General, Technical Data (Direct Shift Automatic Transmission 02e Awd (coupe)) Audi TT 8J

CALCULATING TRANSMISSION RATIO I

Example

i = Z 2 : Z 1 (Z 1 = Number of teeth on the drive gear, Z 2 = number of teeth on the driven gear)

i G = gear ratio = ZG 2 : ZG 1 = 33: 40 = 0.825

i A = axle ratio = ZA 2 : ZA 1 = 72: 20 = 3.6

i total = total ratio= i G x i A = 0.825 x 3.6 = 2.97

CLEAN WORKING CONDITIONS

1. Always clean connection places and surrounding areas with engine or brake cleaner before loosening and dry cleaned places.
2. Immediately seal open lines and connections with clean plugs or protective caps.
3. Place removed parts on a clean surface and cover. Only use lint-free cloths for this!
4. Carefully cover or plug unpacked components if repairs cannot be performed immediately.
5. Only install clean components: Remove the replacement parts from their packaging just prior to installing them.
6. Protect the disconnected connectors from dirt and moisture and only connect when they are dry.

CODE LETTERS, TRANSMISSION ALLOCATIONS, RATIOS AND EQUIPMENT

REPAIR INFORMATION

For the transmission to be repaired successfully and to function correctly, the greatest possible care and cleanliness and proper tools are required. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A series of generally applicable notes for individual repair procedures have been gathered here which otherwise would be listed several times in many places in the repair information. They apply to this repair information.

Guided Fault Finding, On Board Diagnostic (OBD) and Test Instruments

1. Try to determine the exact cause of the fault using "Guided Fault Finding", "OBD" and "Test Instruments" before servicing the transmission using a vehicle diagnostic tester.

Special Tools and Equipment

For a complete list of special tools used in the Repair Information, refer to Service Net under Special Tools and Equipment.

Transmission

1. Do not run engine or tow the vehicle when the oil pan is removed or when there is no transmission fluid.
2. When replacing a transmission, always check the transmission fluid level and add if necessary. Refer to «TRANSMISSION FLUID, CHECKING AND FILLING»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe__transmission-fluid-checking-and-filling) ; capacities, refer to «CAPACITIES»(/audi/tt/8j-2006-2010/remont/automatic-trans/#general-technical-data-direct-shift-automatic-transmission-02e-awd-coupe__capacities) , specifications
3. During installation, make sure that the alignment bushings are installed correctly.

Seals, O-rings, Shaft Seals

Scheme 275

1. Replace the seals, O-rings and the shaft seals.
2. After removing seals, check sealing surfaces on housing or shaft for burrs resulting from removal or damage.
3. Replace the seals, completely remove old seal and clean sealing surfaces.
4. Coat the O-rings with gear oil before inserting to prevent crushing them.
5. Coat the radial shaft seals lightly with oil on the outer circumference and fill the space between the sealing lip -arrow- halfway with sealing grease. For the correct sealing grease
6. Do not use any other lubricants in the gear oil area. Otherwise there is a danger of malfunction of the transmission hydraulics.
7. The open side of the shaft seals point toward the fluid to be sealed in.
8. Follow the rules for clean working conditions, refer to «CLEAN WORKING CONDITIONS»(/audi/tt/8j-2006-2010/remont/automatic-trans/#general-technical-data-direct-shift-automatic-transmission-02e-awd-coupe__clean-working-conditions) .
9. After installing, check the gear oil level and fill if necessary, refer to «TRANSMISSION FLUID, CHECKING AND FILLING»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe__transmission-fluid-checking-and-filling) or check the axle oil level and fill if necessary «AXLE OIL LEVEL, CHECKING AND FILLING»(/audi/tt/8j-2006-2010/remont/axle-shafts/#final-drive-differential-direct-shift-automatic-transmission-02e-awd-coupe__axle-oil-level-checking-and-filling) .

Fasteners

1. Be careful not to overstretch the locking rings. Replace them if necessary.
2. The circlips must fit completely inside the groove.

Bolts and Nuts

1. Loosen the bolts opposite the tightening sequence.
2. Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
3. Replace the self-locking nuts.
4. Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Then install the bolts with locking compound. For the correct locking compound
5. The tightening specifications stated apply to non-oiled nuts and bolts.
6. Tightening specification with additional torque: After tightening to the specification, these bolts must be tightened further to the specified angle, for example, 40 Nm + 90° (90° corresponds to a quarter turn).

CONTACT CORROSION

Contact corrosion can occur if incorrect fasteners are used on the vehicle (bolts, nuts, washers, etc.).

For this reason, only connecting elements with a special surface coating are installed.

In addition, rubber or plastic parts and adhesive are made of materials that do not conduct electricity.

If you are not sure about the suitability of parts, install new parts.

Note. We recommend using Original Replacement Parts only. They have been inspected and are compatible with aluminum. It is recommended to use Audi accessories. Damage resulting from contact corrosion is not covered by the warranty.

TEST DRIVES WITH THE USE OF TEST AND MEASURING DEVICES

If testing equipment must be used during a road test, observe the following

Scheme 276

WORK ON THE VEHICLE

Observe the following to avoid personal injury and vehicle damage

To prevent personal injury and damage or destruction of electrical and electronic components, observe the following

1. Connect and disconnect test equipment only when the ignition is turned off.

Disconnect the battery. Refer to [For transmission(s) 02E] Removal and Installation .

TOWING

Note. If the battery is too weak or the starter does not work, the vehicle cannot be tow-started.

Transmission

The DSG transmission 02E is also called "S-Tronic Transmission" double clutch transmission, it is constructed like a 6-speed manual transmission. The engine torque is transferred to the transmission via the dual-mass flywheel. It is operated like an automatic transmission by both multi-plate clutches that are hydraulically activated. The gears are automatically engaged or can be manually engaged in the Tiptronic position. Clutch pedal is not available.

Selector Mechanism

The parking lock is mechanically engaged by the selector lever cable only in "P". The remaining selector lever positions and shift functions are transmitted to the Direct Shift Gearbox (DSG) Transmission Mechatronic -J743- from the selector lever -E313- in the shift mechanism via the CAN bus.

Gear Oil and Axle Oil

The direct shift automatic transmission and front final drive have a shared gear oil fill. Refer to TRANSMISSION FLUID, CHECKING AND FILLING .

Note. Only the gear oil available as a replacement part may be used for the 02E direct shift automatic transmission. Other transmission fluids can cause malfunctions or transmission failure.

The bevel box has a separate axle oil fill. Refer to AXLE OIL LEVEL, CHECKING AND FILLING .

Note. Only the axle oil available as a replacement part may be used with the bevel box. Other fluids can cause malfunctions or bevel box failure.

Disposal Regulations for Oils and Fluids

Dispose of drained oil properly.

1. Disposing of used oils and fluids improperly endangers the environment.
2. Mixing with solvents, brake fluid and coolant is not permitted.
3. Observe information on oil the packaging.

Shift Point Changes on Inclines and Declines

An additional gear change map automatically selects the gear changes for gradients dependent upon accelerator pedal position and driving speed.

1. The gear change map for extreme inclines is matched to engine output.
2. The gear change map for extreme declines is matched to the engine braking action.
3. By selecting a gear directly in Tiptronic mode, the engine braking effect can be used with a specific gear engage, for example when driving downhill with a trailer.

TRANSMISSION CONTROL MODULE SAFETY FUNCTIONS

If components or sensors fail, the Direct Shift Gearbox (DSG) Transmission Mechatronic -J743- activates the corresponding emergency mode replacement program. The transmission can still be operated without causing damage, but shift function and quality are affected.

When malfunctions are detected by the transmission, a distinction is made between 4 possible statuses.

1. A malfunction is saved and a replacement program is activated at the same time. The gear display in the instrument cluster does not change and indicates the selector lever position engaged. Driving further is possible with restrictions, the condition is not critical for either driving safety or the transmission. The driver will only notice the fault - if it is noticed at all - in terms of handling problems and will then automatically consult Audi Service.
2. The individual selector lever positions blink in the instrument cluster gear display. The driver is shown that a desired gear selection is currently not possible. Example: If the vehicle rolls backwards in "R" selector lever position and the gear indicator "D" blinks when selector lever position "D" is engaged. To prevent damage to the transmission, the DSG transmission Mechatronic prevents 1st gear from being engaged as long as the vehicle is rolling backwards. 1st gear is engaged only when the vehicle comes to a standstill.
3. The gear display lights up completely and blinks, the position engaged is highlighted. The driver is notified of a temporary serious malfunction. Example: The transmission was overloaded and the maximum temperature in the transmission is exceeded, possibly due to towing a trailer with excessively high load. Driving further is possible once the transmission has cooled, but high load must be avoided.
4. The gear display blinks, the position engaged is not recognized. The driver is notified of a permanent serious malfunction. Because individual gears can no longer be engaged, this condition is critical for driving safety and for the transmission. This type of display instructs this driver to go to an Audi service center.

TRANSMISSION IDENTIFICATION

The "6-speed DSG 02E, AWD" is installed in the Audi TT from MY 2007. Refer to CODE LETTERS, TRANSMISSION ALLOCATIONS, RATIOS AND EQUIPMENT .

Scheme 277

The transmission code letters are on top of the transmission near the transmission oil cooler.

Example

1. GKF = Transmission code
2. 10.05.2 = Production date May 10th, 2002.
3. The rest of the numbers depend on manufacturing.

Note. The transmission code is also on the vehicle data stickers.

CAPACITIES

Transmission Capacity

Note. Only the gear oil available as a replacement part may be used for the 02E S-Tronic transmission. Other oils can cause malfunctions or transmission failure. If the gear oil is replaced, transmission oil filter must also be replaced, refer to TRANSMISSION FLUID FILTER .

Transmission fluid level, checking and filling, refer to TRANSMISSION FLUID, CHECKING AND FILLING .

Gear oil, filling after repairs, refer to TRANSMISSION FLUID, REPLACING OR FILLING AFTER REPAIR .

Bevel Box Capacity

Note. Only the axle oil available as a replacement part may be used with the bevel box. Other oils can cause malfunctions or bevel box failure.

Axle oil level, checking and filling, refer to AXLE OIL LEVEL, CHECKING AND FILLING .

Axle oil, filling after repairs, refer to AXLE OIL, DRAINING, OR FILLING AFTER REPAIRS .

See also:
• TRANSMISSION FLUID, CHECKING AND FILLING
• AXLE OIL LEVEL, CHECKING AND FILLING
• [For transmission(s) 02E] Removal and Installation
• TRANSMISSION FLUID FILTER
• TRANSMISSION FLUID, REPLACING OR FILLING AFTER REPAIR
• AXLE OIL, DRAINING, OR FILLING AFTER REPAIRS
• CAPACITIES
• CLEAN WORKING CONDITIONS
• CODE LETTERS, TRANSMISSION ALLOCATIONS, RATIOS AND EQUIPMENT