Direct Shift Auto Transmission

2006 Audi TT
TRANSMISSION 6 Spd. Direct Shift Automatic Transmission 02E, All Wheel Drive
TRANSMISSION
6 Spd. Direct Shift Automatic Transmission 02E, All Wheel Drive
00 TECHNICAL DATA
TRANSMISSION IDENTIFICATION
The "6-speed direct shift automatic transmission02E All Wheel Drive" is installed
in the Audi TT 1999 -->. Allocation --> Code letters, transmission allocation,
ratios, equipment.
Fig. 1: Locating Transmission Identification

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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5:49:37 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2006 Audi TT
The transmission code is located on the top of the transmission, near the oil cooler.
Example:
GKF = transmission code
10.05.2 = date of production: 10th May 2002
The code letters of the transmission are also given on the vehicle data stickers.
CODE LETTERS, TRANSMISSION ALLOCATION, RATIOS, EQUIPMENT
Code letters, transmission allocation, ratios, equipment
Direct shift transmission 02E 02E 02E

Transmission Code letters GYU GYV GYW
from
Manufactured 07.03 07.03 07.03
to
Audi TT Audi TT
Allocation Model Audi TT
USA Japan
3.2 ltr. - 184 3.2 ltr. - 184 3.2 ltr. - 184
Engine kW6 kW6 kW6
cylinders cylinders cylinders
Final drive I for 1st to 69 : 17 = 69 : 17 = 69 : 17 =
Ratios
4th gear 4.059 4.059 4.059
Z :Z Final drive II for 5th/6th 69 : 22 = 69 : 22 = 69 : 22 =
2 1 gear and reverse gear 3.136 3.136 3.136
45 : 13 = 45 : 13 = 45 : 13 =
1st gear
3.46 3.46 3.46
45 : 22 = 45 : 22 = 45 : 22 =
2nd gear
2.05 2.05 2.05
45 : 31 = 45 : 31 = 45 : 31 =
3rd gear
1.45 1.45 1.45
41 : 38 = 41 : 38 = 41 : 38 =
4th gear
1.079 1.079 1.079
39 : 35 = 39 : 35 = 39 : 35 =
5th gear
1.11 1.11 1.11
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2006 Audi TT
35 : 38 = 35 : 38 = 35 : 38 =
6th gear
0.92 0.92 0.92
22 : 14 x 22 : 14 x 22 : 14 x
Reverse gear 33 : 13 = 33 : 13 = 33 : 13 =
3.99 3.99 3.99
Overall ratio in top gear 2.89 2.89 2.89
Allocation: rear final drive Designation: 02D
CALCULATING RATIO "I"
Calculating ratio "i"
Example:
6th gear Final drive

Drive gear ZG = 38 ZA = 22
1 1
Driven gear ZG = 35 ZA = 69
2 2
i = Z : Z * See note
2 1
i = gear ratio = ZG : ZG = 35 : 38 = 0.92

G 2 1
i = axle ratio = ZA : ZA = 69 : 22 = 3.136

A 2 1
i = overall ratio
ov
=i x i = 0.92 x 3.136 = 2.89

G A
* Z = No. of teeth on drive gear, Z = No. of teeth on driven gear

1 2
CAPACITIES
Capacities
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Transmission capacity
Capacities Direct shift transmission 02E

Initial filling 7.2 ltr.
Changing approx. 6.0 ltr.
Change interval
Lubricant, Gear oil for direct shift transmission 02EPart No: Parts
specification Catalog
Only the gear oil available as a replacement part may be used for the direct shift
transmission 02E. Other oils cause faults and/or failure of the transmission.
When changing gear oil always replace the gear oil filter --> Gear oil filter,
removing and installing.
Checking gear oil level and changing gear oil --> Gear oil level, checking and
topping up.
Bevel box capacity
Capacities Bevel box

Initial filling 0.9 ltr.
Changing Filled for life, no change
Lubricant
Only the gear oil available as a replacement part may be used for the bevel box.
Other oils cause faults and/or failure of the bevel box.
Checking oil level in bevel box --> Bevel box gear oil, checking and topping up.
SAFETY PRECAUTIONS
Safety precautions
Observe the following precautions if test and measuring instruments are required
during a test drive:
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CAUTION: Test equipment must always be secured on the

rear seat and operated from that position by a
second person.
If test and measuring instruments are operated
from the front passengers seat and the vehicle is
involved in an accident, there is a possibility that
the person sitting in this seat may suffer serious
injuries when the airbag is triggered.
Observe the following precautions to avoid possible injury and/or the destruction of
electrical and electronic components:
Switch off ignition before disconnecting and connecting measuring instruments
and testers.
CAUTION: Follow steps required when disconnecting

battery --> 27 BATTERY, STARTER,
GENERATOR, CRUISE CONTROL .
Always switch off the ignition before
disconnecting or connecting the battery to
ensure the transmission control module is not
damaged.
Safety functions of transmission control module
In the event of a failure of one or more components/sensors, the transmission

control module will activate appropriate backup functions. This ensures that the
transmission will not be damaged, however, the function and quality of the gear
shifts will be impaired.
Faults detected by the transmission are classified in four different categories.
1) The fault is stored and a backup program enables the vehicle to drive on (in
some cases with restrictions). The driver will not be made aware of the
problem, as it is not critical to driving safety or to the transmission itself. The
gear selection indicator in the instrument cluster will continue to show the
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selector lever position currently engaged in the normal way. If at all, the driver
will only notice the fault if he experiences driveability problems and will then
contact an Audi dealer to identify the cause.
2) Certain positions on the gear selection indicator in the instrument cluster
start to flash. This is to inform the driver that this particular selector lever
position is currently not available. Example: position "D" is not available when
selector lever is in position "R" and vehicle is still rolling backwards. In this
case, selector lever position "D" will start to flash on the gear selection
indicator in the instrument cluster. The transmission control module prevents
the 1st gear from being engaged in order to avoid damage to the transmission.
1st gear will be engaged once the vehicle has come to a standstill.
3) The complete gear selection indicator in the instrument cluster is lit up and
flashing. The current selector lever position is indicated in the instrument
cluster (e.g. "D" is highlighted). This is an indication that the transmission has
been overloaded or the maximum temperature in the transmission has been
exceeded (overheating), e.g. by towing a load that was too heavy.
4) If the complete gear selection indicator in the instrument cluster is lit up and
flashing, this means that a serious fault in the transmission has been identified.
The display in the instrument cluster no longer shows the current selector lever
position. The fault is critical with regard to driving safety or to the transmission
itself. It may no longer be possible to use all gears. The driver is made aware
by the flashing gear selection indicator that he should immediately contact an
Audi dealer.
NOTES ON THE DIRECT SHIFT TRANSMISSION 02E
Notes on the direct shift transmission 02E
Transmission
The direct shift transmission 02E is also referred to as a dual-clutch transmission.

The engine torque is transferred to the transmission via the dual-mass flywheel. The
set-up of the transmission is the same as that of a 6-speed manual transmission. The
two multi-plate "wet" clutches are regulated hydraulically and actuated alternately
so that the transmission is operated like an automatic transmission, i.e. the gears are
engaged automatically or manually via Tiptronic. There is no clutch pedal. For
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more detailed information refer to the relevant Self-Study Program.

Safety functions of the transmission control module
If one or more of the system components or sensors fails, the Transmission Control
Module (TCM) -J217- will switch to a corresponding back-up mode, or emergency
running program. This enables the transmission to continue operating without
becoming damaged, but will impair the operation and smoothness of the gearshifts.
For more detailed information refer to the relevant Self-Study Program.
Selector mechanism
On an automatic transmission, information regarding the selector lever position is

transmitted via the selector lever cable and the multi-function switch. The dual-
clutch transmission, however, has a separate control module in the selector
mechanism to transmit information on selector lever positions and gear shifts to the
transmission control module via the CAN bus. This means that gear shifts are
effected without a cable. Exception: In selector lever position "P" the selector lever
cable is used to mechanically engage the parking lock.
Gear oil
The gear oil level in transmission and final drive (front) is checked and topped up
together --> Gear oil level, checking and topping up.
Only the oil available as a replacement part may be used in the direct shift
transmission 02E. Other oils cause faults and/or failure of the transmission. For
replacement part number --> Capacities.
The oil level in the bevel box is checked and topped up separately --> Bevel box
gear oil, checking and topping up.
Only the gear oil available as a replacement part may be used for the bevel
box. Other oils cause faults and/or failure of the bevel box.
Regulations for the disposal of oil
Make sure that used oil is taken to the appropriate collection center for recycling.
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Improper disposal of used oil endangers the environment.

It is forbidden to add solvents, brake fluid, coolant or similar to the used oil.
Please observe the information shown on the packaging of the oil.
Gear shift point variations for hills
An additional gear change map automatically selects gear changes for hills
depending on accelerator pedal position and driving speed.
Gear change map for extreme uphill stretches is matched to engine output
Gear change map for extreme downhill stretches is matched to the braking
effect of the engine
The engine braking effect can also be fully exploited via a specific gear, e.g. on
hills when towing a trailer, by directly selecting a gear with the tiptronic.
NOTES ON TOW-STARTING AND TOWING
Notes on tow-starting and towing
CAUTION: When the vehicle is being towed, the selector lever

must be set to position N and the vehicle must not be
towed for more than 50 km or at a speed in excess of
50 km/h. Otherwise, the transmission will be
damaged.
NOTE: It is not possible to start the engine by means of tow-

starting, for instance, in the case of insufficient battery
charge or if the starter is not working.
REPAIR INSTRUCTIONS
Repair instructions
Proper tools and the maximum possible care and cleanliness are essential for
successful transmission repairs. The usual basic safety precautions also naturally
apply when performing vehicle repairs.
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A number of generally applicable instructions for the various repair procedures -

which were previously repeated at numerous places in the article - are summarized
here. They apply to the work described in this article.
Guided fault finding, vehicle self-diagnosis and testing system
Fig. 2: VAS 5051 Vehicle Diagnosis, Testing & Information System

Before servicing the transmission, the exact cause of the failure must be
determined as precisely as possible via the vehicle diagnostic, testing and
information system VAS5051 in the modes "Guided Fault Finding", "vehicle
self-diagnosis" and "testing system".
Special tools
For a compilation of the special tools used in this article refer to "Special tools" and
"Workshop equipment"
Transmission
Do not run the engine or tow the vehicle with the oil pan removed or when
there is no gear oil in the transmission.
When replacing the transmission the gear oil --> Gear oil level, checking and
topping up must be checked and topped up, if necessary. Filling quantities and
specification --> Capacities.
Thoroughly clean all joints and surrounding areas before disassembling.
When installing the transmission, ensure that the dowel sleeves are fitted
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correctly.
O-rings, oil seals, gaskets
Always install new 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.
Always replace paper gaskets. Completely remove old gasket and clean sealing
surfaces thoroughly.
Lightly lubricate the outer circumference and sealing lip of oil seals with gear
oil before installing.
Lightly lubricate O-rings with gear oil or Vaseline before inserting to prevent
them from getting crushed during assembly.
Do not use any other lubricants where gear oil is used. Otherwise, there is a
risk of problems occurring in the transmission hydraulics.
The open side of the oil seals faces the side with fluid filling.
Observe the rules for cleanliness --> Rules for cleanliness.
After installing, check the gear oil level, adjust to correct level if necessary -->
Gear oil level, checking and topping up.
Locking elements
Do not overstretch locking rings/circlips; replace if necessary.

Locking rings/ circlips must be properly seated in the base of the groove.
Nuts, bolts
Loosen bolts in reverse sequence to the specified tightening sequence.

Nuts and bolts which secure covers and housings should be loosened and
tightened in a diagonal sequence and in stages if no tightening sequence is
specified.
Replace self-locking nuts.
Clean the threads of bolts which are secured by a locking compound with a
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wire brush. Then apply AMV 185 101 A1 when inserting.

The tightening torques stated apply to non-oiled nuts and bolts.
RULES FOR CLEANLINESS
Rules for cleanliness
Thoroughly clean all joints and surrounding areas before disassembling.

Place removed parts on a clean surface and cover them over. Use sheeting and
paper. Use lint-free cloths.
Carefully cover or seal open components if repairs cannot be performed
immediately.
Only install clean components: do not remove replacement parts from
packaging until just before installation.
Always install new O-rings, oil seals and gaskets.
Always replace paper gaskets. Completely remove old gasket and clean sealing
surfaces thoroughly.
Clean the threads of bolts which are secured by a locking compound with a
wire brush. Then apply AMV 185 101 A1 when inserting.
30 CLUTCH
CLUTCH AND INPUT SHAFT, REMOVING AND INSTALLING
Information for this section was not yet available at the time of publication.
34 CONTROLS, HOUSING
ELECTRICAL/ELECTRONIC COMPONENTS AND LOCATIONS
Data Link Connector (DLC)
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Fig. 3: Data Link Connector (DLC)

Location: below knee padding on left side of steering wheel

Shift lock solenoid -N110-
Fig. 4: Selector Lever E313 With Tiptronic Switch F189 And Selector Lever
Sensor System Control Module J587
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Location: the shift lock solenoid - E - is located in the selector mechanism.
Checked via self-diagnosis
Removing and installing --> Shift lock solenoid -N110- removing and
installing
Direct Shift Gearbox (DSG) Mechatronic -J743-
Fig. 5: Direct Shift Gearbox Components

Location: the Direct Shift Gearbox (DSG) Mechatronic -J743- is bolted to front of
transmission housing and covered by the transmission oil pan.
The control module is an integrated component of the Direct Shift Gearbox (DSG)
Mechatronic -J743-.
Removing and installing Direct Shift Gearbox (DSG) Mechatronic -J743- -->
Direct Shift Gearbox (DSG) Mechatronic -J743-, removing and installing.
Tiptronic switch -F189-
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Location: the Tiptronic switch -F189- is integrated in the selector mechanism; it is

therefore not possible to replace only the switch on its own. Replace selector
mechanism --> Selector mechanism, removing and installing.
Connector - D - for Tiptronic switch -F189-

Removing and installing, replacing selector mechanism --> Selector
mechanism, removing and installing and --> Selector mechanism,
Transmission Range (TR) selector lever display -Y6-
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Fig. 7: Transmission Range (TR) Selector Lever Display -Y6-

Location: integrated into the instrument cluster
NOTE: Selector lever position indicator can only be replaced

together with the instrument cluster.
If selector lever display flashes or is illuminated, take note of the safety functions of
the transmission control module--> Safety functions of transmission control
module.
Removing and installing: --> 90 INSTRUMENTS

Selector lever -E313-
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Location: Selector lever -E313- is a fixed component of the selector mechanism

board and cannot be replaced on its own. To replace it replace the selector
mechanism --> Selector mechanism, removing and installing.
Brake light switch -F-
Fig. 9: Brake Light Switch -F-

Location: the brake light switch - arrow - is located on the pedal cluster.
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Signal transmission from engine control module to transmission control

module via CAN bus
Removing and installing: --> 46 BRAKES - MECHANICAL
COMPONENTS
NOTE: Switch may only be installed once in order to ensure a

firm fit.
Kickdown switch -F8-
Fig. 10: Kickdown Switch -F8-

Location:
On vehicles with gasoline engine, a specific value supplied by the Throttle

Position (TP) sensor -G79- and Sender -2- for accelerator pedal position -
G185-is stored in the engine control module.
Signal transmission from engine control module to transmission control
module via CAN bus
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Removing and installing accelerator pedal module: --> 20 - FUEL SUPPLY

SELECTOR MECHANISM, SERVICING
Selector mechanism, servicing
Special tools, testers and auxiliary items required
Fig. 11: Torque Wrench V.A.G 1331

Torque wrench V.A.G1331
Fig. 12: Identifying Special Tools - Adjustment Pin For Shiftlock 3 3352A
Locking cable adjustment gauge 3352 A
CAUTION: Before working on vehicle when engine is running,

shift selector lever into position "P" and apply
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handbrake.
Overview
Checking selector mechanism --> Selector mechanism, checking
Checking and adjusting selector lever cable --> Selector lever cable, checking
and adjusting
Checking function of ignition key removal lock --> Ignition key removal lock
operation, checking
Disassembling and assembling selector mechanism --> Selector mechanism,
disassembling and assembling
Removing and installing selector lever handle --> Selector lever handle,
removing and installing
Removing and installing selector mechanism cover --> Selector mechanism
cover, removing and installing
Removing and installing selector mechanism --> Selector mechanism,
Removing and installing Tiptronic switch -F189- --> Tiptronic switch -F189-,
Removing and installing Shift lock solenoid -N110- --> Shift lock solenoid -
N110- removing and installing
Removing and installing selector lever cable --> Selector lever cable,
Removing and installing locking cable --> Locking cable, removing and
installing
Adjusting locking cable --> Locking cable, adjusting
Overview of connectors on selector mechanism --> Connectors on selector

mechanism, overview
Selector mechanism, checking
It should not be possible to operate the starter while the selector lever is in
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position "S", "D" or "R" or in the tiptronic position.

When travelling at speeds above 5 km/h and shifting into selector lever
position "N", the shift lock solenoid must not engage and block the selector
lever. The selector lever can be shifted into a driving gear.
When travelling at speeds below 5 km/h (almost stationary) and shifting into
selector lever position "N", the shift lock solenoid should only engage after
about 1 second. The selector lever cannot be shifted out of "N" position until
the brake pedal is depressed.
Selector lever in "P" position, button on selector lever pressed in and ignition
switched on
Brake pedal not depressed:
When the button is pressed in, the selector lever is locked and cannot be shifted out
of "P" position. The shift lock solenoid blocks the selector lever.
Brake pedal depressed:
The shift lock solenoid releases the selector lever. It is possible to shift into a
driving gear. Shift the selector lever slowly from "P" position through "R, N, D and
S" and check whether the display in the instrument cluster shows the correct
selector lever position in each case.
Selector lever in "N" position, button on selector lever pressed in and ignition
switched on
Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of "N" position. The shift lock
solenoid blocks the selector lever.
Brake pedal depressed:

The shift lock solenoid releases the selector lever. It is possible to shift into a
driving gear.
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NOTE: When the brake pedal is depressed, it is also possible

to shift from "N" to "D" position without pressing the
button on the selector lever. However, to shift from "N"
to "R" the button on the selector lever does have to be
pressed.
Selector lever in "D" position, ignition switched on
The selector lever is locked and cannot be shifted from "D" to "S" position.
Press button on selector lever:

The selector lever is released and can be shifted from "D" to "S" position.
Selector lever in "D" position, ignition and lights switched on
Shift selector lever into tiptronic gate:
The illuminated "D" symbol in the selector lever display must go out and the "+"
and "-" symbols light up.
The selector lever display in the instrument cluster should switch from "PRNDS" to
"654321" when the selector lever is shifted into the tiptronic gate.
Move the selector lever in the tiptronic gate to "+" and "-".
When the selector lever is moved to "+" or "-" the display "PRNDS" in the
instrument cluster must move one gear up or down accordingly.
Check selector lever cable and adjust if necessary--> Selector lever cable,
checking and adjusting.
Check ignition key removal lock --> Ignition key removal lock operation,
checking.
Selector lever cable, checking and adjusting
Checking
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CAUTION: Follow steps required when disconnecting battery. --

> 27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL
NOTE: The battery is located in the rear compartment, in the

spare wheel well.
Disconnect ground strap on battery (in rear compartment) with ignition

switched off. --> 27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL
Fig. 13: Air Filter Housing, MAF Sensor, And Retainers

Loosen clamp - 4 - and disconnect intake hose and connector - 1 - from mass
air flow sensor.
If installed, disconnect hose - 5 - from air cleaner housing.
Remove bolts - 2 - and - 3 - to remove complete air cleaner housing.
Shift selector lever into "P" position.
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Fig. 14: Removing Bolts For Support Bracket, Pulling Off Retaining Clip
Upward & Disconnecting Selector Lever Cable From Transmission
Push circlip - A - upward and remove it in direction of arrow.

Press selector lever cable off selector shaft lever in direction of arrow and place
on top.
NOTE: Do not loosen bolt - B -.
Put selector lever cable aside in such a way that end can move freely.
Do not bend or kink selector lever cable.

Move selector lever from "P" to "S".
Check protective sleeve on selector mechanism (on front of selector lever
cable) for damage, if necessary replace cable.
Selector mechanism and selector lever cable should move smoothly. If

necessary, replace selector lever cable (--> Selector lever cable, removing
and installing) or service selector mechanism.
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Carefully press selector lever cable onto selector shaft lever (in opposite
direction of arrow).
Install circlip - A - and press downward to secure.
Selector lever cable, adjusting

Loosen bolt - B -.
Bring selector shaft lever in position "P" on transmission.
Turn both front wheels in one direction, e.g. by pushing vehicle forward, until
detent lever in transmission engages in parking lock gear and wheels are
blocked (it is not possible to turn them both in same direction simultaneously).
NOTE: The selector lever must be in "P" position when the

clamping bolt - B - is loosened; otherwise, the
adjustment will not be correct.
Carefully move selector lever slightly forward and backward, without shifting
lever into a different selector lever position.
Tighten bolt - B - smoothly and evenly (tightening torque: 13 Nm).
NOTE: When tightening bolt - B - , make sure the selector lever

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cable does not move out of position.
Follow steps required after connecting battery. --> 27 BATTERY,

STARTER, GENERATOR, CRUISE CONTROL
Selector lever cable, checking adjustment
Keep button pressed, while pulling selector lever approx. 5 mm to rear out of
"P" position. Then keep lever in this position, do not move it into "R".
Release selector lever.
Selector lever must spring back into "P" position automatically.
If necessary, adjust selector lever

Shift selector lever into position "N".
Keep button pressed, while pulling selector lever approx. 5 mm to rear out of
"N" position. Then keep lever in this position, do not move it into "D".
Selector lever must spring back into "N" position automatically.

Keep button pressed, while pushing selector lever approx. 5 mm to front out of
"N" position. Then keep lever in this position, do not move it into "R".
Selector lever must spring back into "N" position automatically.

Check selector mechanism --> Selector mechanism, checking.
Ignition key removal lock operation, checking
NOTE: Work through the following steps to arrive at - Ignition

key removal lock is OK - at the end of Step 3.
Work sequence
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Step 1
Shift selector lever to - P -.
Switch off ignition.
Remove ignition key.
Attempt to move selector lever out of - P -.
If selector lever cannot be shifted out of - P - , go to - Step 2 -
If selector lever can be shifted out of - P - with button pressed:

Check for a problem in adjustment of locking cable and correct if necessary, --
> Locking cable, adjusting. Then return to beginning of - Step 1 -.
If problem is not in adjustment of locking cable:
Replace faulty selector mechanism or steering lock.
Step 2
Depress brake pedal.

Insert ignition key.
Switch on ignition.
Attempt to move selector lever out of - P -.
If selector lever cannot be shifted out of - P - with button pressed:

> Locking cable, adjusting. Begin sequence again at - Step 1 -.
If selector lever can be shifted out of - P - with button pressed:
Move selector lever to - R - , - N - , - D - , - S - in sequence.

Attempt to remove ignition key from ignition lock.
If ignition key cannot be removed from the ignition lock, go to - Step 3 -.
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If ignition key can be removed from the ignition lock:

Check for a problem in adjustment of locking cable and correct if necessary,-->
Locking cable, adjusting. Begin sequence again at - Step 1 -
Step 3
Depress brake pedal.

Move selector lever to - P -.
If ignition key can now be removed and the selector lever is locked in - P - position:
Ignition key removal lock is OK; checking procedure is completed
If the ignition key cannot be removed and/or the selector lever is not locked in - P -
:
> Locking cable, adjusting. Begin sequence again at - Step 1 -.
Selector mechanism, disassembling and assembling
Lubricate bearings and moving parts with polycarbamide grease Part No.
G052142A2.
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Fig. 16: Selector Mechanism Assembly Overview

1 - Selector lever handle

Removing and installing --> Selector lever handle, removing and installing
2 - Sleeve
Clips into selector lever handle

Prevents selector lever handle from being pulled off
3 - Bolt, 2 Nm
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8x
4 - Retaining ring
5 - Upper cover
Includes symbol insert
6 - Side cover
Removing and installing --> Selector mechanism cover, removing and
installing
7 - Printed circuit board
Can be checked in "Guided fault finding" using VAS5051.

Installed position of printed circuit board Installed position of printed circuit
board
To remove and install printed circuit board first disassemble cover on selector
mechanism
8 - Frame
9 - Selector lever cable
Do not bend or kink

If protective sleeve is damaged, selector lever cable must be replaced
Checking and adjusting --> Selector lever cable, checking and adjusting
Removing and installing --> Selector lever cable, removing and installing
Do not lubricate cable eye and ball socket
10 - Nut, self-locking, 10Nm

For securing cover to selector mechanism
4x
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Always replace
11 - Cover
For selector mechanism

With glued-on gasket
12 - Washer
13 - Intermediate plate for selector mechanism
14 - Bolt
Inserted into intermediate plate
15 - Shift lock solenoid -N110-

Removing and installing --> Shift lock solenoid -N110- removing and
installing
Can be checked in "Guided fault finding", using vehicle diagnostic, testing and
information system VAS 5051.
16 - Retainer for locking cable
17 - Selector mechanism
Removing and installing --> Selector mechanism, removing and installing
With integrated Tiptronic switch -F189-
18 - Bolt, 6 Nm
3x
19 - Locking cable
For ignition key removal lock

Must not be kinked
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Removing and installing --> Locking cable, removing and installing

Adjusting --> Locking cable, adjusting
Checking operation of the ignition key withdrawal lock --> Ignition key
removal lock operation, checking.
20 - Steering lock
21 - Clip
Installed position: Install clip from above. Angled ends of clip must point
toward steering lock.
Installed position of printed circuit board
Fig. 17: Installed Position Of Printed Circuit Board

Position bores on printed circuit board onto guide sleeves of frame - arrows -.
When installing cover, make sure wiring harness - A - is not trapped and that
printed circuit board is not deformed.
Selector lever handle, removing and installing
Removing
Shift selector lever to position "D".
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Fig. 18: Pushing Sleeve Downward, Pulling Button Out Of Handle And
Securing Button Against Springing Back With A Wire Bracket
Slide sleeve - 1 - downward.

Pull locking button - 2 - out of handle - 3 - as far as it will go - arrow -.
Use a wire clip or similar - 4 - to secure locking button so that it does not
spring back.
Pull handle off selector lever.
Installing
Fig. 19: Pushing Sleeve Downward, Pulling Button Out Of Handle And
Securing Button Against Springing Back With A Wire Bracket
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Pull locking button - 2 - out of handle - 3 - as far as it will go - arrow -.

Use a wire clip or similar - 4 - to secure locking button so that it does not
spring back.
Now press handle onto selector lever as far as it will go.
NOTE: Installed position: Button points to driver.
Remove wire clip.

Press button so that pull lever - 5 - engages in pull rod - 6 -.
Button must now spring back onto stop.
Push sleeve - 1 - upward. Sleeve must be felt to engage in handle.

Shift selector lever to position "P".
Selector mechanism cover, removing and installing
Removing

CONTROL

spare wheel well.

CONTROL
Remove selector lever handle --> Selector lever handle, removing and
installing.
Remove rear center console. --> 68 - INTERIOR EQUIPMENT
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Fig. 20: Frame, Retaining Ring, Printed Circuit Board And Cover
Carefully release frame by bending four hooks outward - arrows - with a
screwdriver. Then remove together with retaining ring, printed circuit board
and cover - A -.
Fig. 21: Selector Mechanism, Connector, Nuts And Bolts

Disconnect connector - B - from selector mechanism cover and lift off cover.
Installing
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Perform installation in reverse sequence of removal. Note the following:

Install rear center console. --> 68 - INTERIOR EQUIPMENT
Install selector lever handle --> Selector lever handle, removing and
installing.
Connect ground strap to battery.
Selector mechanism, removing and installing
Removing

CONTROL

spare wheel well.

CONTROL
installing.
Remove selector mechanism cover --> Selector mechanism cover, removing
and installing.
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Fig. 22: Lifting Up Locking Lever And Pulling Off Locking Cable
Lift up locking lever - A - and pull off locking cable in direction of arrow.
NOTE: Do not loosen bolt - B - !

Disconnect connector - A - from selector mechanism.

Remove 2 nuts - 1 - securing selector mechanism (rear) to body.
Remove bolts - 2 -.
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Lift out selector mechanism.
Do not bend or kink the selector lever cable.
Fig. 24: Selector Lever Cable And Lever

Use screwdriver or similar to pry selector lever cable - B - off lever - A - on

underside of selector mechanism.
Lift off selector mechanism.
Installing

For information on tightening torques of nuts and bolts as well as information on
which nuts or bolts to replace please refer to the section on "Disassembling and
assembling selector mechanism - overview" --> Selector mechanism,
disassembling and assembling.
NOTE: Do not bend or kink the selector lever cable.
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Press selector lever cable - B - onto lever - A - on underside of selector
mechanism.
Retaining tabs on inside of selector lever cable must engage in groove on lever -
arrow -.

Install bolts - 2 -.
Install 2 nuts - 1 - securing selector mechanism (rear) to body.
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Plug in connector - A -.
Adjust locking cable --> Locking cable, adjusting.
Check operation of ignition key withdrawal lock --> Ignition key removal
lock operation, checking.
Install selector mechanism cover --> Selector mechanism cover, removing
and installing.
installing.

Adjust selector lever cable --> Selector lever cable, checking and adjusting.
Tiptronic switch -F189-, removing and installing
The tiptronic switch is integrated in the selector mechanism; it is therefore not

possible to replace only the switch on its own. To replace it the selector mechanism
must be replaced--> Selector mechanism, removing and installing.
Shift lock solenoid -N110- removing and installing
Removing
Remove selector mechanism --> Selector mechanism, removing and

installing
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Fig. 27: Shift Lock Solenoid -N110- Connector And Retaining Tab
Disconnect connector - B - from Shift lock solenoid -N110-.

Press retaining tab - A - to rear and simultaneously turn solenoid in direction of
arrow.
Pull out shift lock solenoid.
Installing
For information on tightening torques of nuts and bolts as well as information on

which nuts or bolts to replace please refer to the section on "Disassembling and
assembling selector mechanism - overview" --> Selector mechanism,
disassembling and assembling.
Selector lever cable, removing and installing
Removing

CONTROL

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spare wheel well.

CONTROL

air flow sensor.
Remove bolts - 2 - and - 3 - and remove complete air cleaner housing.
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Remove locking plate - C -.

on top.
NOTE: Do not loosen bolt - B -.

Do not kink selector lever cable.
Fig. 30: Selector Lever And Clip At Transmission

Unhook selector lever cable - 1 - from clip - arrow - on transmission.

Raise vehicle.
Fig. 31: Identifying Center Sound Insulation Fasteners

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Remove center sound insulation fasteners - 1... 3 -.
Fig. 32: Exhaust System, Component Overview

Remove catalytic converter - 18 - --> 26 - EXHAUST SYSTEM, EMISSION

CONTROLS .
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Fig. 33: Unbolting Center Heat Shield At Both Front Securing Points
Unscrew center heat shield and bracket for exhaust system - arrows -.
Mark position of driveshaft with flexible coupling in relation to bevel box
flange.
Fig. 34: Identifying Bevel Gear Transfer Case Flange Bolts

Unscrew driveshaft with flexible coupling from bevel box flange - arrows -.
NOTE: When loosening bolts, counterhold driveshaft

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flange/final drive with a suitable lever.
Fig. 35: Removing/Installing Drive Shaft From Flexible Coupling On Bevel

Box
Unscrew driveshaft from flexible coupling at bevel box - arrows -.
NOTE: Counterhold with a lever on triangle flange when

loosening the bolts.
Press front driveshaft tube as far as possible toward rear.
Fig. 36: Identifying Sealing Ring In Driveshaft Flange

NOTE: After loosening bolts - A - (see Fig. 37) the

engine/transmission assembly will swing slightly to the
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rear. Make sure that the seal - arrow - in the flange of

the driveshaft is not damaged when removing and
installing.
Fig. 37: Identifying Pendulum Support & Bolts

First remove bolts - A - and then bolts - B - on pendulum support.
Remove pendulum support.
Fig. 38: Identifying Front Drive Shaft Tube To Rear Drive Shaft Tube Bolts
Disconnect front driveshaft tube from rear driveshaft tube - arrows -.
Push front driveshaft tube toward front and swivel out from flange of rear
driveshaft tube.
NOTE: Take care when swivelling out that the front driveshaft
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tube is pushed downward as little as possible.
Carefully push engine and transmission to front and prop it up in this position.
This may require help of a second technician.
NOTE: This step must be performed so that the driveshaft tube

can be pulled off the centering pin.
Carefully pull front driveshaft tube from centering pin.
NOTE:
Fig. 39: Identifying Sealing Rings In Driveshaft Flanges

The seal - arrow - in the flange of the driveshaft must

not be damaged. If the seal is damaged driveshaft must
be replaced.
Pull driveshaft horizontally off of guide pin.
Swivel front driveshaft tube downward and remove.
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Fig. 40: Removing Front Heat Shield

Remove heat shield (front) - arrows -.
Fig. 41: Identifying Selector Mechanism Fasteners

Remove four nuts - arrows A -.
NOTE: The two bolts - arrows B - have not been installed.
Carefully push cover including protective sleeve forward over selector lever
cable. Take care not to damage protective sleeve.
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Use screwdriver or similar to pry selector lever cable - B - off lever - A -.
Press two retaining lugs together in order to release selector lever cable from
bracket on underside of selector mechanism.
Carefully pull selector lever cable out of selector mechanism.
Installing
Tightening torques for selector mechanism components --> Selector mechanism,

disassembling and assembling (Disassembling and assembling selector
mechanism).
NOTE: Check the protective sleeve for damage; the protective

sleeve can only be replaced together with the selector
lever cable.
Check that the protective sleeve is not twisted and is
installed correctly.
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Press selector lever cable - B - onto lever - A - on underside of selector
mechanism.
Retaining lugs on inside of selector lever cable must engage in groove on lever -
arrow -.
Engage selector lever cable in bracket on underside of selector mechanism.
Carefully press selector lever cable onto selector shaft lever on transmission -
in opposite direction of arrow -.
Install locking plate - C -.
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Move selector lever from "P" to "S".
Selector mechanism and selector lever cable must move freely. If necessary
replace selector lever cable or service selector mechanism.
Secure cover with attached gasket to shift unit (hand-tight). When doing this
check that gasket makes full contact.
Fig. 45: Identifying Selector Mechanism Fasteners

Tighten nuts - arrows A -.
NOTE: The two bolts - arrows B - have not been installed.
Insert protective sleeve on selector lever cable in cover.

Assemble exhaust system: --> 26 - EXHAUST SYSTEM, EMISSION
CONTROLS .
Adjust selector lever cable --> Selector lever cable, checking and adjusting.
Locking cable, removing and installing
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Removing

CONTROL 27 BATTERY, STARTER, GENERATOR,
CRUISE CONTROL

spare wheel well.

CONTROL
Remove airbag module on drivers side and steering wheel. --> 69 -
PASSENGER PROTECTION - AIRBAGS, SEAT BELTS
Remove trim (left side) beneath instrument panel. --> 68 - INTERIOR
EQUIPMENT
Remove steering column trim. --> 70 - INTERIOR TRIM
Unscrew handle for adjusting steering column height and position.

Turn ignition key to "ignition on" position.
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Fig. 46: Removing/Installing Locking Cable At Steering Lock

Pull out clip - 2 - for locking cable - 3 -.

Pull locking cable out of steering lock - 1 -.
installing.
Lift up locking lever - A - and pull off locking cable in direction of arrow.
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NOTE: Do not loosen bolt - B - !
Pull locking cable out of instrument panel.
Installing

The locking cable must not be kinked.
Adjust locking cable after installing --> Locking cable, adjusting.
Fig. 48: Steering Lock Locking Cable, Wiring Harness, Footwell Vent And
Carpet
Route locking cable - arrow - from steering lock to selector mechanism in

such a way that it passes behind wiring harness - 1 - and underneath footwell
air outlet - 2 - and carpet - 3 -.
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Lift locking lever - A - and fit locking cable in opposite direction of arrow. If
necessary, loosen bolt - B -.
Fig. 50: Removing/Installing Locking Cable At Steering Lock

Push locking cable into steering lock.
The flat side of the locking cable points downward.
Fit clip - 2 - of locking cable - 3 -.

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Installed position:
Fit clip from above. Angled ends of clip must point towards steering lock.
Ensure that clip is properly engaged.
Adjust locking cable --> Locking cable, adjusting.
installing.
Install trim (left side) beneath instrument panel. --> 68 - INTERIOR
EQUIPMENT
Install steering column trim. --> 70 - INTERIOR TRIM
Install handle for adjusting steering column height and position.
Install steering wheel and airbag. --> 69 - PASSENGER PROTECTION -
AIRBAGS, SEAT BELTS
Locking cable, adjusting
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Fig. 51: Identifying Special Tools - Adjustment Pin For Shiftlock 3 3352A
Locking cable adjustment gauge 3352 A
CAUTION: To adjust the locking cable always proceed as

described below.
Requirements
Locking cable is in installed position

Rear center console has been removed.
Selector lever is in position "P"
Ignition key is in removal position.
Adjusting
Steering column in lowest/rearmost position.

CONTROL

spare wheel well.

CONTROL
installing.
Remove selector mechanism cover --> Selector mechanism cover, removing
and installing.
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Fig. 52: Fitting Locking Cable Adjustment Gauge 3352 A Between Locking
Lever And Locking Cable Eye
Loosen bolt at support bracket.

Fit locking cable adjustment gauge 3352 A between locking lever - 1 - and
locking cable eye - 2 -.
To compensate for play, pull support bracket up to limit stop in direction of
arrow to insert gauge.
Tighten bolt - B - at support bracket (10 Nm).
Remove adjustment gauge.
Install selector mechanism cover --> Selector mechanism cover, removing
and installing.
installing.
Connectors on selector mechanism, overview
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Fig. 53: VAS 5051 Vehicle Diagnosis, Testing & Information System
Before checking and servicing the connectors, the exact cause of the failure
must be determined as precisely as possible via the vehicle diagnostic, testing
and information system VAS5051 in the modes "Guided Fault Finding",
"vehicle self-diagnosis" and "testing system".
Before checking connectors, all control modules in the vehicle should be checked
for fault entries; if necessary eliminate faults.
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- A - : Connector for wiring from the vehicles wiring harness to selector lever (with
CAN wires)
- B - : Connector for selector mechanism cover
- C - : Connector for Shift lock solenoid -N110-
- D - : Connector for Tiptronic switch -F189-
Check all wiring and connectors according to wiring diagram Electrical Wiring
Diagrams, Troubleshooting Component Locations
TRANSMISSION, REMOVING AND INSTALLING
Transmission, removing and installing
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Fig. 55: Identifying Special Tools -- Transmission, Removing And Installing


Support bracket 10 - 222 A
Bracket 10 - 222 A /1
Engine/transmission jack V.A.G 1383 A
Transmission support 3282
Shackle 10 - 222 A /12

Hose clamps, up to 25 mm diameter 3094
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Fig. 56: Adjustment Plate 3282/42

Adjustment plate 3282/42
Fig. 57: Hooks 3004

Hooks 3004
NOTE: Read rules for cleanliness when working on the

transmission--> Rules for cleanliness.
General repair instructions --> Repair instructions.
Observe notes on direct shift transmission 02E -->
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Removing
NOTE: All cable ties which are released or cut open when
removing the transmission must be reinstalled in the
same position when installing the transmission.
Fig. 58: Battery Cover

Remove cover panel (front left) - arrows -.
CAUTION: The following steps are required when disconnecting

the battery --> 27 BATTERY, STARTER,

spare wheel well.

CONTROL
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air flow sensor.
Fig. 60: Main Fuse Box/Battery

Unclip complete main fuse box/battery - A - including all wiring from battery
tray.
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Fig. 61: Battery Holder

Remove battery tray - arrows -.
NOTE: The sole purpose of the battery tray is to secure the

main fuse box/battery.
The battery is located in the rear compartment, in the
spare wheel well.

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on top.
Do not loosen bolt - B -.
Remove two bolts - 1 -.
NOTE: Do not kink selector lever cable.
Touch vehicle ground with your hand (without gloves) to discharge any static
electricity.
Fig. 63: Starter And Bayonet Catch

Turn bayonet catch - 1 - of 20-pin connector to release and disconnect it from

transmission.
CAUTION: Never touch contacts in the transmission connector

with your hands, as static discharge would damage
the control module and mechatronic unit.
Disconnect electrical connections from starter.

Remove starter - A -. --> 27 BATTERY, STARTER, GENERATOR,
CRUISE CONTROL
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Fig. 64: Gear Oil Cooler Hoses Clamped Off Using - 3094 - And Gear Oil
Cooler
Clamp off gear oil cooler hoses using - 3094 - and disconnect at gear oil cooler
- A -.
Seal off gear oil cooler with clean plugs.
Fig. 65: Identifying Bolts On Engine/Transmission Flange

Remove all engine/transmission connecting bolts which are accessible from

above.
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Fig. 66: Setting Up Support Bracket 10-222 A With Adapters 10-222 A/3 On
Surface Of Panel Flange
Assemble support bracket 10 - 222 A together with brackets 10 - 222 A /1 and

10 - 222 A /3.
- 1 - : Shackle 10-222 A/12

Position support bracket on wheelhousing flange.
If there are hoses and cable connections in area of engine lifting eye for
support bracket 10 - 222 A, remove these now.
On right side, attach hook of spindle to engine lifting eye via a shackle 10-222
A/12 - 1 -.
Take up weight of engine/transmission assembly via spindle.
Raise vehicle.
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Fig. 68: Left Sound Insulation Panel

Remove sound insulation (left side) - arrows -.

Remove front wheels.
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Fig. 69: Unbolting Bracket For Headlight Range Control In Left

Wheelhousing
If installed, unscrew bracket for headlight range control in left wheelhousing -
arrows - and tie it up to one side.
Fig. 70: Protective Plate At Bottom Of Transmission

If installed, remove protective plate at bottom of transmission - arrows -.
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Fig. 71: Installing Ball Joint Splitter

Press out right and left ball joints --> 40 FRONT SUSPENSION
Fig. 72: Removing Bolts And Secondary Air Injection Pump With Bracket
Remove bolts - 1 - and - 2 - and remove bracket - A -.
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Fig. 73: Locating Bracket And Nut

Unscrew nut - 1 - and push bracket - A - upward so it does not get stuck when
transmission is lowered.
Fig. 74: Disconnecting Exhaust System At Double Clamp

Disconnect exhaust system at clamp - arrows -.

Push clamp toward rear.
Fig. 75: Using Chain To Tie Exhaust System In Position

Tie up exhaust system with a chain by engaging hooks 3004 in openings on

underbody (if necessary remove plugs).
NOTE:
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The flexible pipe connection (de-coupling element) of

the exhaust system must not be bent more than 10 ° -
otherwise it can be damaged.
Fig. 76: Removing Right Driveshaft Heat Shield From Bevel Box
Unbolt heat shield for axle shaft (right side) from bevel box.
Unbolt axle shafts from transmission flanges. --> 40 FRONT SUSPENSION
Lift axle shaft (right side) up and secure with wire.
Move axle shaft (left side) clear toward rear and secure with wire.
Mark position of driveshaft with flexible coupling in relation to bevel box

flange.

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Remove driveshaft with flexible coupling from bevel box flange - arrows -.

Press driveshaft horizontally to rear as far as possible.
CAUTION: When removing the transmission, make sure the

seal in the driveshaft flange is not damaged. If
the seal is damaged the driveshaft must be
replaced.
Loosening bolts for the pendulum
support/subframe causes the
engine/transmission assembly to swing forward
slightly.

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First remove bolts - A - and then bolts - B - on pendulum support.

Push engine/transmission assembly forward slightly and then pull driveshaft
off bevel box.
Place driveshaft above bevel box and secure it to prevent it falling.
Fig. 80: Subframe And Bolts

Remove subframe --> 40 FRONT SUSPENSION .
Fig. 81: Removing Retaining Plate Between Engine Block And Bevel Box
Unscrew bolts - 1 - and - 2 - at bracket for bevel box.
Remove bracket - A - for bevel box.
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Fig. 82: Transmission Support Plate And Bolts

From above:
Remove transmission console - A - (remove bolts - 1 - and - 2 - ).
Lower engine/transmission assembly using spindles until...
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Fig. 84: Dimension Between Transmission Housing And Transmission Bearing

.. distance - a - = 100...110mm between transmission housing and transmission
mounting is attained.
Fig. 85: Transmission Support 3282 Supporting Transmission

To remove the direct shift transmission 02E the transmission support 3282 is set up
together with the adjustment plate 3282/42.
Align arms of transmission support according to holes in adjustment plate.

Bolt support elements as illustrated to adjustment plate 3282/42.
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Place transmission jack under vehicle; arrow symbol on adjustment plate

points in direction of travel/to front of vehicle.
Align adjustment plate parallel with transmission.
Secure support element to transmission using bolt - 1 -.

Screw support element 3282/29 into transmission.
Insert support element - 2 - into transmission and secure by tightening nut.
Support transmission by lifting transmission jack from below.
Remove remaining securing bolts between engine and transmission.
Press transmission off dowel sleeves.
Pull transmission off engine first from bevel box side and then from front side.
Carefully lower transmission, making sure no wires are trapped.
When lowering, change position of transmission via spindles on transmission
support 3282.
Transmission, installing
NOTE: Secure all hose connections with the correct hose

clamps (as original equipment)
Replace gaskets and seals.

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Before installing, ensure that dowel sleeves - A - are correctly seated in
cylinder block.
A: Dowel sleeves for aligning
Before installing transmission, check needle bearing in crankshaft --> 13

ENGINE - CRANKSHAFT, CYLINDER BLOCK .
Fig. 87: Transmission Support 3282 Supporting Transmission

To install the direct shift transmission 02E the transmission support 3282 is set up
together with the adjustment plate 3282/42.
Align arms of transmission support according to holes in adjustment plate.

Bolt support elements as illustrated to adjustment plate 3282/42.
Place transmission jack under vehicle; arrow symbol on adjustment plate
points in direction of travel/to front of vehicle.
Align adjustment plate parallel with transmission.
Secure support element to transmission using bolt - 1 -.

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Screw support element 3282/29 into transmission.

Insert support element - 2 - into transmission and secure by tightening nut.
Raise transmission carefully and move to installation position using
transmission support 3282.
Insert transmission and make sure no wires or hoses become pinched or caught.
Install all securing bolts for engine/transmission assembly. Refer to tightening
torques --> Tightening torques.
Carefully press selector lever cable onto selector shaft lever on transmission in
opposite direction of arrow.
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Install the assembly mounting as follows:
Place transmission support - A - between transmission and transmission

mounting
Pull transmission up to transmission mounting with spindle on support bracket.
CAUTION: Before tightening bolts between the transmission

mounting and the transmission support, the
mounting and support must be aligned in an
absolutely parallel position, otherwise the threads
will be damaged. If necessary, push the transmission
up at the rear with a trolley jack.

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Transmission support - A - to transmission

Replace bolts.
Bolts - 1 - 50 Nm plus 90° (90° is equivalent to a one quarter turn)
Fig. 91: Locating Engine Carrier Bolts (Transmission Side)

Transmission support to transmission mounting - arrows -

Replace bolts.
Initially tighten bolts finger-tight, then tighten to specified torque.
Bolts - arrows - 100 Nm
CAUTION: Only remove support bracket 10 - 222 A after all bolts

for the assembly mounting are tightened to specified
torque and the subframe is installed.
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Screw in securing bolts - 1 - and - 2 - at bracket for bevel box finger-tight.
Secure bracket for bevel box; note following assembly sequence:
Screw in all bolts finger-tight.
Tighten bolts - arrow1 - initially to 3 Nm.
Tighten bolts - arrow2 - to 35 Nm.
Tighten bolts - arrow1 - to 45 Nm.
Replace bolts - 1 -.
Secure support bracket - D - together with selector lever cable to transmission.
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2 x bolt - 1 - , M8Always 20 Nm plus 90° (90° is equivalent to a one

replace bolts quarter turn)
Fig. 94: Subframe And Bolts

Install subframe --> 40 FRONT SUSPENSION .

Screw on pendulum support at transmission - arrows B - , --> Pendulum
support, removing and installing.
Replace bolts.
Press engine/transmission assembly toward bulkhead. Bevel box pin must be
guided carefully into driveshaft flange when doing this.
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NOTE: When removing and installing, do not damage the seals

in the driveshaft flanges. If the seals are damaged, the
driveshaft must be replaced.
Ensure the driveshaft is horizontal when pushing it
onto the guide pin. --> 39 FINAL DRIVE, DIFFERENTIAL
Fig. 97: Identifying Pendulum Support On Subframe

Use new bolts and screw on pendulum support at subframe - arrows A - , -->
Pendulum support, removing and installing.
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Bolt driveshaft with flexible coupling to bevel box flange - arrows - --> 39
FINAL DRIVE, DIFFERENTIAL .
Fig. 99: Aligning Markings On Driveshaft At Flange Of Haldex Clutch

NOTE: Take note of the markings that were made on the

driveshaft and flange when removing. These must align
with each other again - arrows -.
Assemble exhaust system. --> 26 - EXHAUST SYSTEM, EMISSION

CONTROLS
Install heat shield for axle shaft (right side) and tighten bolts to a torque of 25
Nm.
Install axle shafts. --> 40 FRONT SUSPENSION
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Fig. 100: Unbolting Bracket For Headlight Range Control In Left

Wheelhousing
If equipped, install bracket for headlight range control in wheelhousing (left
side) - arrows - --> 40 FRONT SUSPENSION
Fig. 101: Removing Bolts And Secondary Air Injection Pump With Bracket
Install bracket - A - (bolts - 1 - and - 2 - ).
NOTE: Bracket - A - is secured to front of engine oil pan.
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Secure bracket - A - using nut - 1 - to front cover of transmission.
Install battery --> 27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL .
Assemble exhaust system free of stress. --> 26 - EXHAUST SYSTEM,
EMISSION CONTROLS
Check transmission oil level and top up if necessary --> Gear oil level,
checking and topping up.
Check selector lever cable setting and adjust if necessary --> Selector lever
cable, checking and adjusting.
Check coolant level in cooling system.--> 19 ENGINE - COOLING
SYSTEM
Tightening torques
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Transmission to engine
Item Bolt Qty. Nm
1 M 12 x 55 1 80
2 M 10 x 40 with stud M8 secures only starter to transmission 1 40
3 M 12 x 55 with stud M8 1 80
4 M 10 x 45 secures only starter to transmission 1 40
6 M 12 x 55 1 80
7 M 10 x 50 1 40
8 M 10 x 50 1 40
9 M 10 x 45 1 40
A: Dowel sleeves for aligning

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Engine to transmission
Item Bolt Qty. Nm

5 M 12 x 65 1 80
10 M 12 x 70 1 80
All remaining bolted joints:
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Transmission mounting, removing and installing
Fig. 105: Identifying Support Assembly 10-222A

Support bracket 10 - 222 A
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Fig. 106: Shackle 10-222 A /12

Shackle 10 - 222 A /12
Removing
Fig. 107: Battery Cover

Remove cover panel (front left) - arrows -.

CONTROL

spare wheel well.
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CONTROL

air flow sensor.
Fig. 109: Main Fuse Box/Battery

Unclip complete main fuse box/battery - A - including all wiring from battery
tray.
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Fig. 110: Battery Holder

Remove battery tray - arrows -.
NOTE: The sole purpose of the battery tray is to secure the

main fuse box/battery.
The battery is located in the rear compartment, in the
spare wheel well.
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Assemble support bracket 10 - 222 A together with bracket 10 - 222 A /1 and

bracket 10 - 222 A /3.
- 1 - : Shackle 10-222 A/12
Position support bracket on wheelhousing flange.

If there are hoses and cable connections in area of engine lifting eye for
support bracket 10 - 222 A, remove these now.
On right side, attach hook of spindle to engine lifting eye via a shackle - 1 -.
Take up weight of engine/transmission assembly via spindle.

Unscrew bolts - 2 - to release transmission console - A - from transmission

mounting.
Lower engine/transmission assembly slightly via spindle.
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Fig. 113: Engine Mount And Bolts

Remove all components to obtain access to bolts - 1 - and - 2 -.

Unscrew bolts - 1 - and - 2 -.
Take off transmission mounting - A -.
Installing
Fig. 114: Engine Mount And Bolts

Install transmission mounting - A -.

Replace bolts - 1 -.
Description Tightening torque

Bolts - 1 - M 10 x 55 40 Nm plus 90° (90° is equivalent to a one quarter turn)
Bolt - 2 - M 8 x 20 25 Nm
Pull transmission up to transmission mounting with spindle on support bracket.
CAUTION: Before tightening bolts between the transmission

mounting and the transmission support, the
mounting and support must be aligned in an
absolutely parallel position, otherwise the threads
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will be damaged. If necessary, push the transmission

up at the rear with a trolley jack.

Secure transmission mounting to transmission support - A - using bolts - 2 -.

Replace bolts.
Description Tightening torque

Bolts - 2 - 100 Nm
CAUTION: Support bracket 10-222A must not be removed until

all bolts on the left and right assembly mountings
have been tightened to the specified torque.
Pendulum support, removing and installing
Removing
Raise vehicle.
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Remove center sound insulation tray -fasteners - 1... 3 -.

First remove bolts - arrows A - and then bolts - arrows B - on pendulum

support.
Installing
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Attaching pendulum support
Using new bolts, first secure pendulum support to transmission - arrows B - ,

then on subframe - arrows A -.
Component Nm
Pendulum Transmission Replace bolts - 40 plus 90° (90° = one
support to arrow B -. quarter turn)
Subframe Replace bolts - arrow 20 plus 90° (90° = one
A -. quarter turn)
Transporting the automatic transmission
Fig. 119: Bracket T10013

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Bracket T10013
Fig. 120: Identifying Shop Crane VAS 6100

Workshop crane VAS 6100
Fig. 121: Attaching Workshop Crane VAS 6100 To Bracket T10013

Bracket T10013 can be used to transport the automatic transmission and also when
setting up transmission support 3282.
Remove bolt from bracket T10013 (release retaining ring).

Secure bracket T10013 with bolt - 1 - M8 x 40 and a washer (30mm diameter)
to transmission lifting eye.
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CAUTION: When transporting, take note of the transmission oil

cooler to prevent it from becoming damaged.
Attach workshop crane VAS 6100 to bracket T10013.

Securing transmission to assembly stand
Fig. 122: Holding Fixture VW 540

Engine/transmission support VW 540
Fig. 123: Holding Fixture VW 313

Holding fixture VW 313
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Fig. 124: Secure Transmission To Holding Fixture VW 540 And VW 313

Secure transmission to engine/transmission support VW 540 - arrows - and fit
into holding fixture VW 313.
For insertion it is possible to use workshop crane VAS 6100; see Transporting
the automatic transmission --> Transporting the automatic transmission.
CAUTION: The center of gravity of the transmission is outside

the pivot center of the support clamp. A second
technician has to hold the transmission housing
when it is being turned to prevent it from swinging
round.
NOTE: If a filled transmission is turned on the assembly stand

so that oil pan points upward, vent holes on the
transmission housing must be sealed.
GEAR OIL LEVEL, CHECKING AND TOPPING UP
Gear oil level, checking and topping up
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Fig. 125: VAS 5051 Vehicle Diagnosis, Testing and Information System
Vehicle diagnostic, testing and information system VAS 5051
Fig. 126: Identifying Drip Tray V.A.G 1306

Drip tray V.A.G 1306

Adapter VAS6262
Safety goggles
Protective gloves (acid resistant)
An approx. 1 meter long transparent hose (commercially available) which can

be attached to adapter VAS6262 and a suitable funnel.
NOTE: Read the rules for cleanliness when working on the

transmission --> Rules for cleanliness.
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Observe notes on direct shift transmission 02E,
disposing of oil --> Notes on the direct shift
transmission 02E
Gear oil level, checking
CAUTION: The engine must not be started if significant oil

loss has occurred (e.g. during repairs) and there
is little or no oil left in the transmission.
If necessary, perform a pre-filling of gear oil for
the direct shift transmission.
Only the gear oil for the direct shift transmission
(available as a replacement part) may be used for
the direct shift transmission 02E. Other oils
cause faults and/or failure of the transmission.
Transmission must not be in emergency running (backup) mode.

Vehicle must be level (horizontal).
Selector lever at position "P".
Engine idling.
Air conditioning and heating system switched off.

Vehicle diagnostic, testing and information system VAS 5051 connected;
vehicle self-diagnosis and vehicle system "02 - Gearbox electronics" selected.
The gear oil temperature at the beginning of the test must not be higher than
30°C. If necessary, first allow the transmission to cool down.
NOTE: The gear oil temperature is taken from the reading on

the vehicle diagnostic, testing and information system
VAS 5051.
The gear oil level will vary according to the gear oil
temperature.
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If the gear oil level is checked when the gear oil

temperature is too low, this will result in overfilling.
If the gear oil level is checked when the gear oil
temperature is too high, this will result in underfilling.
Both overfilling and underfilling have a detrimental
effect on the functioning of the transmission.
Reading gear oil temperature
Fig. 127: Diagnostic System VAS 5051: Display -- Basic Setting

Indicated on vehicle diagnostic, testing and information system VAS 5051:
From list - 1 - select diagnostic function "08 - Read measured value block".
Fig. 128: Diagnostic System VAS 5051: Display -- Display Group And Key Pad
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1 - Enter display group (max. input value = 255).
Use keypad - 2 - to enter "19" for "Display group number 19" and confirm by
touching Q key.
Fig. 129: Diagnostic System VAS 5051: Display -- Display Fields

Reading for gear oil temperature is shown in display zone - 1 -.
Checking and correcting gear oil level
CAUTION: The filler hose, funnel and filler adapter VAS6262

must be clean; the gear oil must not be mixed with
any other oil types.
Shift selector lever into "P" position, apply parking brake.

Start engine and let it idle.
Press and hold brake pedal.
With brake pressed, select all gear positions "P, R, N, D, S" one after another at
idling speed, maintaining each position for at least 3 seconds.
Drive vehicle onto a four-column hoist or over an inspection pit in order for it
to be absolutely horizontal.
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CAUTION: When working close to the radiator always maintain a

safe distance from the fan - danger of injury! The fan
may switch on automatically.
Place drip tray V.A.G1306 under transmission.
CAUTION: Wear safety goggles.

Wear protective gloves (acid resistant).
Fig. 131: Diagnostic System VAS 5051: Display -- Display Fields

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Read gear oil temperature in display zone - 1 -.
Fig. 132: Locating Oil Inspection Plug

When gear oil has reached a temperature of 35°C, unscrew oil inspection plug -
B -.
NOTE: The inspection plug is located next to the pendulum

support. The gear oil will drain off completely if the
drain plug - A - is opened.
Fig. 133: Identifying Overflow Pipe And Plug

Gear oil in overflow pipe - arrow2 - will drain off first.
NOTE: Even when the gear oil level is low a small amount of oil
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will first drain out of the overflow pipe, as it fills up

during operation.
Check that overflow pipe is secured to transmission with a torque of 3 Nm.

Tighten if necessary.
NOTE: If the overflow pipe is not correctly secured, the oil level
cannot be correctly read.
Drain excess transmission oil.
The gear oil level is correct when a small amount of gear oil still drains out when
the oil temperature is between 35°C and 45°C (level rises due to warming of oil).
In this case, the gear oil does not need to be topped-up; oil level is OK.
NOTE: Every 30 seconds a small surge of oil will come out of

the oil level pipe regardless of the oil level (cause:
intermittent cooling oil supply to the clutch). The surge
is not to be considered a criteria for the correct oil level
and should therefore be disregarded.
Gear oil that has drained off must not be refilled or
reused. Dispose of the gear oil properly.
Fig. 134: Identifying ATF Level Plug Seal

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Replace seal - arrow - for gear oil inspection plug.

Screw in inspection plug - B -.
Tightening torque: 45Nm
The gear oil check is now completed.
End function "08 - Read measured value block" by touching key.

Press "06 - End output".
Switch off ignition and unplug diagnostic connector.
If no gear oil drains out when the oil temperature is between 35°C and 45°C, top up
gear oil --> Gear oil level, topping up.
Gear oil level, topping up
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If no gear oil drains out of the overflow pipe - arrow2 - when the engine is running
and the oil temperature is between 35°C and 45°C, the gear oil must be topped up.
All conditions and procedures for checking the gear oil must be adhered to.

Screw adapter VAS6262 into opening of inspection plug - B - finger tight.

Attach hose with funnel to adapter and hold funnel as high as possible above
transmission.
Initially add only a small amount of gear oil for transmission using funnel Parts
catalog.
Check gear oil level (check as often as necessary)

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Remove hose from adapter VAS6262 and plug hose using a clean plug.

Gear oil in overflow pipe - arrow2 - will drain off first.

Drain excess transmission oil.
The gear oil level is correct when a small amount of gear oil still drains out when
the oil temperature is between 35°C and 45°C (level rises due to warming of oil).
In this case, the gear oil does not need to be topped-up; oil level is OK.
NOTE: Every 30 seconds a small surge of oil will come out of

the oil level pipe regardless of the oil level (cause:
intermittent cooling oil supply to the clutch). The surge
is not to be considered a criteria for the correct oil level
and should therefore be disregarded.
Gear oil that has drained off must not be refilled or
reused. Dispose of the gear oil properly.
If no more gear oil drains out of the inspection plug hole, continue to top up and
check the oil until the oil level is OK.
Unscrew adapter VAS6262 from transmission.
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Replace seal - arrow - for gear oil inspection plug.

The gear oil check is now completed.
End function "08 - Read measured value block" by touching key.

Press "06 - End output".
Switch off ignition and unplug diagnostic connector.
Gear oil, changing or filling after repairs
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Drip tray V.A.G 1306

Adapter VAS6262
Safety goggles
Protective gloves (acid resistant)
An approx. 1 meter long transparent hose (commercially available) which can

be attached to adapter VAS6262 and to a suitable funnel.
Requirements

Selector lever at position "P"
Engine not running.
The gear oil filter must always be replaced when changing gear oil --> Gear
oil filter, removing and installing.
CAUTION: Only the gear oil for the direct shift

transmissions (available as a replacement part)
may be used for the direct shift transmission
02E. Other oils cause faults and/or failure of the
transmission. For part number Parts catalog.
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The engine must not be started and vehicle must

not be towed without gear oil in transmission.
NOTE: Observe all notes and test requirements for "Gear oil
level, checking" --> Gear oil level, checking.
Note regulations for the disposal of oil.

Draining off gear oil and changing gear oil filter

Change gear oil filter --> Gear oil filter, removing and installing
Drive vehicle onto a four-column lifting platform or over an inspection pit in
order for it to be absolutely horizontal.

Remove center sound insulation -fasteners - 1... 3 -.


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Remove drain plug - A -.
Drain gear oil.

Replace seal - arrow - for drain plug.
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Install drain plug - A -.

Remove inspection plug - B -.
CAUTION: The filler hose, funnel and adapter VAS6262 must

be clean; the gear oil must not be mixed with any
other oil types.
The engine must not be started if significant oil
loss has occurred (e.g. during repairs) and there
is little or no gear oil left in the transmission. In
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this case, you must pre-fill the transmission with

gear oil with the engine cold and not running.
Fig. 147: Overflow Pipe, Seal And Bolt

NOTE: An overflow pipe - C - is screwed into the opening of

the inspection plug.
Remove overflow pipe - C -.

Drain off remaining gear oil.
Inspecting the overflow pipe
The overflow pipe (including collar) must be 96 mm long.

The overflow pipe must be blue.
NOTE: Shorter overflow pipes were used for the first

transmissions installed. These must be replaced.
Inspect overflow pipe. It must be replaced if the aforementioned requirements

are not met or if it is damaged.
Filling with gear oil
Screw correct overflow pipe into opening for inspection plug (tightening
torque: 3 Nm).
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Screw adapter VAS6262 into opening of inspection plug - B - finger tight.
Attach hose with funnel to adapter and hold funnel as high as possible above
transmission.
Fill with 6 liters of gear oil for direct shift transmissions using a funnel;
Replacement Part No. Parts catalog.
Unscrew adapter VAS6262 from transmission.
Drain off excess transmission oil.


Shift selector lever into "P" position, apply parking brake.
Press and hold brake pedal.
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Start engine and let it idle.
With brake pressed, select all gear positions "P, R, N, D, S" one after another at
idling speed, maintaining each position for at least 3 seconds.
Check and top up gear oil level --> Gear oil level, checking and topping up.
Bevel box gear oil, checking and topping up

Drip tray V.A.G1306

Safety goggles
NOTE: Rules for cleanliness when working on the

transmission--> Rules for cleanliness.
Observe notes on direct shift transmission 02E,
disposing of oil --> Notes on the direct shift
transmission 02E
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Fig. 151: Oil Seals - Component Overview

Checking gear oil in bevel box - B - :

The bevel box is secured to the side of the transmission and has a separate self-
contained oil reservoir.
Requirements
Engine not running.
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safe distance from the fan - danger of injury!
The fan may switch on automatically.
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Fig. 153: Removing Right Flange Shaft Bolt With Socket And Key T10107
Remove gear oil inspection plug - B -. (Plug - B - must be replaced after

removing).
Oil level is correct when gear oil is up to lower edge of filler hole in bevel box.
If necessary, top up gear oil via hole for inspection plug - B -. Specification
Parts catalog.
Screw in new plug - B -.
Component Nm
Plug - B - 15
Bevel box, refilling with new gear oil
Work sequence
Remove plug - B -. (Plug - B - must be replaced).

Fill up gear oil for bevel box to lower edge of filler hole. Specification Parts
catalog.
Screw in plug - B -.
Start engine, engage a gear and allow transmission to turn for approx. 2
minutes.
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Switch off engine and remove plug - B -.

Fill gear oil for bevel box up to bottom edge of filler hole. Specification Parts
catalog.
Screw in new plug - B -.
Component Nm
Plug - B - for gear oil filler/inspection hole 15
Gear oil, draining from bevel box

Drip tray V.A.G1306

Safety goggles
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Gear oil in bevel box - B - :

The bevel box is secured to the side of the transmission and has a separate self-
contained oil reservoir.
The gear oil in the bevel box only needs to be drained if repairs are required. It is
not necessary to change the oil (lifetime filling).
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Remove drain plug - A -.

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Screw in plug - A - again.
Component Nm
Drain plug - A - 60
Fill up bevel box with new oil.

GEAR OIL COOLER, REMOVING AND INSTALLING
Gear oil cooler, removing and installing
Fig. 159: Identifying Hose Clamps 3094

Hose clamps, up to 25 mm diameter 3094

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Component overview
Fig. 161: Gear Oil Filter Component Overview

8 - Gear oil cooler
9 - Bolts
Always replace
3 x, M8x20
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Tightening torque: 20 Nm plus 90° further (90° is equivalent to a one quarter

turn)
10 - O-ring
Always replace
Removing
CAUTION: Follow steps required when disconnecting battery -->

27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL .

spare wheel well.

CONTROL

air flow sensor.
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Cooler
Clamp off hoses for gear oil cooler with hose clamps up to 25 mm diameter
3094 and disconnect from gear oil cooler.
Fig. 164: Removing/Installing Transmission Oil Cooler

Remove 3 bolts - A -. (Bolts must be replaced).

Remove gear oil cooler - B - together with O-rings - C - from transmission.
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CAUTION: Do not allow coolant to drip into transmission.
Installing
Replace O-rings on gear oil cooler.

Tighten new bolts - A - to 20Nm plus 90° further (90° equals one quarter of a
turn).
Check coolant level in cooling system, --> 19 ENGINE - COOLING
SYSTEM .
GEAR OIL FILTER, REMOVING AND INSTALLING
Gear oil filter, removing and installing

Drip tray V.A.G1306
Requirements
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Engine not running.
Component overview

13 - Filter housing
Tightening torque on transmission, 20 Nm

Lightly lubricate seal with gear oil
14 - Gear oil filter
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Removing

CONTROL

spare wheel well.

switched off --> 27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL .

air flow sensor.
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Cooler
Unscrew filter housing - B -.
NOTE: Tip the filter housing several times before removing to

drain gear oil from the housing.
Slowly remove gear oil filter upward.
NOTE: An O-ring is located in the intake neck of the filter. Make

sure that it does not remain in the transmission;
remove it if necessary.
Installing
Replace gear oil filter.

Lubricate O-ring in intake neck of new filter with gear oil before installing into
transmission.
Lubricate O-ring on filter housing with gear oil before screwing onto
transmission.
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Cooler
Tighten filter housing - B - to 20 Nm.

35 GEARS, SHAFTS
COMPONENT OVERVIEW
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1 - Oil pan
Removing and installing --> Oil pan, removing and installing
2 - Bolts M6
Always replace
5 x, for securing oil pan with oil pan gasket to transmission housing
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2006 Audi TT
3 - Gasket
4 - Bolts M6
Always replace
For securing Direct Shift Gearbox (DSG) Mechatronic -J743- to transmission
housing
turn)
5 - Direct Shift Gearbox (DSG) Mechatronic -J743-
With O-rings at connector; always replace O-rings

Removing and installing --> Direct Shift Gearbox (DSG) Mechatronic -
J743-, removing and installing
6 - Breather pipe
Pressed into transmission; must be replaced after removal
7 - Breather cap
Attached to breather pipe
8 - Gear oil cooler

Removing and installing --> Gear oil cooler, removing and installing
9 - M8 bolt
Always replace
For securing gear oil cooler to transmission housing
turn)
10 - O-ring
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Always replace
11 - Support bracket
12 - M8 bolt
Always replace
2 x, for securing support bracket to transmission housing
turn)
13 - Filter housing
Tightening torque on transmission: 20 Nm
14 - Gear oil filter
Removing and installing --> Gear oil filter, removing and installing
15 - Gear oil pump
Removing and installing --> Gear oil pump, removing and installing
16 - Bolts M6
Always replace
4 x, for securing gear oil pump to transmission housing
turn)
17 - Cover for gear oil pump
With gasket
Removing and installing --> Gear oil pump, removing and installing
18 - Bolts M6
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Always replace
4 x, for securing cover to transmission housing
19 - Drain plug M24

20 - Seal
Always replace
21 - Inspection plug M24

22 - Seal
Always replace
23 - Overflow pipe
24 - Protective shield
25 - Bolt M10
4 x, for securing protective shield to transmission housing

A - Sensor for transmission RPM / Transmission fluid temperature sensor -G182- / -G93-
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Fig. 171: Transmission Sensors And Bolts

Removing and installing --> Sensor for transmission RPM / Transmission

fluid temperature sensor -G182- / -G93-, removing and installing
OIL PAN, REMOVING AND INSTALLING
Oil pan, removing and installing

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Drip tray V.A.G1306


Safety goggles
Removing
Engine not running.
CAUTION: Do not run engine or tow vehicle with oil pan

removed or when there is no gear oil in the
transmission.
NOTE: Rules for cleanliness when working on the

Observe notes on direct shift transmission 02E -->
Lightly lubricate O-rings and seals with gear oil. Other
types of lubricant will cause the transmission
hydraulics to malfunction.

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CONTROL .

spare wheel well.

CONTROL .

Remove center sound insulation tray fasteners - 1... 3 -.
Vehicles with lines for power steering attached to cross piece
Fig. 175: Power Steering Lines At Cross-Piece Pipe

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Disconnect lines for power steering from cross piece - arrows -.
Vehicles with lines for power steering attached to transmission
Disconnect lines for power steering from transmission and remove speed nut
from transmission.
Fig. 176: Front Cross-Piece Pipe

Remove cross piece - arrows -.

Unscrew nut - 1 - and press bracket - A - upward.
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NOTE: Location: bracket - A - is secured to front of

transmission oil pan.

Remove drain plug - A - and allow gear oil to drain off --> Gear oil, changing
or filling after repairs.
Fig. 179: Protective Plate At Bottom Of Transmission

If installed, remove protective plate at bottom of transmission - arrows -.
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Fig. 180: Starter And Bayonet Catch

Turn bayonet catch - 1 - of 20-pin connector to release and separate it from
transmission.
Touch a vehicle ground by hand (without gloves) to discharge any static
electricity.
CAUTION: Only touch or remove the Direct Shift Gearbox (DSG)

Mechatronic -J743- after having discharged any
static electricity by touching a vehicle ground by
hand.
Never allow hands to contact the transmission

connector, as static discharge would damage the
control module and mechatronic.
Fig. 181: Identifying Oil Pan And Fasteners

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Loosen 5 bolts on oil pan - arrows - in diagonal sequence. (Bolts must be
replaced).
NOTE: There is still a small amount of gear oil in the

transmission, as not all oil can drain.
Remove oil pan together with oil pan gasket.

Installing
Installation is performed in reverse sequence. Note the following:

Replace O-rings - B - on 20-pin connector for Direct Shift Gearbox (DSG)
Mechatronic -J743-.
Lubricate O-rings lightly with gear oil.
Clean gasket and sealing surfaces and remove any oil residue.
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NOTE: Make sure the oil pan gasket is installed correctly.

When installing the oil pan, be careful not to trap any
wiring.
Fig. 183: Identifying Oil Pan And Fasteners

Tighten 5 new bolts for oil pan - arrows - in a diagonal sequence in stages.
Component Nm
Oil pan to transmission housing5 x M6 bolts (in stages and in diagonal
10
sequence)
Replace seal for drain plug.

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Install drain plug - A -.
Component Nm
Drain plug to transmission, M24 45
Fill with gear oil --> Gear oil, changing or filling after repairs.
NOTE: The seal for inspection plug must be replaced after

checking gear oil.
Connect battery --> 27 BATTERY, STARTER, GENERATOR, CRUISE

CONTROL .
Follow steps required after connecting battery --> 27 BATTERY, STARTER,
Tightening torques
Component Nm
Drain plug to transmission, M24 45
Inspection plug to transmission, M24 45
Oil pan to transmission housing5 x M6 bolts (in stages and in diagonal
10
sequence)
DIRECT SHIFT GEARBOX (DSG) MECHATRONIC -J743-, REMOVING AND INSTALLING
Direct Shift Gearbox (DSG) Mechatronic -J743-, removing and installing
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Drip tray V.A.G1306


Safety goggles
Engine not running.
CAUTION: Do not run engine or tow vehicle with oil pan

removed or when there is no gear oil in the
transmission.

automatic transmission--> Rules for cleanliness.
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Removing

CONTROL .

spare wheel well.

CONTROL .
Remove oil pan --> Oil pan, removing and installing.
Touch a vehicle ground by hand (without gloves) to discharge any static
electricity.
CAUTION: Only touch or remove the Direct Shift Gearbox (DSG)

Mechatronic -J743- after having discharged any
static electricity by touching a vehicle ground by
hand.
Never allow hands to touch contacts in the

transmission connector, as static discharge would
damage the control module and mechatronic.
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Carefully release connector - A - (e.g. using a small screwdriver) and remove
from mechatronic.
NOTE: Do not pull on the connector wire - A -. If the wire

becomes damaged, the Sensor for transmission RPM /
Transmission fluid temperature sensor -G182- / -G93-
will have to be replaced --> Sensor for transmission
RPM / Transmission fluid temperature sensor -G182- / -
G93-, removing and installing.
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Release wire for sensors from retainers - arrows - on Direct Shift Gearbox
(DSG) Mechatronic -J743-.
Remove bolts in reverse order from - 10 - to - 1 -. (Bolts must be replaced).
Remove Direct Shift Gearbox (DSG) Mechatronic -J743- - C - from
transmission in a forward direction and keep it straight.
NOTE: The long sender on the reverse side of the Direct Shift
Gearbox (DSG) Mechatronic -J743- must not become
damaged.
Installing
Attach Direct Shift Gearbox (DSG) Mechatronic -J743- - C - without using

excessive force.
NOTE: When installing the Direct Shift Gearbox (DSG)

Mechatronic -J743-, the wire for connector - A - must
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not become trapped or pinched. If the wire is damaged,

the Sensor for transmission RPM / Transmission fluid
temperature sensor -G182- / -G93- will have to be
replaced.
The long sender on the reverse side of the Direct Shift
Gearbox (DSG) Mechatronic -J743- must not become
damaged.

Tighten bolts - 1 - to - 10 - finger tight.
Tighten bolts in sequence - 1 - to - 10 - to 5Nm plus 90° further (90° equals
one quarter of a turn).
Secure wire to retainers - arrows -.
Clean gasket and sealing surfaces and remove any oil residue.
Replace O-rings - B - on 20-pin connector for Direct Shift Gearbox (DSG)
Mechatronic -J743-.
Lubricate O-rings - B - lightly with gear oil.
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Install oil pan --> Oil pan, removing and installing.
Connect battery. --> 27 BATTERY, STARTER, GENERATOR, CRUISE

CONTROL
Perform basic setting using vehicle diagnostic, testing and information system
VAS 5051.
Tightening torques
Component Nm
5 plus 90° further (90°
Direct Shift Gearbox (DSG) Mechatronic -J743-
equals one quarter of a
to transmission10 x M6 bolt, in sequence
turn)
SENSOR FOR TRANSMISSION RPM / TRANSMISSION FLUID TEMPERATURE SENSOR -G182- /
-G93-, REMOVING AND INSTALLING
Sensor for transmission RPM / Transmission fluid temperature sensor -G182- / -G93-, removing and installing

Drip tray V.A.G1306

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Safety goggles
Engine not running.
CAUTION: Do not run the engine or tow the vehicle with the oil
pan removed or when there is no gear oil in the
transmission.

automatic transmission--> Rules for cleanliness.
Removing

CONTROL .

spare wheel well.
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CONTROL .
Remove oil pan --> Oil pan, removing and installing.
Remove Direct Shift Gearbox (DSG) Mechatronic -J743- --> Direct Shift
Gearbox (DSG) Mechatronic -J743-, removing and installing.
Fig. 192: Transmission Sensors And Bolts

Unscrew bolt - B -.
Remove sensors - A - from transmission together with wire.
Installing
Lubricate sensors - A - with gear oil and insert into opening on side of
transmission.
Tighten new bolt (M6) - B - to 10Nm.
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Install mechatronic - C - --> Direct Shift Gearbox (DSG) Mechatronic -
J743-, removing and installing.
NOTE: When installing the Direct Shift Gearbox (DSG)

Mechatronic -J743-, the wire for connector - A - must
not become trapped or pinched. If the wire is damaged,
the Sensor for transmission RPM / Transmission fluid
temperature sensor -G93- / -G182- will have to be
replaced --> Sensor for transmission RPM /
Transmission fluid temperature sensor -G182- / -G93-,
Secure wire to retainers - arrows -.

Install oil pan --> Oil pan, removing and installing.
Connect battery --> 27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL .

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Perform basic setting using vehicle diagnostic, testing and information system
VAS 5051.
GEAR OIL PUMP, REMOVING AND INSTALLING
Gear oil pump, removing and installing

Drip tray V.A.G1306

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Safety goggles
Requirements
Engine not running.
CAUTION: Do not run the engine or tow the vehicle with the
cover removed, the gear oil pump removed or when
there is no gear oil in the transmission.

The paper gasket between the gear oil pump and the
transmission must always be replaced.
The cover for the gear oil pump must always be
replaced.
Removing


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Drain gear oil --> Gear oil, changing or filling after repairs.

Remove sound insulation (left side) - arrows -.
Fig. 198: Identifying Cap For Transmission Oil Pump And Fasteners
Remove bolts - arrows - and take off cover for gear oil pump - A -. (Bolts and
cover must be replaced).
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Fig. 199: Identifying Transmission Oil Pump And Fasteners

Remove bolts - arrows - and remove gear oil pump - 1 - forward. (Bolts must
be replaced).
Installing
Fig. 200: Gear Oil Pump Shaft Dimensions

Insert shaft - A - for gear oil pump into transmission up to stop (turn slightly if
necessary).
Installed dimension - a - of shaft is approx. 23mm.
If necessary, carefully remove metal shavings on sender wheel - B - (sender

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wheel must not be demagnetized).

Remove paper gasket between gear oil pump and transmission.
Remove any remnants of gasket and clean inside of transmission.
Clean sealing surfaces of gear oil pump and transmission.
Install new paper gasket between gear oil pump and transmission, and if
necessary, apply gear oil to hold it in place.
Fig. 201: Identifying Transmission Oil Pump And Fasteners

Install gear oil pump - 1 - onto shaft and place in installed position.
Tighten new bolts - arrows - in diagonal sequence to 5Nm plus 90° further
(90° equals one quarter of a turn).
Fig. 202: Identifying Cap For Transmission Oil Pump And Fasteners
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Install new cover for gear oil pump - A - and tighten new bolts - arrows - in
diagonal sequence to 8Nm.
Fill with gear oil and check oil level (top up if necessary) --> Gear oil level,
checking and topping up.
39 FINAL DRIVE - DIFFERENTIAL
OIL SEALS - COMPONENT OVERVIEW
Oil seals - component overview

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5 - Flange shaft oil seal (right)

Replacing --> Oil seal for flange shaft at bevel box (outer), replacing
8 - Oil seal for selector lever shaft
9 - Flange shaft oil seal (left)
Replacing --> Oil seal for flange shaft (left side), replacing
Oil seal for flange shaft (left side), replacing

Drip tray V.A.G1306
Fig. 205: Identifying Thrust Piece 3305

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2006 Audi TT

Thrust piece 3305
Removing
It is possible to replace the oil seals without removing the transmission.

automatic transmission --> Rules for cleanliness.
Remove left axle shaft --> 40 FRONT SUSPENSION .

Remove countersunk bolt for flange shaft; use a drift to prevent turning. (Bolt
must be replaced).
Pull out flange shaft and spring.
Pry out oil seal with assembly lever.
Installing
Fig. 206: Driving Left Flanged Shaft Seal In Onto Stop

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2006 Audi TT
Drive in new oil seal onto stop using thrust piece 3305. Take care to keep seal
straight when installing.
Fill space between sealing lip and dust lip half-full with grease G52 128 A1.
Push flange shaft against spring pressure and secure using new bolt.
Install left axle shaft --> 40 FRONT SUSPENSION .
Checking gear oil level and changing gear oil --> Gear oil level, checking and
topping up.
Tightening torques
Component Nm
Flange shaft to transmission Replace bolts 30
Oil seal for flange shaft at bevel box (outer), replacing
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2006 Audi TT
Fig. 207: Identifying Special Tools - Oil Seal For Flange Shaft At Bevel Box
(Outer), Replacing
Drip tray V.A.G1306

Hex socket T10107
Puller T10037
Thrust piece T10049
Removing
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2006 Audi TT
It is possible to change the oil seals without removing the transmission.

Remove right axle shaft --> 40 FRONT SUSPENSION .
Remove bolt for flange shaft (right side) - arrow1 - using hex key T10107.
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2006 Audi TT
(Bolt must be replaced).
Fig. 210: Removing Flange Shaft With Puller T10037

Remove flange shaft using puller T10037.

Pry out flange shaft oil seal using assembly lever.
Installing
Fig. 211: Driving In New Sealing Ring To Stop Using Thrust Piece T10049
Drive in new oil seal as far as stop using thrust piece T10049.
Fill space between sealing lip and dust lip half-full with grease G52 128 A1.
Carefully drive in flange shaft (while turning).
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2006 Audi TT
Secure flange shaft using new countersunk bolt.
Install right axle shaft --> 40 FRONT SUSPENSION .

Install guard plate for axle shaft onto bevel box.
Tightening torques
Component Nm
Flange shaft to transmission (countersunk bolt), replace bolt 30
Heat shield for axle shaft 25
BEVEL BOX - COMPONENT OVERVIEW
Bevel box - component overview
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2006 Audi TT

1 - Countersunk bolt for securing flange shaft (right side) in transmission, 30Nm
2 - Bolts for securing bracket - A - on bevel box; note tightening sequence
3 - Bolts for securing bracket - A - on engine; note tightening sequence

1
4 - 4 x bolts for securing bevel box - B - to transmission - C - , 40 Nm plus / turn
4
(90°)
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2006 Audi TT
A - Bracket
B - Bevel box
C - Transmission
Bevel box, removing and installing
Fig. 213: Identifying Special Tools - Bevel Box, Removing And Installing
Drip tray V.A.G1306

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2006 Audi TT
Hex socket T10107

Puller T10037
Removing



Remove sound insulation (right side) - arrows -.

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2006 Audi TT
Remove right axle shaft --> 40 FRONT SUSPENSION .
Remove bolt for flange shaft (right side) - arrow1 - using hex key T10107.
(Bolt must be replaced).
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2006 Audi TT
Fig. 218: Removing Flange Shaft With Puller T10037

Remove flange shaft using puller T10037.
Remove front right wheel.
Remove bolts - 1 - and - 2 - at bracket for bevel box.

Remove bracket - A - for bevel box.
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2006 Audi TT
Fig. 220: Disconnecting Exhaust System At Double Clamp

Disconnect exhaust system at clamp - arrows -.
Push clamp toward rear.
Fig. 221: Using Chain To Tie Exhaust System In Position

Tie up exhaust system with a chain. To do so, engage hooks 3004 in openings
on underbody (if necessary remove plugs).
NOTE: The flexible pipe connection (de-coupling element) of

the exhaust system must not be bent more than 10 ° -
otherwise it can be damaged.
Mark relationship of driveshaft and flexible coupling to bevel box flange with
a colored marker.
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2006 Audi TT

Unscrew driveshaft with flexible coupling from bevel box flange - arrows -.
NOTE: When loosening bolts, counterhold driveshaft

flange/final drive with a suitable lever.

Press driveshaft horizontally to rear as far as possible.
CAUTION: When removing the driveshaft, make sure the

seal in the driveshaft flange is not damaged. If
the seal is damaged the driveshaft must be
replaced.
Loosening bolts for the pendulum
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2006 Audi TT
support/subframe causes the

engine/transmission assembly to swing forward
slightly.

Remove bolts - A - and then bolts - B - on pendulum support.
Push engine/transmission assembly forward slightly and then pull driveshaft
off bevel box.
Place driveshaft above bevel box and secure to prevent it from falling.
Prevent bevel box from falling by supporting it from below, e.g. with
engine/transmission jack V.A.G 1383 A. A second technician may be required
to hold bevel box.
CAUTION: There is a risk of the bevel box falling out once

the four securing bolts are removed.
Remove 4 securing bolts for bevel box at transmission.

Separate bevel box from transmission.
Installing
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2006 Audi TT
NOTE: All cable ties which are released or cut open during
removal must be replaced in the same position when
installing.
Secure bevel box to transmission using 4 new bolts.

Insert flange shaft into bevel box (turn flange shaft when doing so).
NOTE: Make sure the flange shaft is kept straight to avoid any
damage to the seal in the transmission.
Secure flange shaft using new countersunk bolt.
Install bracket - A - for bevel box, noting following assembly sequence:

1. First tighten bolts 1 to 3 Nm.
2. Tighten bolts 2 to 35 Nm.
3. Then tighten bolts 1 to 45 Nm.
Press engine/transmission assembly toward bulkhead. Bevel box pin must be

guided carefully into driveshaft flange when doing this.
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2006 Audi TT

NOTE: When removing and installing, do not damage seals in

driveshaft flanges. If seals are damaged, the driveshaft
must be replaced.
Push driveshaft horizontally onto guide pin: --> 39 -

Install pendulum support, using new bolts - arrows A - and - arrows B - -->
Pendulum support, removing and installing.
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2006 Audi TT

Bolt driveshaft with flexible coupling to bevel box flange - arrows - : --> 39 -
Fig. 229: Aligning Markings On Driveshaft At Flange Of Haldex Clutch

NOTE: Take note of the markings that were made on the

driveshaft and flange when removing. These must align
with each other again - arrows -.
Assemble exhaust system. --> 26 - EXHAUST SYSTEM, EMISSION

CONTROLS
Install right axle shaft --> 40 FRONT SUSPENSION .
Install heat shield for axle shaft onto bevel box.
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2006 Audi TT
Tightening torques
Component Nm
Flange shaft to transmission
30
(countersunk bolt), always replace bolt
Bevel box to transmission 4 x bolts 40 Nm plus 90° further (90° is
always replace bolts equivalent to a one quarter turn)
Heat shield for axle shaft 25
DRIVESHAFT, SERVICING
Driveshaft, servicing
For a description of the driveshaft --> 39 - FINAL DRIVE, DIFFERENTIAL .

Rear final drive
For a description of the rear final drive --> 39 - FINAL DRIVE,

DIFFERENTIAL .
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Direct Shift Auto Transmission

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Direct Shift Auto Transmission

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2006 Audi TT

6 Spd. Direct Shift Automatic Transmission 02E, All Wheel Drive

Fig. 1: Locating Transmission Identification

Code letters, transmission allocation, ratios, equipment

Direct shift transmission 02E 02E 02E

Calculating ratio "i"

6th gear Final drive

i = gear ratio = ZG : ZG = 35 : 38 = 0.92

i = axle ratio = ZA : ZA = 69 : 22 = 3.136

=i x i = 0.92 x 3.136 = 2.89

* Z = No. of teeth on drive gear, Z = No. of teeth on driven gear

Capacities Direct shift transmission 02E

Capacities Bevel box

CAUTION: Test equipment must always be secured on the

CAUTION: Follow steps required when disconnecting

In the event of a failure of one or more components/sensors, the transmission

Faults detected by the transmission are classified in four different categories.

Notes on the direct shift transmission 02E

The direct shift transmission 02E is also referred to as a dual-clutch transmission.

more detailed information refer to the relevant Self-Study Program.

On an automatic transmission, information regarding the selector lever position is

Regulations for the disposal of oil

Improper disposal of used oil endangers the environment.

Notes on tow-starting and towing

CAUTION: When the vehicle is being towed, the selector lever

NOTE: It is not possible to start the engine by means of tow-

A number of generally applicable instructions for the various repair procedures -

Guided fault finding, vehicle self-diagnosis and testing system

Fig. 2: VAS 5051 Vehicle Diagnosis, Testing & Information System

Do not overstretch locking rings/circlips; replace if necessary.

Loosen bolts in reverse sequence to the specified tightening sequence.

wire brush. Then apply AMV 185 101 A1 when inserting.

Rules for cleanliness

Thoroughly clean all joints and surrounding areas before disassembling.

Data Link Connector (DLC)

Fig. 3: Data Link Connector (DLC)

Location: below knee padding on left side of steering wheel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 5: Direct Shift Gearbox Components

Location: the Tiptronic switch -F189- is integrated in the selector mechanism; it is

Connector - D - for Tiptronic switch -F189-

Fig. 7: Transmission Range (TR) Selector Lever Display -Y6-

NOTE: Selector lever position indicator can only be replaced

Removing and installing: --> 90 INSTRUMENTS

Location: Selector lever -E313- is a fixed component of the selector mechanism

Fig. 9: Brake Light Switch -F-

Signal transmission from engine control module to transmission control

NOTE: Switch may only be installed once in order to ensure a

Fig. 10: Kickdown Switch -F8-

On vehicles with gasoline engine, a specific value supplied by the Throttle

Removing and installing accelerator pedal module: --> 20 - FUEL SUPPLY

Selector mechanism, servicing

Special tools, testers and auxiliary items required

Fig. 11: Torque Wrench V.A.G 1331

Torque wrench V.A.G1331

Locking cable adjustment gauge 3352 A

CAUTION: Before working on vehicle when engine is running,

Overview of connectors on selector mechanism --> Connectors on selector

position "S", "D" or "R" or in the tiptronic position.

Brake pedal not depressed:

Brake pedal not depressed:

Brake pedal depressed:

NOTE: When the brake pedal is depressed, it is also possible

Selector lever in "D" position, ignition switched on