
35 : 32 = 1.094 35 : 32 = 1.094
35 : 38 = 0.921 35 : 38 = 0.921
22 : 14 x 33 : 13 = 3.99 22 : 14 x 33 : 13 = 3.99
2.888 2.888
2.0 ltr. - TFSI 147 kW
4 cylinders
2.1 Calculating ratio “i”
Example:
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
6th gear Final drive
2 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
3 Capacities
Gearbox capacity
Capacities Direct shift gearbox 02E, front-wheel
drive
Initial filling 6.9 ltr.
Oil change approx. 5.5 ltr.
Change interval ⇒ Maintenance ; Booklet 810
Lubricant Gear oil for direct shift gearbox 02E
Part No. ⇒ 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 oil cause
malfunctions and/or failure of the gearbox.
♦
You must also renew the gear oil filter when you change the
gear oil ⇒ page 78 .
Audi TT 2007 ➤
– Checking gear oil level and topping up ⇒ page 66
– Filling up with gear oil after repairs ⇒ page 72
3. Capacities 3
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Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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.
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.
♦ 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.
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 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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 direct shift gearbox -J743- .
Gear oil (gearbox and final drive)
The direct shift gearbox and front final drive have a common filling
of gear oil ⇒ page 66 .
Audi TT 2007 ➤
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 ⇒
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.
• 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.
5. Notes on the direct shift gearbox 02E 5
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Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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 direct shift 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.
6 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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.
Audi TT 2007 ➤
6. Notes on tow-starting and towing 7
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Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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
⇒ "Special tools, Workshop equipment"
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 66 : capacities
⇒ page 3 ; specification ⇒ Parts catalogue .
♦ When installing gearbox, ensure that dowel sleeves are fitted
correctly.
8 Rep. Gr.00 - Technical data
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Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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
grease ⇒ 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 10 .
♦ After installation, check gear oil level and top up as required
⇒ page 66 .
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 ⇒ 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).
Audi TT 2007 ➤
7. Repair instructions 9
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Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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.
10 Rep. Gr.00 - Technical data
Page 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.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
30 – Clutch
1 Servicing multiple clutch - exploded view
♦ The clutch in the direct shift gearbox 02E consists of two sets
of plates, and is therefore referred to as a “multiple clutch”. The
larger set of plates (located on the outside) 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 13
2 - Circlips
❑ 10x, with different thick‐
nesses for adjusting
multiple clutch
❑ Determining correct
thickness when instal‐
ling multiple clutch
⇒ page 18
3 - Clutch end cover
4 - Corrugated ring
1. Servicing multiple clutch - exploded view 11
Page 16
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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, front-wheel drive - Edition 12.2006
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
❑ 4 x
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
❑ 4 x
5 - Inner plates
❑ 4 x
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 18
9 - Drive plate
10 - Circlip
❑ Renew
12 Rep. Gr.30 - Clutch
Page 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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
Proceed as follows:
– Drain off gear oil ⇒ page 72 .
– Remove direct shift gearbox ⇒ page 43 .
– Secure direct shift gearbox to assembly stand in vertical po‐
sition ⇒ page 57 .
– Renew gear oil filter ⇒ page 78 .
1. Servicing multiple clutch - exploded view 13
Page 18
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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, front-wheel drive - Edition 12.2006
– 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-.
14 Rep. Gr.30 - Clutch
Page 19
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– 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. Servicing multiple clutch - exploded view 15
Page 20
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
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
16 Rep. Gr.30 - Clutch
Page 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– 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. Servicing multiple clutch - exploded view 17
Page 22
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– 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-.
18 Rep. Gr.30 - Clutch
Page 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– 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. Servicing multiple clutch - exploded view 19
Page 24
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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, front-wheel drive - Edition 12.2006
– 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.
20 Rep. Gr.30 - Clutch
Page 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.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– 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. Servicing multiple clutch - exploded view 21
Page 26
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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, front-wheel drive - Edition 12.2006
– 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 ⇒ page 53 .
– Fill up with gear oil for direct shift gearbox ⇒ page 72 .
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
– Perform basic setting.
22 Rep. Gr.30 - Clutch
Page 27
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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, front-wheel drive - Edition 12.2006
34 – Controls, housing
1 Electrical/electronic components and fit‐
ting locations
Diagnostic connector
Fitting location: below knee padding on left side of steering wheel.
Audi TT 2007 ➤
Selector lever lock solenoid -N110-
Fitting location: the selector lever lock solenoid -1- is located in
the selector mechanism.
The solenoid is integrated in the selector mechanism; it is there‐
fore not possible to renew only the solenoid on its own. It can only
be removed or installed together with the selector mechanism
⇒ page 33 .
Mechatronic unit for direct shift gearbox -J743-
Fitting location: the mechatronic unit for direct shift gearbox J743- is bolted to the front of the gearbox housing and covered
by the gearbox oil pan.
The control unit is an integrated component of the mechatronic
unit for direct shift gearbox -J743- .
♦ Checked via self-diagnosis
⇒ “1.3 Removing and installing mechatronic unit for direct shift
gearbox J743 ”, page 85
1. 23
Page 28
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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, front-wheel drive - Edition 12.2006
Gearbox input speed sender -G182- / oil temperature sender for
multi-plate clutch -G509-
Fitting location: the gearbox input speed sender -G182- and
clutch temperature sender -G509- -item A- are bolted to the gear‐
box housing below the mechatronic unit for direct shift gearbox J743- .
♦ Checked via self-diagnosis
⇒ “1.4 Removing and installing gearbox input speed sender G182
and clutch temperature sender G509 ”, page 89 .
Selector lever -E313- with tiptronic switch -F189- , switch for se‐
lector lever locked in position P -F319-
Fitting location: the selector lever -E313- with tiptronic switch F189- and switch for selector lever locked in position P -F319- is
integrated in the printed circuit -B- of the selector mechanism.
These components cannot be renewed separately.
♦ Checked via self-diagnosis
Selector lever -E313- with tiptronic switch -F189- and switch for
selector lever locked in position P -F319- can only be removed
and installed together with selector mechanism ⇒ page 33 .
Selector lever position display -Y6-
Fitting location: integrated into instrument cluster
Note
Selector lever position indicator can only be renewed together
with instrument cluster.
If the selector lever position indicator flashes or lights up, please
refer to safety functions of gearbox control unit ⇒ page 5 .
Removing and installing instrument cluster ⇒ Rep. Gr. 90
Selector lever display illumination bulb -L101-
Fitting location: in trim for selector lever boot -1-.
♦ Is checked via self-diagnosis
Removing and installing selector lever display illumination bulb L101- ⇒ page 28
24 Rep. Gr.34 - Controls, housing
Page 29
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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, front-wheel drive - Edition 12.2006
Brake light switch -F-
Fitting location: the brake light switch -arrow- is located on pedal
cluster.
♦ Is checked via self-diagnosis
Removing and installing brake light switch ⇒ Rep. Gr. 46
Note
To ensure a secure fit, the switch may only be fitted once.
Kickdown switch -F8-
An adapted value from accelerator position sender -G79- and ac‐
celerator position sender 2 -G185- (integrated in accelerator ped‐
al module) is stored in the engine control unit as the kickdown
signal.
♦ Is checked via self-diagnosis
♦ Signal is transmitted from engine control unit to gearbox con‐
trol unit via CAN bus.
Removing and installing accelerator pedal module ⇒ Rep. Gr.
20
Audi TT 2007 ➤
1. 25
Page 30
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
2 Selector lever handle, selector lever display illumination bulb -L101- -
exploded view
1 - Bolt
❑ 1 Nm
❑ Secures trim for selector
lever boot -item 2- to
centre console trim pan‐
el
2 - Trim for selector lever boot
with selector lever display illu‐
mination bulb -L101-
❑ Removing and installing
⇒ page 28
3 - Guide
4 - Hose clip
❑ Removing and installing
⇒ “2.1 Removing and in‐
stalling selector lever
handle”, page 26
5 - Selector lever handle
❑ Removing and installing
⇒ page 26
2.1 Removing and installing selector lever handle
Special tools and workshop equipment required
♦ Hose clip pliers -V.A.G 1275-
26 Rep. Gr.34 - Controls, housing
Page 31
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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, front-wheel drive - Edition 12.2006
Removing
Proceed as follows:
Note
The selector lever handle is removed together with the selector
lever boot.
– Apply handbrake.
– Shift selector lever into position “N”.
– Use a cable tie to secure the interlock button in pulled-out po‐
sition -arrow-, as shown in the illustration.
– Using a small screwdriver, carefully pry out selector lever boot
at the side -arrow 1-.
– Pull up both sides of boot and detach boot -arrows 2 and 3-.
Audi TT 2007 ➤
– Turn selector lever boot -2- inside out over selector lever han‐
dle -3-.
– Release hose clip -1-.
– Pull off selector lever handle together with selector lever boot
-arrow-, taking care not to touch interlock button.
2. Selector lever handle, selector lever display illumination bulb L101 - exploded view 27
Page 32
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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, front-wheel drive - Edition 12.2006
Installing
Installation is carried out in reverse sequence; note the following:
Note
♦
To install the selector lever handle, the interlock button must
be pulled out as far as it will go and secured with either a cable
tie -arrow- or with the assembly aid supplied with the new han‐
dle.
♦
If the interlock button was not secured, do not attempt to pull
it out of the selector lever handle using mechanical tools. In‐
stead, apply a compressed air gun to the bottom of the handle,
blow out the interlock button and secure it in this position.
– Push selector lever handle fully onto selector lever.
• The interlock button faces the driver.
• The handle must engage in the annular groove on the selector
lever.
– Remove cable tie or assembly aid.
• The interlock button mechanism should engage in the vertical
groove on the selector lever. If not, press the interlock button
into the selector lever handle.
– Bring hose clip -1- into correct position.
• The lug -arrow- on the hose clip faces front right.
– Clamp selector lever handle -2- on selector lever by tightening
hose clip with hose clip pliers -V.A.G 1275- .
– Clip retainer frame -3- for selector lever boot onto trim for se‐
lector lever boot.
2.2 Removing and installing selector lever display illumination bulb -L101-
Removing
Proceed as follows:
– Apply handbrake.
– Shift selector lever into position “N”.
– Switch off ignition and take out ignition key.
28 Rep. Gr.34 - Controls, housing
Page 33
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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, front-wheel drive - Edition 12.2006
– Using a small screwdriver, carefully pry selector lever boot out
of trim for selector lever boot -arrow 1-.
– Pull up both sides of boot and detach boot -arrows 2 and 3-.
– Turn selector lever boot inside out over selector lever handle.
– Using removal wedge -3409- , pry trim panel for centre console
out of centre console -arrows-.
– Unplug electrical connectors and remove trim panel for centre
console.
Audi TT 2007 ➤
– Remove bolts -arrows- and detach trim for selector lever boot
-1- together with selector lever display illumination bulb L101- .
Installing
• Tightening torque ⇒ page 26 .
Perform installation in reverse sequence of removal.
2. Selector lever handle, selector lever display illumination bulb L101 - exploded view 29
Page 34
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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, front-wheel drive - Edition 12.2006
3 Servicing selector mechanism - exploded view
Note
Lubricate all bearings and moving surfaces with polycarbamide grease ⇒ Parts catalogue .
1 - Support bracket
❑ For selector lever cable
2 - Bolt
❑ 20 Nm + 90°
❑ 2 x
❑ Renew
3 - Retaining clip
❑ Renew
4 - Bolt
❑ 13 Nm
5 - Locking plate
❑ Renew
6 - Selector lever cable
❑ Do not bend or kink
❑ Renew selector lever
cable if sleeves are
damaged
❑ Adjusting ⇒ page 40
❑ Removing and installing
⇒ page 36
❑ Do not grease cable eye
7 - Nut
❑ 8 Nm
❑ Selector mechanism to
body
❑ 4 x
8 - Buffer stop for selector lever
❑ Clipped onto selector
mechanism
9 - Shift unit
❑ With integrated printed circuit for selector mechanism ( selector lever -E313- )
Caution
Electronic components
of selector mechanism
can be damaged by elec‐
trostatic discharge.
♦Do not touch printed cir‐
cuit with bare hands.
❑ Incorporates tiptronic switch -F189- and selector lever lock solenoid -N110❑ tiptronic switch -F189- and selector lever lock solenoid -N110- can be checked via “Guided Fault Finding”
⇒ Vehicle diagnosis, testing and information system VAS 5051
❑ If tiptronic switch -F189- or selector lever lock solenoid -N110- are defective, renew shift unit
30 Rep. Gr.34 - Controls, housing
Page 35
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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, front-wheel drive - Edition 12.2006
❑ Manual release of selector mechanism ⇒ page 31
❑ Removing and installing ⇒ page 41
10 - Detent spring
11 - Bolt
❑ 3.5 Nm
12 - Pivot pin
13 - Bolt
❑ 3.5 Nm
❑ 4 x
14 - Detent plate
15 - Cover for shift unit
❑ With glued-on gasket
16 - Nut
❑ 9 Nm
❑ 4 x
❑ Self-locking
❑ Renew
17 - Bracket
18 - Lock washer
❑ 2 x
19 - Locking plate
❑ Renew
Audi TT 2007 ➤
3.1 Manual release of selector mechanism
In the event of failure of the supply voltage to the selector lever
lock solenoid (discharged battery or defective fuse), or if the sol‐
enoid itself is defective, the selector lever cannot be shifted out
of position “P”. The vehicle then cannot be moved because the
parking lock is engaged.
Proceed as follows:
– Check fuses ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– Check battery voltage ⇒ Rep. Gr. 27 .
– If no fault is found in the supply voltage, release the selector
mechanism manually as follows:
– Using a small screwdriver, carefully pry selector lever boot out
of trim for selector lever boot -arrow 1-.
– Pull up both sides of boot and detach boot -arrows 2 and 3-.
– Turn selector lever boot inside out over selector lever handle.
3. Servicing selector mechanism - exploded view 31
Page 36
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Release selector lever lock solenoid -A- by pressing lever
-B- inwards -arrow- with a screwdriver -1- and holding it in this
position.
• The solenoid will then release the selector lever.
– Now press button on selector lever handle and shift selector
lever out of “P”.
Note
However, if the selector lever is now moved back to “P”, the se‐
lector lever lock solenoid will again lock it mechanically in position
“P” and it will have to be released once again.
3.2 Checking selector mechanism and igni‐
tion key removal lock
Proceed as follows:
♦ It should not be possible to operate the starter while the se‐
lector lever is in position “S”, “D” or “R” or in the tiptronic
position.
♦ If the selector lever is moved into position “N” while the vehicle
is rolling at a speed above 5 km/h, the solenoid for the selector
lever lock must not engage and block the selector lever. The
selector lever can be shifted into a driving gear.
♦ If the selector lever is moved into position “N” while the vehicle
is rolling at a speed below 5 km/h (almost at a standstill), the
solenoid for the selector lever lock should only engage after a
delay of approx. one second. The selector lever cannot be
shifted out of position “N” until brake pedal is depressed.
Selector lever in position “P” and ignition switched off:
The ignition key can be removed.
Selector lever in any position other than “P” and ignition switched
off:
The ignition key cannot be removed.
Selector lever in position “P”, button on selector lever pressed in
and ignition switched on:
• Brake pedal not depressed:
The selector lever is locked with the button pressed in, and cannot
be shifted out of position “P”. The solenoid for selector lever lock
blocks the selector lever.
• Brake pedal depressed:
The solenoid for selector lever lock releases the selector lever
and a gear can be engaged. Shift the selector lever slowly from
position “P” through “R, N, D and S” and check whether the dis‐
play in the instrument cluster shows the correct selector lever
position in each case.
Selector lever in position “N”, button on selector lever pressed in
and ignition switched on:
• Brake pedal not depressed:
32 Rep. Gr.34 - Controls, housing
Page 37
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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, front-wheel drive - Edition 12.2006
The selector lever is locked and cannot be shifted out of position
“N”. The solenoid for selector lever lock blocks the selector lever.
• Brake pedal depressed:
The solenoid for selector lever lock releases the selector lever
and a gear can be engaged.
Note
♦
If you depress the brake pedal you can shift from “N” to “D”
without pressing the button on the selector lever.
♦
However, to shift from “N” to “R” you do have to additionally
press the button on the selector lever.
Selector lever in position “D”, ignition switched on:
The selector lever is locked and cannot be shifted from “D” to “S”.
• Press button on selector lever:
The selector lever is released and can be shifted from “D” to “S”.
Selector lever in position “D”, ignition and lights switched on:
• Shift selector lever into tiptronic gate:
The illuminated “D” symbol in the selector lever position indicator
should go out and the “+” and “–” symbols should light up.
The selector lever position indicator in the instrument cluster
should switch from “PRNDS” to “654321” when the selector lever
is moved into the tiptronic gate.
• Move the selector lever in the tiptronic gate to “+” and “–”.
When you move the selector lever to “+” or “–”, the display
“654321” in the instrument cluster should move one gear up or
down accordingly.
– If the selector mechanism or the ignition key removal lock does
not operate as described, connect vehicle diagnostic, testing
and information system -VAS 5051B- .
Audi TT 2007 ➤
– “Interrogate fault memory - all fault menus”, trace and elimi‐
nate any faults displayed via “Guided Fault Finding”.
3.3 Removing and installing selector mech‐
anism
Removing
Proceed as follows:
– Switch off ignition.
– Remove selector lever handle ⇒ page 26 .
– Remove trim panel for centre console ⇒ Rep. Gr. 68 .
– Remove ashtray ⇒ Rep. Gr. 68 .
3. Servicing selector mechanism - exploded view 33
Page 38
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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, front-wheel drive - Edition 12.2006
– Unplug electrical connector -A-.
Note
-Items 1, B, C- can be disregarded.
– Unplug electrical connector -3- from air mass meter -G70- .
– Release clamps -1 and 2- and disconnect air intake hose from
air mass meter -G70- .
– Unbolt front intake duct from lock carrier -4-.
– Remove engine cover panel.
– Shift selector lever into position “P”.
– Detach locking plate -C-.
– Press retaining clip -A- upwards and detach.
– Press selector lever cable off selector shaft lever -arrow- and
pull out of support bracket -D-.
Note
♦
Do not bend or kink the selector lever cable.
♦
-Items 1 and B- can be disregarded.
– Remove Lambda probe after catalytic converter -G130- ⇒
Rep. Gr. 24 .
– Remove tunnel brace and bracket for exhaust system
-arrows-.
34 Rep. Gr.34 - Controls, housing
Page 39
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove heat shield -arrows-.
Caution
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
The flexible joints in the exhaust system can be damaged.
♦ The flexible joints in the front exhaust pipe must not be
bent further than 10°.
– Disconnect exhaust system at clamp -1-.
– Lower front exhaust pipe with catalytic converter and front si‐
lencer slightly and pull out heat shield towards rear of vehicle.
– Re-connect exhaust system at clamp.
3. Servicing selector mechanism - exploded view 35
Page 40
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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, front-wheel drive - Edition 12.2006
Note
A second mechanic is required to help detach the selector mech‐
anism under the vehicle.
– Unscrew nuts -arrows- (from above).
Note
-Items 1 and 2- can be disregarded.
– Detach selector mechanism together with selector lever cable
from below.
Note
♦
Do not bend or kink the selector lever cable.
♦
It is also possible to remove the selector mechanism without
the selector lever cable; to do so, you first have to detach the
selector lever cable from the selector mechanism
⇒ “3.4 Removing and installing selector lever cable”,
page 36 .
Installing
• Tightening torques ⇒ page 30
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew locking plate and retaining clip for selector lever cable.
♦
Do not bend or kink the selector lever cable.
– Install heat shield ⇒ Rep. Gr. 66 .
– Install exhaust system and align so it is free of stress ⇒ Rep.
Gr. 26 .
– Install ashtray ⇒ Rep. Gr. 68 .
– Install trim panel for centre console ⇒ Rep. Gr. 68 .
– Install selector lever handle ⇒ page 26 .
– Adjust selector lever cable ⇒ page 40 .
– Check selector mechanism and ignition key removal lock
⇒ page 32 .
3.4 Removing and installing selector lever cable
Removing
Proceed as follows:
– Shift selector lever into position “P”.
– Switch off ignition.
36 Rep. Gr.34 - Controls, housing
Page 41
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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, front-wheel drive - Edition 12.2006
– Unplug electrical connector -3- from air mass meter -G70- .
– Release clamps -1 and 2- and disconnect air intake hose from
air mass meter -G70- .
– Unbolt front intake duct from lock carrier -4-.
– Remove engine cover panel.
– Detach locking plate -C-.
– Press retaining clip -A- upwards and detach.
– Press selector lever cable off selector shaft lever -arrow- and
pull out of support bracket -D-.
Audi TT 2007 ➤
Note
♦
Do not bend or kink the selector lever cable.
♦
-Items 1 and B- can be disregarded.
– Remove Lambda probe after catalytic converter -G130- ⇒
Rep. Gr. 24 .
– Remove tunnel brace and bracket for exhaust system
-arrows-.
3. Servicing selector mechanism - exploded view 37
Page 42
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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, front-wheel drive - Edition 12.2006
– Remove heat shield -arrows-.
Caution
The flexible joints in the exhaust system can be damaged.
♦ The flexible joints in the front exhaust pipe must not be
bent further than 10°.
– Disconnect exhaust system at clamp -1-.
– Lower front exhaust pipe with catalytic converter and front si‐
lencer slightly and pull out heat shield towards rear of vehicle.
– Re-connect exhaust system at clamp.
– Detach cover for shift unit -arrows-.
– Carefully slide cover for shift unit together with sleeve along
selector lever cable towards front of vehicle, taking care not to
damage sleeve.
Caution
Electronic components of selector mechanism can be dam‐
aged by electrostatic discharge.
♦ Do not touch printed circuit -B- with bare hands.
– Unscrew bolts -arrows-.
– Unclip retaining tabs on both sides and detach detent plate
-A- from shift unit.
38 Rep. Gr.34 - Controls, housing
Page 43
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Shift selector lever to position “S”.
– Pull down locking plate -1- for selector lever cable and remove.
– Pull plastic retaining spring -2- forwards slightly and press piv‐
ot pin -3- upwards only as far as necessary -arrow-.
Note
Ensure that pin is not pressed out completely.
– Pull selector lever cable -4- out of shift unit.
Note
Do not bend or kink the selector lever cable.
Installing
• Tightening torques ⇒ page 30
Installation is carried out in reverse sequence; note the following:
Audi TT 2007 ➤
Note
♦
Renew locking plates and retaining clip for selector lever ca‐
ble.
♦
The selector lever cable must be renewed if the sleeves are
damaged.
– Guide selector lever cable into cover for shift unit, taking care
not to damage sleeve.
– Engage sleeve in cover for shift unit.
Note
Check that the sleeve is seated correctly and not twisted.
– Insert end of selector lever cable -4- into joint on selector lever.
– Press pivot pin -3- downwards -arrow-.
• The plastic securing spring -2- should lock the pin in position.
– Secure selector lever cable to shift unit using new locking plate
-1-.
• Installation position: angled end of locking plate faces shift
unit.
3. Servicing selector mechanism - exploded view 39
Page 44
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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, front-wheel drive - Edition 12.2006
Caution
Electronic components of selector mechanism can be dam‐
aged by electrostatic discharge.
♦ Do not touch printed circuit -B- with bare hands.
– Clip detent plate -A- into position on both sides.
– Tighten bolts -arrows-.
– Loosely attach cover for shift unit (with glued-on seal) to shift
unit -arrows-, making sure that seal is seated correctly.
– Fit sleeve for selector lever cable in cover for shift unit.
– Press selector lever cable onto selector shaft lever on gearbox
in opposite direction of -arrow-.
– Fit retaining clip -A- and press downwards to secure.
– Install locking plate -C-.
– Move selector lever from “S” to “P”.
Note
♦
Check that selector lever moves freely.
♦
If the selector mechanism is stiff, renew the selector lever ca‐
ble or service the selector mechanism.
– Secure cover for shift unit -arrows-.
– Install heat shield ⇒ Rep. Gr. 66 .
– Install exhaust system so it is free of stress ⇒ Rep. Gr. 26 .
– Adjust selector lever cable ⇒ page 40 .
– Check selector mechanism ⇒ page 32 .
3.5 Adjusting selector lever cable
Procedure
Proceed as follows:
40 Rep. Gr.34 - Controls, housing
Page 45
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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, front-wheel drive - Edition 12.2006
– Remove air cleaner housing (top and bottom sections) ⇒ Rep.
Gr. 24 .
• Selector mechanism and selector lever cable operate smooth‐
ly when changing gears.
• Sleeve on selector lever cable is undamaged.
• Retaining clip -A- is fitted correctly (pressed down and locked).
Note
♦
If the selector mechanism is stiff, renew the selector lever ca‐
ble or service the selector mechanism.
♦
The selector lever cable must be renewed if a sleeve is dam‐
aged.
– Shift selector lever into position “P”.
– Slacken bolt -B-.
– Set selector shaft lever on gearbox to position “P”.
– Push vehicle forwards until wheels lock so that detent lever in
gearbox engages in parking lock gear.
– To release tension in selector lever cable, carefully move se‐
lector lever slightly forwards and backwards, without shifting
into a different position.
– Tighten bolt -B-, taking care not to alter position of selector
lever cable.
Checking adjustment of selector lever cable
– Keep button pressed, while pulling selector lever approx. 5
mm to the rear out of position “P”. Then keep lever in this po‐
sition, do not move it into “R”.
– Release selector lever.
• The selector lever should spring back into position “P” by itself.
Audi TT 2007 ➤
– Shift selector lever into position “N”.
– Keep button pressed, while pulling selector lever approx. 5
mm to the rear out of position “N”. Then keep lever in this po‐
sition, do not move it into “D”.
– Release selector lever.
• The selector lever should spring back into position “N” by itself.
– Keep button pressed, while pushing selector lever approx. 5
mm to the front out of position “N”. Then keep lever in this
position, do not move it into “R”.
– Release selector lever.
• The selector lever should spring back into position “N” by itself.
– Repeat the adjustment if the selector lever does not react as
described.
– Check selector mechanism ⇒ page 32 .
3.6 Removing and installing tiptronic switch
-F189-
The tiptronic switch -F189- is integrated in the shift unit; it cannot
be renewed separately.
3. Servicing selector mechanism - exploded view 41
Page 46
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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, front-wheel drive - Edition 12.2006
Note
The shift unit has to be renewed if the tiptronic switch -F189- is
defective ⇒ page 33 .
3.7 Removing and installing selector lever lock solenoid -N110-
The selector lever lock solenoid -N110- is integrated in the shift
unit; it cannot be renewed separately.
Note
The shift unit has to be renewed if the selector lever lock solenoid
-N110- is defective ⇒ page 33 .
3.8 Checking connectors on selector mech‐
anism
Proceed as follows if malfunctions occur in the selector mecha‐
nism:
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
– “Interrogate fault memory - all fault menus”, trace and elimi‐
nate any faults displayed via “Guided Fault Finding”.
A - 10-pin connector for wiring from selector mechanism to gear‐
box (with CAN wires)
B - 4-pin connector for wiring to selector lever lock solenoid N110- and selector lever locked in position P switch -F319-
C - 10-pin connector for wiring to cover of selector mechanism
42 Rep. Gr.34 - Controls, housing
Page 47
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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.
4 Removing gearbox
Special tools and workshop
equipment required
♦ Support bracket -10 - 222
A-
♦ Hooks -10 - 222 A /10-
♦ Hose clamps, up to 25 mm
-3094-
♦ Gearbox support -3282-
♦ Pin -3282/29-
♦ Adjustment plate -3282/42
A-
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
4. Removing gearbox 43
Page 48
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Engine support bracket, ba‐
sic set -T40091-
♦ Engine support bracket,
supplementary set T40093-
Procedure
Proceed as follows:
Note
♦
Observe general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
♦
All cable ties which are released or cut open during removal
must be fitted in the same position when installing.
– Shift selector lever into position “P”.
44 Rep. Gr.34 - Controls, housing
Page 49
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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, front-wheel drive - Edition 12.2006
– Unplug electrical connector -3- from air mass meter -G70- .
– Release clamps -1 and 2- and disconnect air intake hose from
air mass meter -G70- .
– Unbolt front intake duct from lock carrier -4-.
– Remove engine cover panel.
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 the ignition switched off, disconnect battery earth cable
⇒ Rep. Gr. 27 .
– Detach locking plate -C-.
– Press retaining clip -A- upwards and detach.
– Press selector lever cable off selector shaft lever -arrow- and
pull out of support bracket -D-.
Audi TT 2007 ➤
Note
♦
Do not bend or kink the selector lever cable.
♦
-Items 1 and B- can be disregarded.
– Cut open cable tie -arrow- for dust boot.
– Unplug electrical connector -2-.
– Push back dust boot -1- and disconnect B+ wire from starter
solenoid.
– Disconnect earth wire -3-.
Caution
The control unit (mechatronic unit) can be damaged by elec‐
trostatic discharge.
♦ Do not touch contact pins in gearbox connector with bare
hands.
– Touch vehicle earth with your hand (without gloves) to dis‐
charge any static electricity.
– Turn fastener anti-clockwise and unplug electrical connector
-4- on gearbox.
4. Removing gearbox 45
Page 50
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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, front-wheel drive - Edition 12.2006
– Clamp off coolant hoses at gearbox oil cooler with hose
clamps -3094- and disconnect hoses from gear oil cooler -A-.
Note
Seal off open lines and connections with clean plugs or sealing
caps to prevent dirt from entering.
– Remove bottom bolt -2- for starter (accessible from above).
– Remove top bolt -1- for starter and detach starter.
– Remove engine/gearbox securing bolts -1, 3, 10- (accessible
from above).
– Release clamp -2-.
– Remove nut -3-.
– Unplug electrical connector -4-.
Note
-Item 1- can be disregarded.
46 Rep. Gr.34 - Controls, housing
Page 51
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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, front-wheel drive - Edition 12.2006
– Set up support bracket -10 - 222 A- on body flanges using the
following equipment:
♦ Rack -10 - 222 A /1- (2x)
♦ Adapter -10 - 222 A /4-
♦ Connecting piece -T40091/3- (2x)
– Attach adapters -T40093/3-2- (left-side) and -T40093/3-3-
(right-side) to supports -T40093/3- .
– Disconnect earth wire from longitudinal member (left-side).
– Remove securing bolt for front section of longitudinal member
(both sides).
– Bolt adapters -arrow- to longitudinal members, using bolts re‐
moved previously.
Audi TT 2007 ➤
Note
Illustration shows left side of vehicle.
– Insert square bars -T40091/1- with connecting pieces -
T40093/4- into connecting pieces -T40091/3- and supports T40093/3- as illustrated.
4. Removing gearbox 47
Page 52
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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, front-wheel drive - Edition 12.2006
– Insert support -T40091/2- with slide -T40093/5- into the two
connecting pieces -T40093/4- .
WARNING
Accidents can be caused if parts of the support bracket are not
correctly secured.
♦ Secure support -T40091/2- using retaining pins and split
pins of the connecting pieces -T40093/4- .
♦ Secure connecting pieces and supports using clamping
bolts.
– Attach hook -10 - 222 A /10- to slide and to engine lifting eye.
– Take up weight of engine/gearbox assembly via the spindle,
but do not raise.
– Remove both front wheels.
– Release fasteners -1 ... 4- and remove centre noise insulation.
– Remove noise insulation (left and right) -arrows-.
– Remove frame for noise insulation -arrow-.
48 Rep. Gr.34 - Controls, housing
Page 53
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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, front-wheel drive - Edition 12.2006
– Release spring-type clip -1- and hose clip -2- and remove air
intake hose leading to charge air cooler.
– Remove bolt -1- and take out intake connecting pipe from be‐
low.
Note
-Items 2, 3, 4- can be disregarded.
Audi TT 2007 ➤
– Remove nuts -arrows- and move bracket with wiring towards
front of vehicle.
– Free coolant hose running from continued coolant circulation
pump -V51- to radiator.
– Unbolt heat shield for drive shaft (right-side) -arrows-.
– Unbolt drive shafts (left and right) from flange shafts on gear‐
box ⇒ Rep. Gr. 40 .
– Tie up drive shafts with cable ties.
Note
Make sure you do not damage surface coating on drive shafts.
4. Removing gearbox 49
Page 54
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Remove bolt -arrow- and detach flange shaft (right-side) from
gearbox.
– Unscrew bolts -1 ... 3- and remove pendulum support.
– Unplug electrical connector -3- from vehicle level sender (front
left) -G78- .
– Remove bolt -2-.
Note
-Item 1- can be disregarded.
– Press swivel joint (left-side) off wheel bearing housing ⇒ Rep.
Gr. 40 .
– Pull suspension strut outwards slightly and support in this po‐
sition.
50 Rep. Gr.34 - Controls, housing
Page 55
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Remove bolts -1- and -2- and detach gearbox support -A-.
– Lower engine/gearbox assembly using spindle of support
bracket -10 - 222 A- until distance -a- is obtained between
gearbox housing and gearbox mounting.
• Dimension -a- = 100 ... 110 mm
Audi TT 2007 ➤
To remove the direct shift gearbox 02E, set up gearbox support
-3282- with adjustment plate -3282/42A- and place on engine and
gearbox jack -V.A.G 1383 A- .
Note
The illustration shows a gearbox for a four-wheel drive vehicle;
however, the attachment points are the same for the front-wheel
drive version.
– Align arms of gearbox support according to holes in adjust‐
ment plate -3282/42A- .
– Secure support elements as illustrated on adjustment plate
-3282/42A- . However, use -retainer plate with drilling- as front
support element.
– Place engine and gearbox jack -V.A.G 1383 A- underneath
vehicle.
• The arrow symbol on the adjustment plate points in the direc‐
tion of travel.
– Align gearbox support -3282- parallel with gearbox.
– Screw pin -3282/29- into gearbox.
– Secure -retainer plate with drilling- firmly to gearbox as illus‐
trated -arrow-.
– Insert last support element in gearbox as illustrated.
– Support gearbox by lifting from underneath with engine and
gearbox jack -V.A.G 1383 A- .
4. Removing gearbox 51
Page 56
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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, front-wheel drive - Edition 12.2006
– Remove remaining engine/gearbox securing bolts -5 … 9-.
– Press gearbox off dowel sleeves.
– Pull gearbox off engine.
– Carefully lower gearbox using engine and gearbox jack -V.A.G
1383 A- .
– While lowering gearbox, change position of gearbox using
spindles on gearbox support -3282- .
52 Rep. Gr.34 - Controls, housing
Page 57
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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, front-wheel drive - Edition 12.2006
5 Installing gearbox
Procedure
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew bolts which are tightened by turning through a speci‐
fied angle.
♦
Renew seals, gaskets and self-locking bolts and nuts.
♦
Renew locking plate and retaining clip for selector lever cable.
♦
Hose connections and hoses for charge air system must be
free from oil and grease before fitting.
♦
Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .
♦
Re-attach all cable ties at the same locations when re-instal‐
ling.
Audi TT 2007 ➤
Tightening torques:
⇒ “5.1 Tightening torques (installing gearbox)”, page 55
– Check needle bearing in crankshaft ⇒ Rep. Gr. 13 .
– Clean splines of input shaft and hub; remove corrosion.
– Grease clutch plate splines with a very small amount of grease
for clutch plate splines ⇒ Parts catalogue . It is important to
remove excess grease.
– Check that dowel sleeves -A- are correctly seated in cylinder
block.
– Engage intermediate plate at sealing flange on engine and
push onto dowel sleeves.
– Renew oil seal for flange shaft (right-side) ⇒ page 98 .
5. Installing gearbox 53
Page 58
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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, front-wheel drive - Edition 12.2006
– Carefully raise gearbox using engine and gearbox jack -V.A.G
1383 A- and position correctly using gearbox support -3282- .
Note
The illustration shows a gearbox for a four-wheel drive vehicle;
however, the attachment points are the same for the front-wheel
drive version.
– Join gearbox to engine, taking care not to trap wiring or other
connections.
– Secure gearbox to engine.
– Install assembly mountings (note correct sequence)
⇒ page 60 .
– Detach gearbox support -3282- from gearbox.
– Secure swivel joint (left-side) to wheel bearing housing ⇒ Rep.
Gr. 40 .
– Install flange shaft (right-side) ⇒ page 95 .
– Install drive shafts ⇒ Rep. Gr. 40 .
– Install heat shield for drive shaft (right-side).
– First secure pendulum support to gearbox -arrow B- and
-arrow C-, then on subframe -arrow A-. Tightening torques
⇒ page 59 .
– Install starter ⇒ Rep. Gr. 27 .
– Adjust assembly mountings ⇒ Rep. Gr. 10 .
– Tighten bolts -arrows- for assembly mounting (gearbox side).
– Detach support bracket -10 - 222 A- from engine.
54 Rep. Gr.34 - Controls, housing
Page 59
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– When installing air intake hoses with plug-in connections,
make sure retaining clip -arrow- snaps onto retaining lug -A-.
– Observe correct procedure after connecting battery ⇒ Rep.
Gr. 27 .
– Adjust selector lever cable ⇒ page 40 .
– Check gear oil level and top up as required ⇒ page 66 .
– Check coolant level ⇒ Rep. Gr. 19 .
5.1 Tightening torques (installing gearbox)
Tightening torques
Note
♦
Tightening torques apply only to lightly greased, oiled,
phosphated or black-finished nuts and bolts.
♦
Additional lubricant such as engine or gear oil may be used,
but do not use graphite lubricant.
♦
Do not use parts which have been degreased.
♦
Tolerance for tightening torques ±15%.
Audi TT 2007 ➤
Securing direct shift gearbox to engine
Item Bolt Nm
1, 3, 6 M12x55 80
5 M12x65 80
7, 8 M10x50 40
9 M10x45 40
10 M12x70 80
A Dowel sleeves for centralising
Note
-Items 2 and 4- can be disregarded.
• Additional tightening torques
⇒ “8 Assembly mountings - exploded view”, page 59 .
5. Installing gearbox 55
Page 60
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
6 Transporting the direct shift gearbox
Special tools and workshop equipment required
♦ Workshop hoist -VAS 6100-
♦ Retainer -T10013-
Procedure
Use retainer -T10013- to transport the direct shift gearbox and
when setting up gearbox support -3282- .
– Remove threaded pin from retainer -T10013- (release retain‐
ing ring).
– Secure retainer -T10013- to gearbox lifting eye with bolt
(M8x40) -1- and washer (outside diameter 30 mm).
– Hook workshop hoist -VAS 6100- onto retainer -T10013- .
Caution
The gearbox oil cooler can be damaged when the gearbox is
transported.
♦ Guide gearbox as required when transporting.
56 Rep. Gr.34 - Controls, housing
Page 61
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
7 Securing gearbox to assembly stand
Special tools and workshop
equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Engine/gearbox support -
VW 540-
♦ Workshop hoist -VAS
6100-
Audi TT 2007 ➤
7. Securing gearbox to assembly stand 57
Page 62
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
Securing gearbox in horizontal position
– Secure gearbox to engine/gearbox support -VW 540-
-arrows-.
– Using workshop hoist -VAS 6100- , insert gearbox into support
clamp -VW 313- ⇒ page 56 .
WARNING
The gearbox can swing round suddenly in the support clamp.
♦ The centre of gravity of the gearbox is outside the pivot
centre of the support clamp. A second mechanic is there‐
fore required to hold the gearbox housing when the gear‐
box is rotated in the clamp.
Oil can escape when the gearbox is rotated in the support
clamp.
♦ The breathers on the gearbox housing must be sealed off
if the gearbox (with oil filling) is turned on the assembly
stand so that the oil pan faces upwards.
Securing gearbox in vertical position
– Secure gearbox to gearbox support -VW 353- and fit into sup‐
port clamp -VW 313- using support plate -VW 309- .
58 Rep. Gr.34 - Controls, housing
Page 63
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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, front-wheel drive - Edition 12.2006
8 Assembly mountings - exploded view
1 - Bolt
❑ 40 Nm + 90°
❑ Gearbox support to
gearbox
❑ Renew
2 - Bolts
❑ 40 Nm + 90°
❑ Pendulum support to
gearbox
❑ Renew
3 - Engine support
4 - Bolt
❑ Engine support to en‐
gine
❑ Tightening torque ⇒
Rep. Gr. 10
5 - Engine mounting
6 - Bolt
❑ Engine mounting to
body
❑ Tightening torque ⇒
Rep. Gr. 10
7 - Connecting bracket
8 - Bolt
❑ Connecting bracket to
engine mounting
❑ Tightening torque ⇒
Rep. Gr. 10
9 - Bolt
❑ Connecting bracket to
body
❑ Tightening torque ⇒ Rep. Gr. 10
10 - Bolt
❑ Engine mounting to body
❑ Tightening torque ⇒ Rep. Gr. 10
11 - Bolts
❑ Engine mounting to engine support
❑ Tightening torque ⇒ Rep. Gr. 10
12 - Pendulum support
❑ Removing and installing ⇒ page 64
13 - Bolt
❑ 100 Nm + 90°
❑ Pendulum support to subframe
❑ Renew
14 - Bolt
❑ 60 Nm + 90°
Audi TT 2007 ➤
8. Assembly mountings - exploded view 59
Page 64
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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, front-wheel drive - Edition 12.2006
❑ Gearbox mounting to gearbox support
❑ Renew
15 - Bolt
❑ 40 Nm + 90°
❑ Gearbox mounting to body
❑ Renew
16 - Gearbox mounting
❑ Removing and installing ⇒ page 61
❑ Tightening sequence ⇒ page 60
17 - Bolt
❑ 40 Nm + 90°
❑ Gearbox support to gearbox
❑ Renew
18 - Bolt
❑ 40 Nm + 90°
❑ Gearbox support to gearbox
❑ Renew
19 - Gearbox support
❑ Tightening sequence ⇒ page 60
Assembly mounting on gearbox side: tightening sequence
– Fit gearbox support -A- between gearbox and support arm of
gearbox mounting.
– Bolt gearbox support to gearbox.
– Pull gearbox up to support arm of gearbox mounting using
spindle of support bracket -10 - 222 A- .
– Screw in bolts -2- initially hand-tight.
Caution
Screw in bolts straight when fitting as otherwise the threads in
the support arm of the gearbox mounting will be damaged.
♦ Before fitting the bolts -2-, the gearbox support and the
support arm of the gearbox mounting must be aligned ab‐
solutely parallel. If necessary, push the gearbox up at the
rear with a trolley jack.
– Only tighten bolts after subframe has been installed ⇒ Rep.
Gr. 40 and assembly mountings aligned ⇒ Rep. Gr. 10 .
60 Rep. Gr.34 - Controls, housing
Page 65
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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, front-wheel drive - Edition 12.2006
8.1 Removing and installing gearbox mounting
Special tools and workshop
equipment required
♦ Support bracket -10 - 222
A-
♦ Hooks -10 - 222 A /10-
♦ Engine support bracket, ba‐
sic set -T40091-
♦ Engine support bracket,
supplementary set T40093-
Audi TT 2007 ➤
Removing
Proceed as follows:
– Unplug electrical connector -3- from air mass meter -G70- .
– Release clamps -1 and 2- and disconnect air intake hose from
air mass meter -G70- .
– Unbolt front intake duct from lock carrier -4-.
– Remove engine cover panel.
8. Assembly mountings - exploded view 61
Page 66
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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, front-wheel drive - Edition 12.2006
– Set up support bracket -10 - 222 A- on body flanges using the
following equipment:
♦ Rack -10 - 222 A /1- (2x)
♦ Adapter -10 - 222 A /4-
♦ Connecting piece -T40091/3- (2x)
– Attach adapters -T40093/3-2- (left-side) and -T40093/3-3-
(right-side) to supports -T40093/3- .
– Disconnect earth wire from longitudinal member (left-side).
– Remove securing bolt for front section of longitudinal member
(both sides).
– Bolt adapters -arrow- to longitudinal members, using bolts re‐
moved previously.
Note
Illustration shows left side of vehicle.
– Insert square bars -T40091/1- with connecting pieces -
T40093/4- into connecting pieces -T40091/3- and supports T40093/3- as illustrated.
62 Rep. Gr.34 - Controls, housing
Page 67
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Insert support -T40091/2- with slide -T40093/5- into the two
connecting pieces -T40093/4- .
WARNING
Accidents can be caused if parts of the support bracket are not
correctly secured.
♦ Secure support -T40091/2- using retaining pins and split
pins of the connecting pieces -T40093/4- .
♦ Secure connecting pieces and supports using clamping
bolts.
– Attach hook -10 - 222 A /10- to slide and to engine lifting eye.
– Take up weight of engine/gearbox assembly via the spindle,
but do not raise.
– Unscrew bolts -arrows-.
Audi TT 2007 ➤
– Open retainers for wiring duct -arrows-.
– Cut open cable tie -1- and push electrical wiring to one side.
– Unclip wiring duct.
8. Assembly mountings - exploded view 63
Page 68
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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, front-wheel drive - Edition 12.2006
– Remove bolts -1- and detach gearbox mounting -A-.
Installing
• Tightening torques ⇒ page 59
Installation is carried out in reverse sequence; note the following:
– Secure gearbox mounting -A-.
Caution
Screw in bolts straight when fitting as otherwise the threads in
the support arm of the gearbox mounting will be damaged.
♦ Before fitting the bolts -arrows-, the gearbox support and
the support arm of the gearbox mounting must be aligned
absolutely parallel. If necessary, push the gearbox up at
the rear with a trolley jack.
– Pull gearbox up with spindle on support bracket until gearbox
support contacts support arm of gearbox mounting.
– Adjust assembly mountings ⇒ Rep. Gr. 10 .
– Secure support arm of gearbox mounting to gearbox support.
– Detach support bracket -10 - 222 A- from engine.
8.2 Removing and installing pendulum sup‐
port
Removing
Proceed as follows:
– Release fasteners -1 ... 4- and remove centre noise insulation.
– Unscrew bolts -1 ... 3- and remove pendulum support.
64 Rep. Gr.34 - Controls, housing
Page 69
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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, front-wheel drive - Edition 12.2006
Installing
• Tightening torques ⇒ page 59
Installation is carried out in reverse sequence; note the following:
– First secure pendulum support to gearbox -arrow B- and
-arrow C-, then on subframe -arrow A-.
Audi TT 2007 ➤
8. Assembly mountings - exploded view 65
Page 70
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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, front-wheel drive - Edition 12.2006
9 Gear oil in direct shift gearbox - overview
Inspection plug for gear oil
Inspection plug -arrow 1-
• 45 Nm
• Renew seal
Overflow pipe -arrow 2-
• 3 Nm
Overview:
♦ ⇒ “9.1 Checking gear oil level and topping up”, page 66
♦ ⇒ “9.2 Changing gear oil or filling up after performing repairs”,
page 72
9.1 Checking gear oil level and topping up
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system -VAS
5051B-
♦ Used oil collection and extraction unit -V.A.G 1782-
♦ Adapter for oil filling -VAS 6262-
♦ Safety goggles
♦ Protective gloves (acid resistant)
66 Rep. Gr.34 - Controls, housing
Page 71
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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, front-wheel drive - Edition 12.2006
♦ Gear oil for direct shift gearbox 02E, Part No. ⇒ Parts cata‐
logue
Procedure
Proceed as follows:
Note
♦
Observe general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
♦
Observe notes on direct shift gearbox 02E, “Regulations for
the disposal of oil” ⇒ page 5 .
♦
Use only the correct type of gear oil for the direct shift gearbox
02E (available as a replacement part). Other types of oil cause
malfunctions and/or failure of the gearbox.
Audi TT 2007 ➤
WARNING
Hot gearbox oil can cause burns.
♦ Wear safety goggles.
♦ Wear protective gloves (acid resistant).
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.
Caution
Risk of damage to the gearbox.
♦ The engine must NOT be started if there is only little or no
oil left in the gearbox after repair work or after excessive
loss of oil.
♦ After repair work or after excessive loss of oil, put in a
suitable amount of gear oil before proceeding.
• Gearbox not in backup mode (emergency running mode)
• Vehicle must be on a 4-pillar lifting platform or standing over
an inspection pit so it is absolutely horizontal.
• Selector lever in position “P”, handbrake applied.
9. 67
Page 72
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
• Engine idling.
• Air conditioner and heating system switched off.
Reading off gear oil temperature
Note
♦
The gear oil level varies according to the oil temperature: if the
oil temperature is too low, this will result in overfilling; if it is too
high this will result in underfilling.
♦
An incorrect gear oil level will impair the function of the gear‐
box.
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
Display on -VAS 5051B- :
– From menu -1-, select “Self-diagnosis” and activate by press‐
ing → button.
Display on -VAS 5051B- :
– From menu -1-, select vehicle system “02 - Gearbox electron‐
ics” and activate by pressing → button.
68 Rep. Gr.34 - Controls, housing
Page 73
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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, front-wheel drive - Edition 12.2006
Display on -VAS 5051B- :
– From menu -1-, select function “011 - Measured values” and
activate by pressing → button.
Display on -VAS 5051B- :
1 - Enter display group
– Using keypad -1- press buttons 1 9 for “Display group 019”
and confirm entry by pressing Q
button.
Audi TT 2007 ➤
Display on -VAS 5051B- :
– Read off gear oil temperature in display zone -1-.
• Specification at commencement of test: Not higher than 30 °
C, otherwise allow gearbox to cool down.
Checking gear oil level
• Tightening torques ⇒ page 66
– Release fasteners -1 ... 4- and remove centre noise insulation.
– Press and hold brake pedal.
– With brake pedal depressed, select all gear positions “P, R, N,
D, S” one after the other at idling speed, maintaining each po‐
sition for at least 3 seconds.
– Place used oil collection and extraction unit -V.A.G 1782- be‐
low gearbox.
9. 69
Page 74
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
Display on -VAS 5051B- :
– Read off gear oil temperature in display zone -1-.
• Specification: 35 °C.
– Unscrew inspection plug -B- when specified temperature is
reached.
Note
-Item A- can be disregarded.
70 Rep. Gr.34 - Controls, housing
Page 75
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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, front-wheel drive - Edition 12.2006
• The gear oil that has collected in the overflow pipe -arrow 2will drain off first.
Note
Regardless of the gear oil level itself, a certain amount of gear oil
will always drain off when inspection plug -arrow 1- is opened.
– Check that overflow pipe is securely screwed into inspection
plug opening.
Note
The gear oil level cannot be checked reliably if the overflow pipe
is loose.
• The gear oil level is correct if a small amount of oil drains out
when the oil temperature is between 35 and 45 °C (the oil level
rises as the oil temperature continues to increase).
Audi TT 2007 ➤
Note
♦
Every 30 seconds a small surge of oil will come out of the
overflow pipe, regardless of the oil level (this is caused by the
intermittent supply of cooling oil to the multiple clutch). This
surge of oil is not relevant when checking the gear oil level and
can be disregarded.
♦
Do not re-use drained-off gear oil.
– If gear oil level is OK ⇒ page 72 .
Filling up with gear oil
– If no gear oil drains out when the oil temperature is between
35°C and 45°C, top up gear oil as follows.
Caution
Take care not to mix the gear oil with different types of oil.
♦ Check that the adapter for oil filling -VAS 6262- is clean.
The gear oil for the direct shift gearbox must not be mixed
with different types of oil.
– Screw container of gear oil for direct shift gearbox onto adapter
for oil filling -VAS 6262- .
– Screw adapter for oil filling -VAS 6262- -item A- hand-tight into
opening for inspection plug.
– Hold container with adapter for oil filling -VAS 6262- as high
as possible over gearbox and let gear oil run into gearbox.
– To check whether enough oil has run into direct shift gearbox,
detach quick-release coupling on adapter for oil filling -VAS
6262- at regular intervals and plug the connection with a finger
or a clean plug.
9. 71
Page 76
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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, front-wheel drive - Edition 12.2006
• The gear oil that has collected in the overflow pipe -arrow 2will drain off first.
Note
Regardless of the gear oil level, a certain amount of gear oil will
always drain off.
• The gear oil level is correct if a small amount of oil drains out
when the oil temperature is between 35 and 45 °C (the oil level
rises as the oil temperature continues to increase).
Note
♦
Every 30 seconds a small surge of oil will come out of the
overflow pipe, regardless of the oil level (this is caused by the
intermittent supply of cooling oil to the multiple clutch). This
surge of oil is not relevant when checking the gear oil level and
can be disregarded.
♦
Do not re-use drained-off gear oil.
♦
Check the gear oil temperature on vehicle diagnostic, testing
and information system -VAS 5051B- while filling the gearbox
with oil. Stop filling and allow the gearbox to cool down if the
temperature exceeds 45 °C.
– If gear oil level is OK ⇒ page 72 .
Final steps
• Tightening torques ⇒ page 66
Note
Renew seal -arrow- for inspection plug.
– Unscrew adapter for oil filling -VAS 6262- from gearbox.
– Tighten inspection plug -B-.
Note
-Item A- can be disregarded.
– Exit from function “011 - Measured values” by pressing ← but‐
ton.
– Press “06 - End output”.
– Switch off ignition and unplug diagnostic connector.
9.2 Changing gear oil or filling up after per‐
forming repairs
Special tools and workshop equipment required
72 Rep. Gr.34 - Controls, housing
Page 77
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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, front-wheel drive - Edition 12.2006
♦ Used oil collection and extraction unit -V.A.G 1782-
♦ Adapter for oil filling -VAS 6262-
Audi TT 2007 ➤
♦ Safety goggles
♦ Protective gloves (acid resistant)
♦ Gear oil for direct shift gearbox 02E, Part No. ⇒ Parts cata‐
logue
Procedure
Proceed as follows:
Note
♦
Observe general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
♦
Observe notes on direct shift gearbox 02E, “Regulations for
the disposal of oil” ⇒ page 5 .
♦
Use only the correct type of gear oil for the direct shift gearbox
02E (available as a replacement part). Other types of oil cause
malfunctions and/or failure of the gearbox.
9. 73
Page 78
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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, front-wheel drive - Edition 12.2006
WARNING
Hot gearbox oil can cause burns.
♦ Wear safety goggles.
♦ Wear protective gloves (acid resistant).
Caution
Risk of damage to the gearbox.
♦ The engine must not be started when there is no oil in the
gearbox.
• Gearbox not in backup mode (emergency running mode)
• Vehicle must be on a 4-pillar lifting platform or standing over
an inspection pit so it is absolutely horizontal.
• Selector lever in position “P”, handbrake applied.
• Engine not running.
Draining off gear oil
– Renew gear oil filter ⇒ page 78 .
– Release fasteners -1 ... 4- and remove centre noise insulation.
– Place used oil collection and extraction unit -V.A.G 1782- be‐
low gearbox.
– Unscrew inspection plug -A- and remove together with seal
-B-.
• The gear oil that has collected in the overflow pipe -C- will drain
off first.
– Unscrew overflow pipe and allow remaining gear oil to drain.
Filling up with gear oil
– Screw overflow pipe into inspection plug opening and tighten
to specified torque.
Caution
Take care not to mix the gear oil with different types of oil.
♦ Check that the adapter for oil filling -VAS 6262- is clean.
The gear oil for the direct shift gearbox must not be mixed
with different types of oil.
– Screw container of gear oil for direct shift gearbox onto adapter
for oil filling -VAS 6262- .
74 Rep. Gr.34 - Controls, housing
Page 79
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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, front-wheel drive - Edition 12.2006
– Screw adapter for oil filling -VAS 6262- -item A- hand-tight into
opening for inspection plug.
– Hold container with adapter for oil filling -VAS 6262- as high
as possible over gearbox and fill 5.5 litres of gear oil into gear‐
box.
– Start engine and run at idling speed.
– Depress brake pedal and select all gear positions “P, R, N, D,
S” one after the other at idling speed, maintaining each posi‐
tion for at least 3 seconds.
– Shift selector lever into position “P”.
– Check gear oil level and top up as required ⇒ page 66 .
After changing gear oil:
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- to vehicle.
– Select Guided Functions for gearbox.
– Perform the “Basic setting” program.
Audi TT 2007 ➤
9. 75
Page 80
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
10 Gear oil cooler and gear oil filter - exploded view
Note
-Items 1 … 7, 15 … 18, 24, 25- can be disregarded here. For description see
⇒ “1.1 Oil pan, mechatronic unit, gear oil pump”, page 80 .
8 - Gear oil cooler
❑ Removing and installing
⇒ page 76
9 - Bolt
❑ 20 Nm + 90°
❑ Renew
10 - O-ring
❑ Renew
13 - Housing
❑ 20 Nm
❑ For gear oil filter
❑ Removing and installing
⇒ page 78
❑ O-ring on housing
❑ Renew O-ring
14 - Filter element
❑ For gear oil filter
❑ Removing and installing
⇒ page 78
❑ With O-ring on intake
neck
❑ Renew O-ring
10.1 Removing and installing gear oil cooler
Special tools and workshop equipment required
76 Rep. Gr.34 - Controls, housing
Page 81
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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, front-wheel drive - Edition 12.2006
♦ Hose clamps, up to 25 mm -3094-
Removing
Proceed as follows:
WARNING
Risk of scalding from hot steam and hot coolant.
♦ The cooling system is under pressure when the engine is
hot.
♦ Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
Audi TT 2007 ➤
– Open filler cap on expansion tank.
– Unplug electrical connector -3- from air mass meter -G70- .
– Release clamps -1 and 2- and disconnect air intake hose from
air mass meter -G70- .
– Unbolt front intake duct from lock carrier -4-.
– Remove engine cover panel.
– Clamp off coolant hoses at gear oil cooler using hose clamps
-3094- .
– Disconnect coolant hoses from gear oil cooler.
10. Gear oil cooler and gear oil filter - exploded view 77
Page 82
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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, front-wheel drive - Edition 12.2006
– Remove bolts -A-.
– Detach gear oil cooler -B- together with two O-rings -C- from
gearbox.
Caution
Do not allow coolant to drip into gearbox.
Installing
• Tightening torque ⇒ page 76 .
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew bolts for gear oil cooler.
♦
Renew O-rings.
– Check coolant level ⇒ Rep. Gr. 19 .
– Check gear oil level and top up as required ⇒ page 66 .
10.2 Removing and installing gear oil filter
Special tools and workshop equipment required
♦ Used oil collection and extraction unit -V.A.G 1782-
Removing
Proceed as follows:
– Unplug electrical connector -3- from air mass meter -G70- .
– Release clamps -1 and 2- and disconnect air intake hose from
air mass meter -G70- .
– Unbolt front intake duct from lock carrier -4-.
– Remove engine cover panel.
78 Rep. Gr.34 - Controls, housing
Page 83
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Place used oil collection and extraction unit -V.A.G 1782- un‐
der gearbox.
– Unscrew housing for gear oil filter.
Note
To allow the gear oil to drain back into the gearbox from the hous‐
ing for the gear oil filter, tilt the housing slightly in its seat before
removing it.
– Then lift out filter element slowly.
Note
Audi TT 2007 ➤
If the O-ring on the intake neck -arrow- of the filter element does
not come off together with the filter element, you must remove it
from the gearbox separately.
Installing
• Tightening torque ⇒ page 76 .
Installation is carried out in reverse sequence; note the following:
Note
Renew filter element and O-ring on oil filter housing.
– Lightly lubricate O-ring on intake neck -arrow- of filter element
with gear oil.
– Install filter element with intake neck facing downwards.
– Lightly lubricate O-ring on housing of gear oil filter with gear
oil.
– Tighten filter housing.
– Check gear oil level and top up as required ⇒ page 66 .
10. Gear oil cooler and gear oil filter - exploded view 79
Page 84
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
35 – Gears, shafts
1 Oil pan, mechatronic unit, gear oil
pump - exploded view
1.1 Oil pan, mechatronic unit, gear oil pump
Note
-Items 8 ... 14- can be disregarded here. For description see
⇒ “10 Gear oil cooler and gear oil filter - exploded view”, page 76 .
1 - Oil pan
❑ Removing and installing
⇒ page 82
2 - Bolt
❑ 5 x
❑ Tightening sequence
⇒ page 81
❑ Renew
3 - Gasket
❑ Renew
4 - Bolt
❑ 10 x
❑ Tightening sequence
⇒ page 81
❑ Renew
5 - Mechatronic unit for direct
shift gearbox -J743-
❑ With O-rings on connec‐
tor
❑ Renew O-rings
❑ Removing and installing
⇒ page 85
6 - Breather pipe
❑ Pressed into gearbox
❑ Must be renewed if re‐
moved
7 - Breather cap
❑ Fitted onto breather
pipe
15 - Gear oil pump
❑ Removing and installing
⇒ page 90
❑ Install with new gasket
16 - Bolt
❑ Tightening sequence ⇒ page 82
❑ 4 x
80 Rep. Gr.35 - Gears, shafts
Page 85
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
❑ Different bolts according to version
❑ Renew
17 - Cover for gear oil pump
❑ With gasket
❑ Renew
❑ Removing and installing ⇒ “1.5 Removing and installing gear oil pump”, page 90
18 - Bolt
❑ Tightening sequence ⇒ page 82
❑ 4 x
❑ Different bolts according to version
❑ Renew
24 - Guard plate
❑ Depending on version
25 - Bolt
❑ 32 Nm
❑ 4 x
Audi TT 2007 ➤
Tightening sequence for oil pan
– Tighten bolts -arrows- diagonally in stages.
• 16 Nm
Mechatronic unit for direct shift gearbox -J743- ; tightening se‐
quence
– Tighten bolts in the sequence -1 ... 10- in 2 stages as follows:
1. Tighten bolts to 5 Nm.
2. Turn bolts 90° further.
1. Oil pan, mechatronic unit, gear oil pump - exploded view 81
Page 86
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
Gear oil pump; tightening sequence
Note
There are different types of bolts -A or B-; observe correct tight‐
ening method.
– Tighten bolts -arrows- in diagonal sequence (different bolts
according to version):
Countersunk-head bolts -A-:
– Tighten countersunk-head bolts to 8 Nm.
Pan-head bolts -B-:
– Tighten pan-head bolts in 2 stages as follows:
1. Tighten bolts to 8 Nm.
2. Turn bolts 90° further.
Cover for gear oil pump -A-; tightening sequence
– Tighten bolts -arrows- diagonally in stages.
• 8 Nm
Gearbox input speed sender -G182- and clutch temperature
sender -G509-
A - Gearbox input speed sender -G182- and clutch tempera‐
ture sender -G509-
• Removing and installing ⇒ page 89
B - Bolt
• 10 Nm
C - Electrical connector
1.2 Removing and installing oil pan
Special tools and workshop equipment required
82 Rep. Gr.35 - Gears, shafts
Page 87
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Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
♦ Used oil collection and extraction unit -V.A.G 1782-
Removing
Proceed as follows:
Caution
Risk of damage to the gearbox.
♦ Do not run the engine or tow the vehicle with the oil pan
removed or when there is no gear oil in the gearbox.
Audi TT 2007 ➤
Note
♦
Observe the general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
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 the ignition switched off, disconnect battery earth cable
⇒ Rep. Gr. 27 .
– Drain off gear oil ⇒ page 72 .
– Unscrew nut -1- at front of oil pan and press bracket -A- up‐
wards.
1. Oil pan, mechatronic unit, gear oil pump - exploded view 83
Page 88
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– If fitted, remove guard plate -A- on underside of gearbox
-arrows-.
Caution
Mechatronic unit for direct shift gearbox -J743- can be dam‐
aged by electrostatic discharge.
♦ Do not touch contact pins in connector for mechatronic
unit for direct shift gearbox -J743- with bare hands.
– Touch vehicle earth with your hand (without gloves) to dis‐
charge any static electricity.
– Turn fastener anti-clockwise and unplug electrical connector
-4- on gearbox.
Note
-Items 1, 2, 3- can be disregarded.
– Place used oil collection and extraction unit -V.A.G 1782- un‐
der gearbox.
– Slacken oil pan bolts -arrows- in diagonal sequence.
– Detach oil pan together with oil pan gasket, allowing remaining
gear oil in oil pan to drain off into used oil collection and ex‐
traction unit -V.A.G 1782- .
84 Rep. Gr.35 - Gears, shafts
Page 89
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
Installing
• Tightening torque ⇒ page 81 .
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew gasket and bolts for oil pan.
♦
Renew O-rings -arrows- on connector for mechatronic unit for
direct shift gearbox -J743- .
– Clean sealing surfaces; they must be free from oil and grease.
– Fit oil pan with oil pan gasket and tighten bolts ⇒ page 81 .
Audi TT 2007 ➤
Note
Make sure no electrical wiring is trapped when fitting oil pan.
– Lightly lubricate O-rings on connector for mechatronic unit for
direct shift gearbox -J743- with gear oil
– Fill up with gear oil ⇒ page 72 and check gear oil level
⇒ page 72 .
– Observe correct procedure after connecting battery ⇒ Rep.
Gr. 27 .
1.3 Removing and installing mechatronic unit for direct shift gearbox -J743-
Removing
Proceed as follows:
Caution
Risk of damage to the gearbox.
♦ Do not run the engine or tow the vehicle with the oil pan
removed or when there is no gear oil in the gearbox.
Note
♦
Observe the general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
– Drain off gear oil ⇒ page 72 .
– Remove oil pan ⇒ page 82 .
1. Oil pan, mechatronic unit, gear oil pump - exploded view 85
Page 90
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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, front-wheel drive - Edition 12.2006
– Remove noise insulation (left-side) -arrows-.
Note
In order to pull the mechatronic unit out of the gearbox without
damage, you must first remove the cover for the gear oil pump.
– Unscrew bolts -arrows- and detach cover for gear oil pump
-A-.
Caution
The mechatronic unit can be damaged by electrostatic dis‐
charge.
♦ Do not touch the contact pins in the connector with bare
hands.
– Touch vehicle earth with your hand (without gloves) to dis‐
charge any static electricity.
Caution
The electrical wiring can be damaged.
♦ Do not pull on the electrical wiring.
– Using a small screwdriver -arrow-, carefully release electrical
connector for gearbox input speed sender -G182- and clutch
temperature sender -G509- and unplug connector.
Note
-G182- and -G509- will have to be renewed if the electrical wiring
is damaged.
86 Rep. Gr.35 - Gears, shafts
Page 91
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Release wiring leading to -G182- and -G509- from retaining
tabs on mechatronic unit -arrows I and II-.
– Remove bolts in the sequence -1 ... 10-.
Audi TT 2007 ➤
– Carefully pull the mechatronic unit out of the gearbox housing
until the long sender “arm” is clear of the gearbox housing.
– Carefully swivel out mechatronic unit downwards.
Caution
The mechatronic unit can be damaged.
♦ Do not lift the mechatronic unit by the sender “arm” or put
down the unit so it rests on the sender arm.
1. Oil pan, mechatronic unit, gear oil pump - exploded view 87
Page 92
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Put down the mechatronic unit correctly.
Caution
The mechatronic unit can be damaged.
♦ Do not lift the mechatronic unit by the sender “arm” or put
down the unit so it rests on the sender arm.
Note
The mechatronic unit must be renewed if the sender “arm” is
damaged.
Installing
• Tightening torques ⇒ page 80 , ⇒ page 81
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew bolts for mechatronic unit for direct shift gearbox J743- and for cover for gear oil pump.
♦
Renew cover for gear oil pump.
♦
When re-installing, renew O-rings -arrows- on connector for
mechatronic unit for direct shift gearbox -J743- .
♦
The O-rings are supplied with the replacement unit if the me‐
chatronic unit for direct shift gearbox -J743- is being renewed.
– Carefully fit mechatronic unit for direct shift gearbox -J743- in
gearbox housing.
• The mechatronic unit must be fitted onto the dowel pins
-arrow-.
• The “sender arm” must fit in the guide in the gearbox housing
as shown in the detail view.
• The electrical wiring for -G182- and -G509- must not become
trapped.
88 Rep. Gr.35 - Gears, shafts
Page 93
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Tighten bolts for mechatronic unit for direct shift gearbox -
J743- ; note correct tightening sequence ⇒ page 81 .
– Engage electrical wire in top retaining tab first -arrow II-, then
in bottom tab -arrow I-.
– Attach connector for -G182- and -G509- , and check that it is
properly engaged.
– Install oil pan ⇒ page 82 .
– Attach electrical connector for mechatronic unit for direct shift
gearbox -J743- and turn retainer to secure connector.
– Install cover for gear oil pump ⇒ page 90 .
– Fill up with gear oil ⇒ page 72 and check gear oil level
⇒ page 72 .
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
– Perform basic setting.
Audi TT 2007 ➤
1.4 Removing and installing gearbox input
speed sender -G182- and clutch tem‐
perature sender -G509-
Removing
Proceed as follows:
Caution
Risk of damage to the gearbox.
♦ Do not run the engine or tow the vehicle with the oil pan
removed or when there is no gear oil in the gearbox.
1. Oil pan, mechatronic unit, gear oil pump - exploded view 89
Page 94
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
Note
♦
Observe the general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
– Drain off gear oil ⇒ page 72 .
– Remove oil pan ⇒ page 82 .
– Remove mechatronic unit for direct shift gearbox -J743-
⇒ page 85 .
– Remove bolt -B-.
– Pull gearbox input speed sender -G182- and clutch tempera‐
ture sender -G509- -item A- out of gearbox together with
wiring.
Installing
• Tightening torques ⇒ page 80 , ⇒ page 82
Installation is carried out in reverse sequence; note the following:
– Lightly lubricate -G182- and -G509- with gear oil.
– Insert -G182- and -G509- in opening on side of gearbox and
secure with bolt ⇒ page 82 .
– Install mechatronic unit for direct shift gearbox -J743-
⇒ page 85 .
– Install oil pan ⇒ page 82 .
– Fill up with gear oil ⇒ page 72 and check gear oil level
⇒ page 72 .
– Connect vehicle diagnostic, testing and information system -
VAS 5051B- .
– Perform basic setting.
1.5 Removing and installing gear oil pump
Removing
Proceed as follows:
Caution
Risk of damage to the gearbox.
♦ Do not run the engine or tow the vehicle with the oil pan
removed or when there is no gear oil in the gearbox.
Note
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
♦
Observe the general repair instructions ⇒ page 8 .
– Drain off gear oil ⇒ page 72 and leave used oil collection and
extraction unit -V.A.G 1782- in position below gearbox.
90 Rep. Gr.35 - Gears, shafts
Page 95
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Remove noise insulation (left-side) -arrows-.
– Remove bolts -arrows- and detach cover for gear oil pump
-A-, allowing remaining gear oil in cover to drain off into used
oil collection and extraction unit -V.A.G 1782- .
Audi TT 2007 ➤
– Remove bolts -arrows- and detach cover for gear oil pump
-1-.
Installing
• Tightening torques ⇒ page 80 , ⇒ page 82
Installation is carried out in reverse sequence; note the following:
Note
♦
Renew bolts for gear oil pump and for cover for gear oil pump.
♦
Renew gasket -B- and cover for gear oil pump.
– Check that dowel sleeves -C- are fitted in gearbox housing.
– Slide drive shaft -A- for gear oil pump into gearbox as far as
stop, turning shaft slightly as required.
1. Oil pan, mechatronic unit, gear oil pump - exploded view 91
Page 96
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
• If drive shaft -A- for gear oil pump is inserted correctly, dimen‐
sion -a- = approx. 23 mm.
– If necessary, carefully remove any metal particles on sender
wheel -B- (the sender wheel must not be demagnetised).
– Remove paper gasket between gear oil pump and gearbox.
– Remove remaining pieces of paper gasket and clean inside of
gearbox.
– Clean sealing surfaces; they must be free from oil and grease.
– Fit new paper gasket between gear oil pump and gearbox, if
necessary, apply gear oil to hold it in place while assembling.
– Fit gear oil pump -1- onto drive shaft and secure with bolts
⇒ page 82 .
Note
There are different types of bolts -A or B-; observe correct tight‐
ening method ⇒ page 82 .
– Clean sealing surface between gearbox housing and cover for
gear oil pump.
– Fit cover -A- for gear oil pump and secure with bolts
⇒ page 82 .
– Fill up with gear oil ⇒ page 72 and check gear oil level
⇒ page 72 .
92 Rep. Gr.35 - Gears, shafts
Page 97
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
39 – Final drive - differential
1 Flange shafts and oil seals - exploded view
1 - Oil seal
❑ For flange shaft (right-
side)
❑ Renewing ⇒ page 98
2 - Flange shaft (right-side)
❑ Removing and installing
⇒ page 95
3 - Bolt
❑ 30 Nm
❑ Renew
4 - Nut
❑ 20 Nm
5 - Selector shaft lever
❑ Removing and installing
⇒ “1.5 Renewing oil seal
for selector shaft”,
page 100
6 - Oil seal for selector shaft
❑ Renewing ⇒ page 100
7 - Oil seal for flange shaft (leftside)
❑ Renewing ⇒ page 97
8 - Flange shaft (left-side)
❑ Removing and installing
9 - Bolt
❑ 30 Nm
❑ Renew
⇒ page 94
Audi TT 2007 ➤
Heat shield for drive shaft (right-side)
Bolts -arrows-
• 35 Nm
1. Flange shafts and oil seals - exploded view 93
Page 98
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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, front-wheel drive - Edition 12.2006
1.1 Removing and installing flange shaft
(left-side)
Special tools and workshop equipment required
♦ Used oil collection and extraction unit -V.A.G 1782-
Removing
Proceed as follows:
Note
♦
Observe general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
– Remove front left wheel.
– Release fasteners -1 ... 4- and remove centre noise insulation.
– Remove noise insulation (left-side) -arrows-.
94 Rep. Gr.39 - Final drive - differential
Page 99
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
– Carry out steps required for removing drive shaft (left-side);
however, bolt -2- securing drive shaft -1- to wheel hub does
not have to be removed ⇒ Rep. Gr. 40 .
– Move drive shaft (left-side) clear to the side and tie in position.
– Place used oil collection and extraction unit -V.A.G 1782- be‐
low gearbox.
– Remove bolt securing flange shaft (left-side). To do so, screw
two bolts into flange and counterhold flange shaft with suitable
lever.
– Pull out flange shaft together with spring, thrust washer and
tapered ring.
Installing
• Tightening torque ⇒ page 93 .
Installation is carried out in reverse sequence; note the following:
– Push flange shaft in against spring pressure securing bolt.
– Install drive shaft (left-side) ⇒ Rep. Gr. 40 .
– Secure swivel joint to wishbone ⇒ Rep. Gr. 40 .
– Secure coupling rod to anti-roll bar ⇒ Rep. Gr. 40 .
– Check gear oil level and top up as required ⇒ page 66 .
Audi TT 2007 ➤
1.2 Removing and installing flange shaft (right-side)
Special tools and workshop equipment required
♦ Used oil collection and extraction unit -V.A.G 1782-
Removing
Proceed as follows:
1. Flange shafts and oil seals - exploded view 95
Page 100
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Audi TT 2007 ➤
Direct shift gearbox 02E, front-wheel drive - Edition 12.2006
Note
♦
Observe general repair instructions ⇒ page 8 .
♦
Observe rules for cleanliness when working on the gearbox
⇒ page 10 .
– Release fasteners -1 ... 4- and remove centre noise insulation.
– Remove right noise insulation -arrows-.
– Remove heat shield for drive shaft (right-side) -arrows-.
– Unbolt drive shaft (right-side) from flange shaft on gearbox ⇒
Rep. Gr. 40 .
– Unplug electrical connector -1- at oil level and oil temperature
sender -G266- .
– Unclip bracket -2- for electrical wiring leading to oil level and
oil temperature sender -G266- at subframe.
96 Rep. Gr.39 - Final drive - differential
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