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

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 ➤

Direct shift gearbox 02E, front-wheel drive - Edition 12.2006

7. Securing gearbox to assembly stand

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Summary of Contents for TT 2007

Page 1: ...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 Workshop Manual Audi TT 2007 Direc...

Page 2: ...Repair Groups Repair Group 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 bec...

Page 3: ...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 leve...

Page 4: ...ing 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 explo...

Page 5: ...1 Gearbox identification The 6 speed direct shift gearbox 02E front wheel drive is in stalled in the Audi TT 2007 Allocation page 2 The gearbox code is located on the top of the gearbox near the gear...

Page 6: ...69 17 4 059 69 17 4 059 Z2 Z1 Final drive II for 5th 6th gear and reverse gear 69 22 3 136 69 22 3 136 1st gear 45 13 3 461 45 13 3 461 2nd gear 43 20 2 150 43 20 2 150 3rd gear 41 28 1 464 41 28 1 46...

Page 7: ...r 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 sh...

Page 8: ...t 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...

Page 9: ...J743 Gear oil gearbox and final drive The direct shift gearbox and front final drive have a common filling of gear oil page 66 Note Use only the correct type of gear oil for the direct shift gearbox...

Page 10: ...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...

Page 11: ...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 spe...

Page 12: ...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 di...

Page 13: ...blems 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...

Page 14: ...horoughly 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...

Page 15: ...f 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 circl...

Page 16: ...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 pl...

Page 17: ...h Special tools and workshop equipment required Assembly sleeve T10302 Retaining pin T10303 Note Assembly sleeve T10302 must be cleaned before use do not use an assembly sleeve if it is scratched Remo...

Page 18: ...formation in this document Copyright by AUDI AG 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 clut...

Page 19: ...mation in this document Copyright by AUDI AG Detach drive plate arrows Pry out circlip arrow using a screwdriver or long nose pliers Take multiple clutch out of gearbox After removing multiple clutch...

Page 20: ...nto 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...

Page 21: ...er plate carrier 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...

Page 22: ...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 c...

Page 23: ...r 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...

Page 24: ...ve 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...

Page 25: ...age 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...

Page 26: ...n 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...

Page 27: ...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 togeth...

Page 28: ...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 Select...

Page 29: ...gnosis 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...

Page 30: ...es 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 c...

Page 31: ...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...

Page 32: ...ton 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...

Page 33: ...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...

Page 34: ...ing 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 integra...

Page 35: ...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 t...

Page 36: ...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 s...

Page 37: ...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...

Page 38: ...sconnect 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...

Page 39: ...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 Lowe...

Page 40: ...he 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...

Page 41: ...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...

Page 42: ...r 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 Carefu...

Page 43: ...ightening torques page 30 Installation is carried out in reverse sequence note the following Note Renew locking plates and retaining clip for selector lever ca ble The selector lever cable must be ren...

Page 44: ...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 pre...

Page 45: ...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 o...

Page 46: ...nit 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 C...

Page 47: ...ity 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 Hos...

Page 48: ...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 clean...

Page 49: ...tched 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 br...

Page 50: ...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 access...

Page 51: ...onnecting 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...

Page 52: ...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 Atta...

Page 53: ...e bolt 1 and take out intake connecting pipe from be low Note Items 2 3 4 can be disregarded Remove nuts arrows and move bracket with wiring towards front of vehicle Free coolant hose running from con...

Page 54: ...G 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 N...

Page 55: ...ws 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...

Page 56: ...f information in this document Copyright by AUDI AG Remove remaining engine gearbox securing bolts 5 9 Press gearbox off dowel sleeves Pull gearbox off engine Carefully lower gearbox using engine and...

Page 57: ...e 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 i...

Page 58: ...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 j...

Page 59: ...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 Ad...

Page 60: ...AS 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 Se...

Page 61: ...pect to the correctness of information in this document Copyright by AUDI AG 7 Securing gearbox to assembly stand Special tools and workshop equipment required Support plate VW 309 Support clamp VW 31...

Page 62: ...nly 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...

Page 63: ...ort 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 tor...

Page 64: ...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...

Page 65: ...cial 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 Removing Proceed as follo...

Page 66: ...cting 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 sect...

Page 67: ...arts 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...

Page 68: ...ounting 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...

Page 69: ...ith respect to the correctness of information in this document Copyright by AUDI AG Installing Tightening torques page 59 Installation is carried out in reverse sequence note the following First secur...

Page 70: ...ow 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...

Page 71: ...and or failure of the gearbox 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 eng...

Page 72: ...es 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 fun...

Page 73: ...play group 019 and confirm entry by pressing Q button 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 ge...

Page 74: ...bility with respect to the correctness of information in this document Copyright by AUDI AG Display on VAS 5051B Read off gear oil temperature in display zone 1 Specification 35 C Unscrew inspection p...

Page 75: ...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 l...

Page 76: ...mittent 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 tem...

Page 77: ...otective 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...

Page 78: ...nning 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 inspe...

Page 79: ...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...

Page 80: ...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...

Page 81: ...under pressure when the engine is hot Cover filler cap on expansion tank with a cloth and open carefully to release pressure Open filler cap on expansion tank Unplug electrical connector 3 from air m...

Page 82: ...ried 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 i...

Page 83: ...er element slowly Note 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 Tighten...

Page 84: ...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...

Page 85: ...ling 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 Tighteni...

Page 86: ...sion 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 p...

Page 87: ...he 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 Caution When discon...

Page 88: ...s 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 an...

Page 89: ...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 ge...

Page 90: ...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 wit...

Page 91: ...g tabs on mechatronic unit arrows I and II Remove bolts in the sequence 1 10 Carefully pull the mechatronic unit out of the gearbox housing until the long sender arm is clear of the gearbox housing Ca...

Page 92: ...d 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...

Page 93: ...nstall 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 oi...

Page 94: ...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...

Page 95: ...used oil collection and extraction unit V A G 1782 Remove bolts arrows and detach cover for gear oil pump 1 Installing Tightening torques page 80 page 82 Installation is carried out in reverse sequen...

Page 96: ...earbox 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 necess...

Page 97: ...ight 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 sh...

Page 98: ...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 Obs...

Page 99: ...o 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 Inst...

Page 100: ...ss 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 s...

Page 101: ...d tapered ring Installing Tightening torque page 93 page 93 Installation is carried out in reverse sequence note the following Push flange shaft in against spring pressure securing bolt Install drive...

Page 102: ...tool T20143 2 Installing Pack space between sealing lip and dust lip arrow half full with sealing grease Parts catalogue Drive in new oil seal onto stop using thrust piece 3305 Take care to keep seal...

Page 103: ...ote The oil seal can be renewed with the gearbox installed Observe general repair instructions page 8 Observe rules for cleanliness when working on the gearbox page 10 Remove flange shaft right side p...

Page 104: ...aling lip and dust lip arrow half full with sealing grease Parts catalogue Install flange shaft right side page 95 Check gear oil level and top up as required page 66 1 5 Renewing oil seal for selecto...

Page 105: ...ctor shaft Pry out oil seal with extractor tool T20143 1 Installing Tightening torque page 93 Installation is carried out in reverse sequence note the following Lightly oil outer circumference of new...

Page 106: ...the correctness of information in this document Copyright by AUDI AG Fit selector shaft lever on selector shaft and secure in place arrow Selector shaft lever can only be fitted in one correct positio...

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