Removal & Installation - 02E: Other Audi TT 8N facelift

TRANSMISSION

The transmission code is located on the top of the transmission, near the oil cooler. (Scheme 108) The code letters of the transmission are also given on the vehicle data stickers.

Scheme 108

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.

GEAR OIL

The gear oil level in transmission and final drive (front) is checked and topped up together. See SERVICING - 02E article.

1. 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.

The oil level in the bevel box is checked and topped up separately.

1. 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.

1. Improper disposal of used oil endangers the environment.
2. It is forbidden to add solvents, brake fluid, coolant or similar to the used oil.
3. Please observe the information shown on the packaging of the oil.

NOTES ON TOW STARTING & TOWING

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

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.

1. Do not run the engine or tow the vehicle with the oil pan removed or when there is no gear oil in the transmission.
2. When replacing the transmission the gear oil, checking and topping up must be checked and topped up, if necessary. Filling quantities and specification. See «SERVICING - 02E»(ref-172698) article.
3. Thoroughly clean all joints and surrounding areas before disassembling.
4. When installing the transmission, ensure that the dowel sleeves are fitted correctly.

O-RINGS, OIL SEALS, GASKETS

1. Always install new O-rings, oil seals and gaskets.
2. 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.
3. Always replace paper gaskets. Completely remove old gasket and clean sealing surfaces thoroughly.
4. Lightly lubricate the outer circumference and sealing lip of oil seals with gear oil before installing.
5. Lightly lubricate O-rings with gear oil or Vaseline before inserting to prevent them from getting crushed during assembly.
6. Do not use any other lubricants where gear oil is used. Otherwise, there is a risk of problems occurring in the transmission hydraulics.
7. The open side of the oil seals faces the side with fluid filling.
8. Observe the rules for cleanliness. See
9. After installing, check the gear oil level, adjust to correct level if necessary. See «SERVICING - 02E»(ref-172698) article.

LOCKING ELEMENTS

1. Do not overstretch locking rings/circlips; replace if necessary.
2. Locking rings/ circlips must be properly seated in the base of the groove.

NUTS, BOLTS

1. Loosen bolts in reverse sequence to the specified tightening sequence.
2. 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.
3. Replace self-locking nuts.
4. Clean the threads of bolts which are secured by a locking compound with a wire brush. Then apply AMV 185 101 A1 when inserting.
5. The tightening torques stated apply to non-oiled nuts and bolts.

RULES FOR CLEANLINESS

1. Thoroughly clean all joints and surrounding areas before disassembling.
2. Place removed parts on a clean surface and cover them over. Use sheeting and paper. Use lint-free cloths.
3. Carefully cover or seal open components if repairs cannot be performed immediately.
4. Only install clean components: do not remove replacement parts from packaging until just before installation.
5. Always install new O-rings, oil seals and gaskets.
6. Always replace paper gaskets. Completely remove old gasket and clean sealing surfaces thoroughly.
7. Clean the threads of bolts which are secured by a locking compound with a wire brush. Then apply AMV 185 101 A1 when inserting.

BATTERY DISCONNECT PRECAUTIONS

Before disconnecting battery, obtain anti-theft code for radio. After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.

On vehicles equipped with Audi Telematics by OnStar(R), switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery. Emergency battery is turned on and off using VAG 1551/VAG 1552 or VAS 5051/VAS 5052 scan tool in address word 75 - TELEMATICS set to function 10 - ADAPTATION CHANNEL 08.

Scheme 109

1. Support bracket 10 - 222 A
2. Bracket 10 - 222 A /1
3. Engine/transmission jack V.A.G 1383 A
4. Transmission support 3282
5. Shackle 10 - 222 A /12
6. Hose clamps, up to 25 mm diameter 3094 (Scheme 109)
7. Adjustment plate 3282/42
8. Hooks 3004

NOTES

1. Read rules for cleanliness when working on the transmission. See «RULES FOR CLEANLINESS»(ref-172873-S02696559072005030800000) .
2. General repair instructions. See «REPAIR INSTRUCTIONS»(ref-172873-S03412920192005030800000) .
3. Observe notes on direct shift transmission 02E. See «NOTES ON THE DIRECT SHIFT TRANSMISSION 02E»(ref-172873-S36098539642005030800000) .

TRANSMISSION, 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.

Remove cover panel (front left) - arrows -. (Scheme 110)

Scheme 110

Disconnect ground strap on battery with ignition switched off.

Loosen clamp - 4 - and disconnect intake hose and connector - 1 - from mass air flow sensor. (Scheme 111) If installed, disconnect hose - 5 - from air cleaner housing. Remove bolts - 2 - and - 3 - and remove complete air cleaner housing.

Scheme 111

Unclip complete main fuse box/battery - A - including all wiring from battery tray. (Scheme 112)

Scheme 112

Remove battery tray - arrows -. (Scheme 113)

Scheme 113

Shift selector lever into "P" position.

Push circlip - A - upward and remove it in direction of arrow. (Scheme 114)

Scheme 114

Press selector lever cable off selector shaft lever in direction of arrow and place 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.

Turn bayonet catch - 1 - of 20-pin connector to release and disconnect it from transmission. (Scheme 115)

Scheme 115

Disconnect electrical connections from starter.

Remove starter - A -. (Scheme 115)

Clamp off gear oil cooler hoses using - 3094 - and disconnect at gear oil cooler - A -. (Scheme 116) Seal off gear oil cooler with clean plugs.

Scheme 116

Remove all engine/transmission connecting bolts which are accessible from above. (Scheme 117)

Scheme 117

Assemble support bracket 10 - 222 A together with brackets 10 - 222 A /1 and 10 - 222 A /3. (Scheme 118) (- 1 -: Shackle 10-222 A/12.)

Scheme 118

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.

Remove center sound insulation fasteners - 1 through 3 -. (Scheme 119)

Scheme 119

Remove sound insulation (left side) - arrows -. (Scheme 120)

Scheme 120

Remove front wheels.

If installed, unscrew bracket for headlight range control in left wheelhousing - arrows - and tie it up to one side. (Scheme 121)

Scheme 121

If installed, remove protective plate at bottom of transmission - arrows -. (Scheme 122)

Scheme 122

Press out right and left ball joints. (Scheme 123)

Scheme 123

Remove bolts - 1 - and - 2 - and remove bracket - A -. (Scheme 124)

Scheme 124

Unscrew nut - 1 - and push bracket - A - upward so it does not get stuck when transmission is lowered. (Scheme 125)

Scheme 125

Disconnect exhaust system at clamp - arrows -. (Scheme 126)

Scheme 126

Push clamp toward rear.

Tie up exhaust system with a chain by engaging hooks 3004 in openings on underbody (if necessary remove plugs). (Scheme 127)

Scheme 127

Note. The flexible pipe connection (de-coupling element) of the exhaust system must not be bent more than 10° - otherwise it can be damaged.

Unbolt heat shield for axle shaft (right side) from bevel box. (Scheme 128)

Scheme 128

Unbolt axle shafts from transmission flanges. For more information, see AXLE SHAFTS - FWD & AWD article.

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. Remove driveshaft with flexible coupling from bevel box flange - arrows -. (Scheme 129)

Scheme 129

Press driveshaft horizontally to rear as far as possible. (Scheme 130)

Scheme 130

First remove bolts - A - and then bolts - B - on pendulum support. (Scheme 131)

Scheme 131

Remove 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.

Remove subframe. See SUBFRAME in SUSPENSION - FRONT article. (Scheme 132)

Scheme 132

Unscrew bolts - 1 - and - 2 - at bracket for bevel box. (Scheme 133) Remove bracket - A - for bevel box.

Scheme 133

From above: Remove transmission console - A - (remove bolts - 1 - and - 2 - ). (Scheme 134)

Scheme 134

Lower engine/transmission assembly using spindles until distance a = 100-110mm between transmission housing and transmission mounting is attained. (Scheme 135)

Scheme 135

To remove the direct shift transmission 02E the transmission support 3282 is set up together with the adjustment plate 3282/42. (Scheme 136)

Scheme 136

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 -. (Scheme 136) 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

Perform installation in reverse sequence of removal. Note the following

Note. Secure all hose connections with the correct hose clamps. Replace gaskets and seals.

Before installing, ensure that dowel sleeves - A - are correctly seated in cylinder block. (Scheme 117)

Before installing transmission, check needle bearing in crankshaft.

To install the direct shift transmission 02E the transmission support 3282 is set up together with the adjustment plate 3282/42. (Scheme 136)

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 -.

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 .

Carefully press selector lever cable onto selector shaft lever on transmission in opposite direction of arrow. (Scheme 114) Install circlip - A - and press downward to secure.

Note. Do not kink selector lever cable.

Install the assembly mounting as follows: Place transmission support - A - between transmission and transmission mounting. (Scheme 134)

Pull transmission up to transmission mounting with spindle on support bracket.

Replace transmission support bolts.

Tighten bolts - 1 - to 50 Nm, plus 90° (90° is equivalent to a one quarter turn). (Scheme 134)

Replace bolts for transmission support to transmission mounting - arrows -. (Scheme 137) Initially tighten bolts finger-tight, then tighten to specified torque of 100 Nm.

Scheme 137

Screw in securing bolts - 1 - and - 2 - at bracket for bevel box finger-tight. (Scheme 133)

Secure bracket for bevel box; note following assembly sequence

Screw in all bolts finger-tight. Tighten bolts - arrow 1 - initially to 3 Nm. (Scheme 133) Tighten bolts - arrow 2 - to 35 Nm.

Replace cable support bracket bolts (- 1 -). (Scheme 114) Secure support bracket - D - together with selector lever cable to transmission.

Tighten NEW cable support bracket bolts - 1 - (M8) to 20 Nm, plus 90° (90° is equivalent to a one quarter turn).

Note. Do not kink selector lever cable.

Install subframe. SUBFRAME in SUSPENSION - FRONT article.

Install ball joint to wheel bearing housing. Tighten NEW nuts to 70 Nm.

Screw on pendulum support at transmission - arrows B -. (Scheme 131) Replace bolts.

Press engine/transmission assembly toward bulkhead. Bevel box pin must be guided carefully into driveshaft flange when doing this.

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.

Use new bolts and screw on pendulum support at subframe - arrows A -. (Scheme 131) See PENDULUM SUPPORT TORQUE SPECIFICATIONS.

Bolt driveshaft with flexible coupling to bevel box flange - arrows -. (Scheme 129) Tighten bolts to 60 Nm.

Take note of the markings that were made on the driveshaft and differential flange when removing. These must align with each other again - arrows -. (Scheme 138) Tighten bolts to 60 Nm.

Scheme 138

Assemble exhaust system.

Install heat shield for axle shaft (right side) and tighten bolts to a torque of 25 Nm.

Install front axle shaft to transmission flanges. Initially tighten bolts to 89 INCH lbs. (10 N.m). Final tighten to 52 ft. lbs. (70 N.m).

If equipped, install bracket for headlight range control in wheelhousing (left side) - arrows -. (Scheme 121)

Install bracket - A - (bolts - 1 - and - 2 - ). (Scheme 124) Bracket - A - is secured to front of engine oil pan.

Secure bracket - A - using nut - 1 - to front cover of transmission. (Scheme 125)

Install front wheels. Tighten wheel lug bolts to 120 N.m.

Install battery. Follow steps required after connecting battery. See BATTERY DISCONNECT PRECAUTIONS .

Assemble exhaust system free of stress.

Check transmission oil level and top up if necessary. See SERVICING - 02E article.

Check selector lever cable setting and adjust if necessary.

Check coolant level in cooling system. See COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING article.

Scheme 139

Scheme 140

Scheme 141

Scheme 142

1. Support bracket 10 - 222 A
2. Shackle 10 - 222 A /12

Removing

Remove cover panel (front left) - arrows -. (Scheme 110)

Disconnect ground strap on battery with ignition switched off.

Loosen clamp - 4 - and disconnect intake hose and connector - 1 - from mass air flow sensor. (Scheme 111) If installed, disconnect hose - 5 - from air cleaner housing. Remove bolts - 2 - and - 3 - and remove complete air cleaner housing.

Unclip complete main fuse box/battery - A - including all wiring from battery tray. (Scheme 112)

Remove battery tray - arrows -. (Scheme 113)

Note. The sole purpose of the battery tray is to secure the main fuse box/battery.

Assemble support bracket 10 - 222 A together with bracket 10 - 222 A /1 and bracket 10 - 222 A /3. (Scheme 118) (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 -. (Scheme 118)

Take up weight of engine/transmission assembly via spindle.

Unscrew bolts - 2 - to release transmission console - A - from transmission mounting. (Scheme 134)

Lower engine/transmission assembly slightly via spindle.

Remove all components to obtain access to bolts - 1 - and - 2 - on transmission mounting. (Scheme 143) Unscrew bolts - 1 - and - 2 -.

Scheme 143

Take off transmission mounting - A -.

Installing

Perform installation in reverse sequence of removal. Note the following.

Install transmission mounting - A -. (Scheme 143) Replace bolts - 1 -.

TRANSMISSION MOUNTING A BOLT TORQUE SPECIFICATION

Pull transmission up to transmission mounting with spindle on support bracket.

Secure transmission mounting to transmission support - A - using NEW bolts - 2 -. Bolts - 2 - Tightening torque 100 Nm. (Scheme 134)

Raise vehicle.

Remove center sound insulation tray -fasteners - 1 through 3 -. (Scheme 119)

First remove bolts - arrows A - and then bolts - arrows B - on pendulum support. (Scheme 131)

Remove pendulum support.

Perform installation in reverse sequence of removal. Note the following

Using new bolts, first secure pendulum support to transmission - arrows B -, then on subframe - arrows A -. (Scheme 131)

PENDULUM SUPPORT TORQUE SPECIFICATIONS

Scheme 144

1. Bracket T10013
2. Workshop crane VAS 6100 (Scheme 144)

Transporting

Bracket T10013 can be used to transport the automatic transmission and also when setting up transmission support 3282. See .

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.

Attach workshop crane VAS 6100 to bracket T10013 .

Scheme 145

1. Engine/transmission support VW 540
2. Holding fixture VW 313 (Scheme 145)

Securing

Secure transmission to engine/transmission support VW 540 - arrows - and fit into holding fixture VW 313. (Scheme 146)

Scheme 146

For insertion it is possible to use workshop crane VAS 6100, see TRANSPORTING THE AUTOMATIC TRANSMISSION .

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.