Audi TT 2007 Operating instructions

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.
Repair Manual
Audi TT 2007 ➤
Manual Transmission
Edition 10.2009
Service
Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - General, 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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt D3E8007A75E

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.
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Overall Transmission Ratio i, Calculating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Powertrain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Code Letters, Assembly Allocation, Ratios and Capacities . . . . . . . . . . . . . . . . . . . . . . . . 9
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Determining Clutch Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Clutch System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Information Regarding the Removal and Installation of the Clutch Master or Slave Cylinder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Clutch Master Cylinder and Clutch Slave Cylinder, Function Test . . . . . . . . . . . . . . . . . . . . 13
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Clutch Mechanism Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Pedal Assembly, Master Cylinder Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Hydraulics Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Clutch Release Mechanism, Clutch Slave Cylinder Assembly Overview . . . . . . . . . . . . . . 21
2.5 Sachs Clutch Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6 LuK Clutch Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Hose/Line Assembly or Plastic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Over-Center Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Clutch Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.6 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.7 Slave Cylinder with Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.8 Sachs Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.9 LuK Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.1 Manual Transmission, Checking Gear Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.2 Gear Oil in Bevel Box, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Gear Oil in Bevel Box, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Selector Mechanism Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.2 Shift Knob and Covers Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Shift Lever and Shift Housing for Vehicles to VIN 8J-7-013000 Assembly Overview . . . . 56
2.4 Shift Lever and Shift Housing for Vehicles from VIN 8J-7-013001 Assembly Overview . . 59
2.5 Shift Cable and Selector Cable to Model Year 2007 Assembly Overview . . . . . . . . . . . . . . 61
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
Contents i

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2.6 Transmission Shift Lever and Selector Relay Lever to Model Year 2007 Assembly
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.7 Shift Cable and Selector Cable from Model Year 2008 Assembly Overview . . . . . . . . . . . . 65
2.8 Shift Mechanism, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.9 Subframe Mount Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.10 Transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.11 Transmission Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.12 Transmission Housing and Shift Mechanism Assembly Overview . . . . . . . . . . . . . . . . . . . . 77
2.13 Input Shaft, Output Shafts, Differential, Bevel Box and Selector Rods Assembly Overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.14 Transmission Housing Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.15 Clutch Housing Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.16 Shift Mechanism Assembly Overview, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.17 Shift Forks Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.1 Bevel Box Oil Filler Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2 Manual Transmission Oil Filler Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.3 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.1 Shift Knob with Shift Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3 Shift Cable and Selector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.4 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.5 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.6 Transmission, Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.7 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.8 Transmission Mount, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.9 Transmission Mount, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.10 Pendulum Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.11 Bevel Box, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.12 Bevel Box, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.13 Input Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.14 Selector Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.15 Selector Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2 Transmission without Circlip A for Cap/Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 Transmission with Circlip A for the Cap/Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.4 Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.5 Transmission Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.6 Clutch Housing, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Grooved Ball Bearing Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.1 Input Shaft Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.2 Output Shaft for 1st to 4th Gears Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.3 Output Shaft, 1st to 4th Gears, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.4 Output Shaft for 5th/6th Gear/Reverse Gear Assembly Overview . . . . . . . . . . . . . . . . . . . . 187
2.5 Output Shaft for 5th/6th Gear and Reverse Gear, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . 188
3 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.1 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.2 Output Shaft, 1st to 4th Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
ii Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3.3 Output Shaft for 5th/6th Gear and Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.1 Flange Shaft and Seals on Transmission Assembly Overview . . . . . . . . . . . . . . . . . . . . . . 219
1.2 Flange Shaft and Seals on Bevel Box Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . 220
1.3 Differential Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.4 Adjustment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.5 Differential, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.1 Left Flange Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.2 Left Flange Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.3 Shaft Sealing Ring for Bevel Box with Manual Transmission Installed, Replacing . . . . . . 229
3.4 Right Flange Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.5 Right Flange Shaft Seat on Outer Bevel Box, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.6 Right Flange Shaft Needle Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.7 Seal between Transmission and Bevel Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.8 Bevel Box Drive Flange Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.1 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
Contents iii

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
iv Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
00 – General, Technical Data
1 General Information
⇒ “1.1 Location on Transmission”, page 1
⇒ “1.2 General Repair Information”, page 2
⇒ “1.3 Contact Corrosion”, page 2
⇒ “1.4 Repair Instructions”, page 2
⇒ “1.5 Overall Transmission Ratio i, Calculating”, page 6
1.1 Location on Transmission
The 6-speed manual transmission 02Q , AWD is installed in the
Audi TT from MY 2007. Allocation, refer to
⇒ “3.1 Code Letters, Assembly Allocation, Ratios and Capacities”,
page 9 .
Location on Transmission
♦ Engine code and build date-arrow 1-
♦ Manual Transmission 02Q All Wheel Drive-arrow 2-
Manual Transmission 02Q AWD -arrow-
Transmission Code Letters and Build Date -arrow-
Example: GUM 04 08 3
I I I I
Code letters Day Month Year 2003 of pro‐
duction
Additional data gives information about the factory.
Note
The transmission code letters are also included on the vehicle
data labels.
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
1. General Information 1

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1.2 General Repair Information
The maximum possible care and cleanliness and proper tools are
essential to ensure satisfactory and successful transmission re‐
pairs. The usual basic safety precautions also apply when carry‐
ing out vehicle repairs.
A number of generally applicable instructions for individual repair
operations, which are otherwise mentioned at various points in
the Workshop Manual, are summarized here. It applies to this
repair manual.
1.3 Contact Corrosion
Contact corrosion can occur if non-approved fasteners are used
such as bolts, nuts, washers, etc.
For this reason, only connecting elements with a special surface
coating are installed.
In addition, rubber or plastic parts and adhesive are made of ma‐
terials that do not conduct electricity.
If you are not sure about the suitability of parts, install new parts.
Refer to the electronic parts catalog ETKA.
Note
♦ The transmission housing consists of a magnesium alloy.
♦ We only recommend original replacement parts. They have
been checked and are compatible with aluminum.
♦ It is recommended to use Audi accessories.
Caution
Warranty does not cover contact corrosion damage.
1.4 Repair Instructions
Special Tools and Equipment
♦ Complete list of special tools used in this Workshop Manual,
see ServiceNet under Special Tools.
Transmission
♦ Thoroughly clean all connections and the surrounding area
before disconnecting.
♦ When installing the transmission, make sure that the align‐
ment sleeves between the engine and transmission are posi‐
tioned correctly.
♦ Allocate bolts and other component using the. Refer to the
electronic parts catalog ETKA.
♦ When installing mounting brackets, as well as other waxed
components, the contacts surfaces must be cleaned. Contact
surfaces must be free of grease and wax.
♦ After replacement of the manual transmission with a bevel
box, check the oil level in the manual transmission. Refer to
⇒ “1.1 Manual Transmission, Checking Gear Oil Level”, page
47 and in the bevel box
⇒ “1.2 Gear Oil in Bevel Box, Checking”, page 48 .
♦ Capacities, refer to
⇒ “3.1 Code Letters, Assembly Allocation, Ratios and Capaci‐
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
2 Rep. Gr.00 - General, Technical Data

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ties”, page 9 , Specification, refer to the electronic parts
catalog ETKA.
Shaft Seals, Sealing Rings, O-rings, Seals
♦ Always replace shaft sealing rings, O-rings, and seals.
♦ After removing gaskets and seals, always inspect the contact
surfaces at housing or shaft for burrs resulting from removal,
or for other signs of damage.
♦ Before installing the shaft seals, lightly oil the outer circumfer‐
ence and fill the space between the sealing lips -arrow- half‐
way with sealing grease -G 052 128 A1- .
♦ The open side of the shaft seals point toward the fluid to be
sealed in.
♦ When pressing in new shaft seal, make sure the sealing lip
does not run on the same point as the sealing lip of the old
seal (use insertion depth tolerances).
♦ To prevent crushing when installing, lightly lubricate O-rings
before inserting.
♦ After replacement of seals, O-rings, and shaft sealing rings,
check the oil level in the manual transmission. Refer to
⇒ “1.1 Manual Transmission, Checking Gear Oil Level”, page
47 or in the bevel box
⇒ “1.2 Gear Oil in Bevel Box, Checking”, page 48 .
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ing compounds.
♦ Apply the sealing compound -AMV 188 200 03- evenly and not
too thick.
♦ Do not allow sealing compound to enter ventilation openings.
Fasteners
♦ Do not stretch the circlips.
♦ Replace damaged or stretched circlips.
♦ Circlips must locate properly in the groove.
♦ Replace spring pins. Installed position: the slit -A- should be
in line with the line of force -arrow-.
Bolts and Nuts
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
1. General Information 3

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♦ Loosen bolts and nuts in reverse of tightening sequence.
♦ Tighten and loosen bolts or nuts for securing covers and hous‐
ings without tightening sequence in diagonal sequence in
stages.
♦ Replace self-locking bolts and nuts.
♦ The tightening specifications stated apply to non-oiled nuts
and bolts.
♦ Threaded holes into which self-locking bolts or bolts coated
with locking fluid are screwed, must be cleaned (for example
tap). Otherwise there is a risk that the bolts will shear the next
time they are removed.
♦ Ensure with screwed connections that the contact surfaces as
well as the visible surfaces of nuts and bolts are waxed after
assembly, if necessary.
Mount
♦ Install new tapered roller bearing as supplied and do not use
additional oil.
♦ Install various bearings (removed tapered roller bearings) into
transmission, lubricated with gear oil.
♦ Heat the inner rings of the tapered roller bearings to approxi‐
mately 100 °C (212 °F) with the inductive heat unit -VAS 6414-
before installing. Press on to the stop when installing so that
there is no axial clearance.
♦ Do not interchange the outer or inner races of bearings of the
same size.
♦ Tapered roller bearings installed on a shaft must be replaced
as a set and use same make of bearings.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
Adjusting Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to find the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Only install perfect shims.
Synchronizer Rings
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
4 Rep. Gr.00 - General, Technical Data

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♦ When reusing synchronizer rings, do not interchange them
and always assign them to the same selector gear.
♦ Check for wear and replace if necessary.
♦ Check the grooves -arrow 1- of synchronizer ring -A- and inner
race for flat areas (grooves are worn).
♦ For coated synchronizer rings, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the intermediate
ring on the outer contact surface -arrow 2- and inner contact
surface -arrow 3- for grooves, scoring and blue coloring (from
overheating).
♦ Check taper of drive gear for grooves and scoring.
♦ Coat with gear oil before installing.
Gears
♦ Clean prior to pressing on.
♦ For installation heat to approximately 100 °C (212 °F) with the
inductive heat unit -VAS 6414- and during installation press
on to the stop so that there is no axial clearance.
Selector Gears and Sliding Sleeves
♦ After installing, check 1st through 6th gear for minimal amount
of axial clearance and for ease of movement.
♦ Damage to the synchronizer ring or gear wheel:
A - Worn clutch spline camber on the synchronizer ring or gear
wheel
♦ Compare: synchronizer ring or gear wheel not damaged:
B - Worn clutch spline camber on the synchronizer ring or gear
wheel
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
1. General Information 5

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♦ Picture of damage on the locking collar:
C - Worn longitudinal inner spline camber and the locking collar
♦ Comparison: locking collar not damaged:
D - Undamaged longitudinal inner spline camber and the locking
collar
Clutch Mechanism, Clutch
♦ If the clutch pedal does not return to the starting position (rest
position) after the recoupling procedure, bleed the clutch sys‐
tem (further measures. Refer to
⇒ “1.3 Information Regarding the Removal and Installation of
the Clutch Master or Slave Cylinder”, page 13 ).
♦ Do not tilt clutch pressure plate; loosen and tighten one after
another in 90° increments.
♦ To reduce odor caused by a burnt clutch, thoroughly clean the
transmission housing around the clutch as well as the engine
on the transmission side.
♦ Only use compressed air to blow out the dual-mass flywheel.
♦ The clutch pressure plates are corrosion-protected and
greased. With the exception of the friction surface on the clutch
plate, do not clean the pressure plate. This will shorten the
service life of the clutch considerably.
♦ The friction surfaces on the pressure plate and on the dual
mass flywheel must be cleaned thoroughly (degreased).
1.5 Overall Transmission Ratio i, Calculat‐
ing
Example:
6th Gear Final Drive
Driving gear ZG1 = 34 ZA1 = 22
Driven gear ZG2 = 31 ZA2 = 72
i = ZG2 : ZG1 1)
iG = gear ratio = ZG2 : ZG1 = 31 : 34 = 0.912
iA = axle ratio = ZA2 : ZA1 = 72 : 22 = 3.273
itotal = total ratio = iG x iA = 0.912 x 3.273 = 2.985
1) Z1 = No. of teeth drive gear, Z2 = No. of teeth driven gear
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
6 Rep. Gr.00 - General, Technical Data

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 Description and Operation
⇒ “2.1 Powertrain Overview”, page 7
2.1 Powertrain Overview
Designation
Arrows point in direction of travel
1 - Engine
2 - Clutch
3 - Manual Transmission
4 - Input Shaft
5 - Output Shaft II - 5th/6th
Gear/Reverse Gear
6 - Output Shaft I - 1st to 4th
Gear
7 - Differential
8 - Bevel Box
9 - Driveshaft
10 - Haldex Clutch
11 - Rear Final Drive
12 - Differential
Gear Ratios
Arrows point in direction of travel
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
2. Description and Operation 7

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I - 1st Gear
II - 2nd Gear
III - 3rd Gear
IV - 4th Gear
V - 5th Gear
VI - 6th Gear
R - Reverse Gear
A - Final Drive
W1 - Front Bevel Drive
W2 - Rear Bevel Drive
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
8 Rep. Gr.00 - General, Technical Data

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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3 Specifications
⇒ “3.1 Code Letters, Assembly Allocation, Ratios and Capacities”,
page 9
3.1 Code Letters, Assembly Allocation, Ratios and Capacities
Manual Transmission
Code Letters JLV JYV KDP
Manufactured from 04.06 11.06 06.07
to 11.06 05.07 02.08
Allocation Model Audi TT from MY 2007 Audi TT from MY
2007
Audi TT from MY
2007
Engine 3.2l MPI - 184 kW 3.2l MPI - 184 kW 3.2l MPI - 184 kW
Gear ratios Final drive I
for 1st to 4th
gear
72 : 17 = 4.235 72 : 17 = 4.235 72 : 17 = 4.235
Z2 : Z1 = i Final drive II
for 5th/6th gear
and reverse
gear
72 : 22 = 3.273 72 : 22 = 3.273 72 : 22 = 3.273
1st gear 47 : 14 = 3.357 47 : 14 = 3.357 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469 47 : 32 = 1.469 47 : 32 = 1.469
4th gear 37 : 34 = 1.088 37 : 34 = 1.088 37 : 34 = 1.088
5th gear 41 : 37 = 1.108 41 : 37 = 1.108 41 : 37 = 1.108
6th gear 31 : 34 = 0.912 31 : 34 = 0.912 31 : 34 = 0.912
Reverse gear 34 : 23 x 14 : 14 = 3.990 34 : 23 x 14 : 14 =
3.990
34 : 23 x 14 : 14 =
3.990
itotal in highest gear 2.985 2.985 2.985
Capacity in manual transmission 2.3 liters
Capacity in bevel box 0.9 liters
Hydraulic Hydraulic
Please obtain the following information from the electronic parts catalog ETKA.
♦ Gear oil specification
♦ Bevel box axle oil specification
♦ Drive axle flanges allocation
♦ Clutch allocation
♦ Rear final drive allocation
Manual transmission
Code letters KNT KZN
Manufactured from 01.08 12.09
to 12.09
Allocation Model Audi TT from MY 2007 Audi TT from MY 2007
Engine 3.2l MPI - 184 kW 3.2l MPI - 184 kW
Gear ratios Final drive I
for 1st to 4th gear
72 : 17 = 4.235 72 : 17 = 4.235
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
3. Specifications 9

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Manual transmission
Code letters KNT KZN
Z2 : Z1 = i Final drive II
for 5th/6th gear and
reverse gear
72 : 22 = 3.273 72 : 22 = 3.273
1st gear 47 : 14 = 3.357 47 : 14 = 3.357
2nd gear 48 : 23 = 2.087 48 : 23 = 2.087
3rd gear 47 : 32 = 1.469 47 : 32 = 1.469
4th gear 37 : 34 = 1.088 37 : 34 = 1.088
5th gear 41 : 37 = 1.108 41 : 37 = 1.108
6th gear 31 : 34 = 0.912 31 : 34 = 0.912
Reverse gear 34 : 23 x 14 : 14 = 3.990 34 : 23 x 14 : 14 = 3.990
itotal in highest gear 2.985 2.985
Capacity in manual transmission 2.3 liters
Capacity in bevel box 0.9 liters
Hydraulic Hydraulic
Please obtain the following information from the electronic parts catalog ETKA.
♦ Gear oil specification
♦ Bevel box axle oil specification
♦ Drive axle flanges allocation
♦ Clutch allocation
♦ Rear final drive allocation
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
10 Rep. Gr.00 - General, Technical Data

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30 – Clutch
1 General Information
⇒ “1.1 Determining Clutch Manufacturer”, page 11
⇒ “1.2 Clutch System, Bleeding”, page 12
⇒ “1.3 Information Regarding the Removal and Installation of the
Clutch Master or Slave Cylinder”, page 13
⇒ “1.4 Clutch Master Cylinder and Clutch Slave Cylinder, Func‐
tion Test”, page 13
1.1 Determining Clutch Manufacturer
Note
A clutch could be installed from either of the manufacturers,
Sachs or LuK.
Clutch makes can be differentiated with transmission installed as
follows:
– Remove noise insulation in center by loosening fasteners
-1 through 4-.
Some recesses -arrows- are located between engine -A- and
transmission -B- in lower area of engine oil pan.
– Through these recesses, inspect the outer contour of the fly‐
wheel.
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
1. General Information 11

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A - Round Outer Contour -arrows- = Clutch Made by Sachs
Assembly overview - clutch made by Sachs. Refer to
⇒ “2.5 Sachs Clutch Assembly Overview”, page 22 .
B - Round Outer Contour -arrows 1- and a Peripheral Depression
-arrow 2- = Clutch Made by LuK
Assembly overview - clutch made by LuK. Refer to
⇒ “2.6 LuK Clutch Assembly Overview”, page 25 .
Round Outer Contour -arrows 1- and a Peripheral Depression
-arrow 2- = Clutch Made by LuK
Assembly overview - clutch made by LuK. Refer to
⇒ “2.6 LuK Clutch Assembly Overview”, page 25 .
1.2 Clutch System, Bleeding
Note
♦ After working on the hydraulic clutch mechanism, the system
must be bled.
♦ During the following procedures, make sure that brake fluid
does not leak onto the longitudinal member or the transmis‐
sion.
♦ Before bleeding, fill the brake fluid reservoir to the max mark‐
ing with brake fluid.
Special tools and workshop equipment required
♦ Brake Filler/Bleeder Unit -VAS 5234-
♦ Brake fluid specifications, refer to ⇒ Brake System; Rep. Gr.
47. ; General Information
Procedure
• Tightening specification, refer to
⇒ “2.3 Hydraulics Assembly Overview”, page 19 .
– Completely remove the air filter housing. Refer to ⇒ Fuel In‐
jection and Ignition; Rep. Gr. 24 ; Removal and Installation .
– Pull the clutch pedal back to the rest position.
– Connect the -VAS 5234- to the brake fluid reservoir.
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
12 Rep. Gr.30 - Clutch

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– Remove the protective cap on the vent screw -arrow- and
connect bleeder bottle hose -A-.
– Switch on brake filler/bleeder unit.
• Working pressure 2.0 bar positive pressure.
–Now open the vent screw approximately 1/4 turn and let 100
cm3 brake fluid drain out.
– With the vent screw open, press the clutch pedal by hand very
quickly 15 to 20 times from one stop to the other (approxi‐
mately 2 presses per second).
– Close the vent screw.
– Switch the -VAS 5234- off and completely release the pres‐
sure on the bleeder unit.
– Now press the clutch pedal slowly 10 times from stop to stop.
– Check clutch system function when doing so.
– Pull off bleeder hose and set protective cap in place.
– Remove the -VAS 5234- from the brake fluid reservoir.
– Install the air filter housing. Refer to ⇒ Fuel Injection and Ig‐
nition; Rep. Gr. 24 ; Removal and Installation .
1.3 Information Regarding the Removal and
Installation of the Clutch Master or Slave
Cylinder
♦ If the clutch master or slave cylinder is to be replaced as a
result of a suspected defect, it must first be checked for func‐
tion. Refer to
⇒ “1.4 Clutch Master Cylinder and Clutch Slave Cylinder,
Function Test”, page 13 .
♦ If the clutch slave cylinder is removed from the transmission
with hose/line assembly connector, do not operate (depress)
clutch pedal any more. Otherwise, the pistons are pushed out
of the clutch slave cylinder and thus damaged.
♦ Carefully actuate the clutch pedal after installing the clutch
slave cylinder. If an abnormally difficult pressure point is no‐
ticed when depressing the clutch pedal, do not depress the
clutch pedal any further. The plunger of the clutch slave cyl‐
inder was probably guided past the clutch release lever. Be‐
yond a pedal force of approximately 300 N, clutch slave
cylinder is destroyed.
1.4 Clutch Master Cylinder and Clutch
Slave Cylinder, Function Test
Before replacing master or slave cylinder, you must first carry out
the corresponding tests in the event of the following problems.
Noises when actuating the clutch:
♦ First check the over-center spring and the clutch pedal switch
for noises.
♦ If noises are heard, remove the over-center spring and repeat
the test.
♦ Replace affected component.
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
1. General Information 13

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Clutch pedal remains on floor or does not return to rest position
after recoupling (clutch pedal no longer actuated):
♦ Check whether clutch pedal returns completely to rest posi‐
tion, thus freeing bleeder hole in clutch master cylinder.
♦ The bleeder hole is integrated into the clutch slave cylinder. It
is not visible from the outside.
♦ The clutch hydraulic system can only bleed itself when the
bleeder hole is clear.
♦ Explain to the customer that they should not rest their foot on
the clutch pedal. It can interfere with the self-bleeding function
of the clutch system, because the bleeder hole in the clutch
slave cylinder can not perform its function.
♦ The following can inhibit the self-bleeding function in the clutch
system: loose footwell trim or floor mats, a blocked clutch ped‐
al switch or drivers who constantly rest their foot on the clutch
pedal.
Check the entire hydraulic system for leaks.
♦ Check the brake fluid level in the brake fluid reservoir.
♦ Visually inspect the clutch master and slave cylinders as well
as hose/line assembly with its connecting points for leaks to
outside.
♦ If you find you leaks, you must replace the affected compo‐
nent.
♦ Bleed the clutch system. Refer to
⇒ “1.3 Information Regarding the Removal and Installation of
the Clutch Master or Slave Cylinder”, page 13 .
Pedal force:
♦ Approximately 140 N over entire life of clutch
High pedal force:
♦ Pressure plate/clutch plate mechanical defect. Refer to
⇒ “2.5 Sachs Clutch Assembly Overview”, page 22 or
⇒ “2.6 LuK Clutch Assembly Overview”, page 25 .
Clutch does not disengage or does not disengage completely:
♦ Air in hydraulic system, bleed clutch system. Refer to
⇒ “1.3 Information Regarding the Removal and Installation of
the Clutch Master or Slave Cylinder”, page 13 or check hy‐
draulic system for external and internal leakage
♦ Clutch plate is difficult to move on the drive shaft splines (for
example: due to rust or dirt)
♦ Foreign body in the clutch system
♦ Pressure plate/clutch plate mechanical defect. Refer to
⇒ “2.5 Sachs Clutch Assembly Overview”, page 22 or
⇒ “2.6 LuK Clutch Assembly Overview”, page 25 .
♦ Incorrect components installed or components missing (for
example intermediate plate or alignment sleeves) during re‐
pair work.
Audi TT 2007 ➤
Manual Transmission - Edition 10.2009
14 Rep. Gr.30 - Clutch