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

CLEAN WORKING CONDITIONS

1. Always clean connection places and surrounding areas with engine or brake cleaner before loosening and try 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 parts: Remove packing from replacement parts immediately prior to installation and not before.
6. Protect disconnect electrical connectors from dirt and moisture and only connect when they are dry.

TRANSMISSION IDENTIFICATION

The 6-spd. direct shift transmission 02E, front wheel drive is installed in Audi TT from 2008. For allocation, refer to CODE LETTERS, ALLOCATION, RATIOS AND EQUIPMENT .

Scheme 278

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

Example

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

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

CODE LETTERS, ALLOCATION, RATIOS AND EQUIPMENT

CALCULATING OVERALL TRANSMISSION RATIOS "i"

Example

i = Z 2 : Z 1 (Z 1 = No. of teeth drive gear, Z 2 = No. of teeth 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

General Information

Transmission

The Direct Shift transmission 02E is also called S-Tronic 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 alternating hydraulically activated multi-plate clutches. The gears are automatically engaged or can be manually engaged in the Tiptronic position. A clutch pedal is not installed.

Selector mechanism

The parking lock is mechanically engage with selector lever cable only in P position. The remaining selector lever positions and shift functions are transmitted to direct shift transmission (DSG) mechatronic -J743- from selector lever -E313- in shift mechanism via CAN bus.

Gear oil and axle oil

The Direct Shift transmission 02E and front final drive have a shared gear oil fill. Refer to GEAR OIL LEVEL, CHECKING AND FILLING .

Note. Only the gear oil available as a replacement part may be used for the Direct Shift transmission 02E. Other oils can cause malfunctions or transmission failure.

DISPOSAL REGULATIONS FOR OILS

Drained oil must be disposed of properly.

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

GEAR SHIFT POINT VARIATIONS FOR HILLS

An additional gear shift map automatically selects gear shifts for hills dependent upon accelerator pedal position and driving speed.

1. The gear shift map for extreme inclines is matched to engine output.
2. The gear shift map for extreme declines is matched to 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) mechatronic -J743- activates 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 gear indicator D blinks when selector lever position "D" is engaged. To prevent damage to the transmission, the direct shift transmission (DSG) mechatronic -J743- 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.

TOW STARTING AND TOWING

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

REPAIR INSTRUCTIONS

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 measuring technology

1. Before performing repairs on the transmission, the cause of the malfunction must be determined as accurately as possible in the operating modes guided fault finding, vehicle on-board diagnosis and test instruments.

Special tools and equipment

For a complete list of special tools used in the Repair Information see ServiceNet under Special Tools.

Transmission

1. Do not run engine or tow vehicle with oil pan removed or without transmission fluid.
2. When replacing the transmission, check and top off gear oil. Refer to «GEAR OIL LEVEL, CHECKING AND FILLING»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd-coupe__gear-oil-level-checking-and-filling) ; capacities «CAPACITIES»(/audi/tt/8j-2006-2010/remont/automatic-trans/#general-technical-data-direct-shift-automatic-transmission-02e-fwd-coupe__capacities) , specification.
3. Make sure alignment bushings are properly installed during installation.

Seals, O-rings, shaft seals

Scheme 279

1. Replace seals, O-rings, shaft seals
2. After removing seals, check sealing surfaces on housing or shaft for burrs resulting from removal or damage.
3. Replace seals, completely remove old seal and clean sealing surfaces.
4. Coat O-rings with gear oil before inserting to prevent crushing rings during installation.
5. Lightly oil outer diameter of radial shaft seals and fill space between sealing lips -arrow- halfway with sealing grease, sealing grease.
6. Do not use any other lubricants in gear oil area. Otherwise, there is a risk that the hydraulic transmission controls could malfunction.
7. The open side of the shaft seals point toward the fluid to be sealed in.
8. Observe rules for cleanliness. Refer to «CLEAN WORKING CONDITIONS»(/audi/tt/8j-2006-2010/remont/automatic-trans/#general-technical-data-direct-shift-automatic-transmission-02e-fwd-coupe__clean-working-conditions) .
9. After installing, check transmission oil level and top off. Refer to «GEAR OIL LEVEL, CHECKING AND FILLING»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd-coupe__gear-oil-level-checking-and-filling) .

Locking elements

1. Do not strain circlips (replace if necessary).
2. Circlips must be properly seated in base of groove.

Bolts and nuts

1. Loosen bolts in reverse order of tightening.
2. Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
3. Replace self-locking nuts.
4. Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with locking compound; locking compound.
5. The tightening torques stated apply to unoiled bolts and nuts.
6. Tightening torque with additional torque: After tightening to torque, these bolts must be tightened further to the specified angle, for example 40 Nm plus an additional 90° (90° corresponds to a quarter turn).

CAPACITIES

Transmission capacity

Note. Only the gear oil available as a replacement part may be used for the 02E Direct Shift 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 OIL FILTER .

Gear oil level, checking and topping off. Refer to GEAR OIL LEVEL, CHECKING AND FILLING .

Gear oil, filling after repairs. Refer to TRANSMISSION FLUID, CHANGING AND FILLING .

See also:
• GEAR OIL LEVEL, CHECKING AND FILLING
• Maintenance, Diagnosis
• TRANSMISSION OIL FILTER
• TRANSMISSION FLUID, CHANGING AND FILLING
• CODE LETTERS, ALLOCATION, RATIOS AND EQUIPMENT
• CAPACITIES
• CLEAN WORKING CONDITIONS