Servicing - 09G: Other Audi TT 8N facelift

TRANSMISSION

This transmission can be identified by code letters stamped on case. (Scheme 47) The code letters of the transmission are also given on the vehicle data plates.

Scheme 47

TRANSMISSION CODE EXPLANATION (EXAMPLE)

Transaxle

Check fluid level at 20,000 mile intervals. Fluid is filled for life. No changing is required.

Final Drive

Check fluid level at 20,000 mile intervals. Fluid is filled for life. No changing is required.

09G Transaxle

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Requirements for checking ATF level are as follows: Transmission not in emergency running mode. Vehicle in horizontal position. Air conditioner and heating must be switched off.
2. Mount reservoir of ATF filler system (V.A.G. 1924) as high as possible on vehicle. Drive vehicle onto a four column lifting platform or over an assembly pit in order for it to be absolutely horizontal.
3. Remove sound insulation tray (arrows). (Scheme 51)
4. Place drip tray (V.A.G. 1306) under transmission. Remove drain plug (arrow "B"). (Scheme 48) Allow ATF to drain out.
5. Unscrew ATF inspection plug (A). Unscrew overflow pipe (C), and allow remaining ATF to drain away. (Scheme 52)
6. Replace seal on ATF drain plug (B), and install plug. (Scheme 48) Tighten ATF drain plug to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
7. Install overflow pipe (C). (Scheme 52) Tighten overflow pipe to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
8. Using Torx socket head (T55), remove filler plug (arrow). (Scheme 53)
9. Attach hook of filler system (V.A.G. 1924) in filler plug hole (arrow). (Scheme 54) Top off ATF until ATF emerges via overflow pipe (arrow "2") from inspection hole. (Scheme 50)
10. Move selector lever to "P" position. Start engine. Continue to top off ATF with V.A.G. 1924 until ATF emerges from inspection hole again. Install ATF inspection plug. Tighten ATF inspection plug to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
11. With brake pedal depressed, and engine running at idle, select all selector lever positions "P,R,N,D,S" in sequence. Hold each position for a minimum of 3 seconds. Move selector lever to "P" position. Check and top off ATF level. See «CHECKING FLUID LEVELS»(ref-170597-S16947090572005011200000).
12. Install all components. Tighten all bolts and plugs to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).

SHIFT MECHANISM

1. It should not be possible to actuate starter if selector lever is in "S", "D" or "P" position, or Tiptronic setting.
2. At speeds over 3 MPH (5 km/h), and with selector lever set to "N", shift lock solenoid should not engage, and should lock selector lever. Selector lever can be shifted into a driving gear. When travelling at speeds below 3 Mph (5 km/h), and shifting into selector lever position "N", shift lock solenoid must not engage until after approximately 1 second. Selector lever cannot be shifted out of "N" position until brake pedal is depressed.
3. With selector lever in "P" position, ignition switched on and brake pedal not depressed, selector lever is locked and cannot be moved from "P" position. Shift lock solenoid locks selector lever.
4. With Selector lever in "P" position, ignition switched on and brake pedal depressed, Shift lock solenoid releases selector lever. It is possible to shift into a driving gear. Slowly shift selector lever from "P" through "R, N, D, S", checking whether display on instrument cluster corresponds to selector lever position.
5. With selector lever in "N" position, ignition on and brake pedal not depressed, selector lever is locked and cannot be shifted out of "N" position. Sift lock solenoid locks selector lever.
6. With selector lever in "N" position, ignition on and brake pedal depressed, shift lock solenoid releases selector lever. It is possible to shift into a driving gear.
7. With selector lever in "D" position, ignition and light switched on and selector lever shifted into Tiptronic gate, "D" symbol in selector lever display should no longer be illuminated and "+" and "-" symbols should illuminate. Selector lever position display in instrument cluster must switch from "PRDNS" to "654321" when selector lever is shifted into Tiptronic gate.
8. Check and adjust selector lever cable. See «SELECTOR LEVER CABLE»(ref-170597-S16863672122005011200000) under ADJUSTMENTS.

IGNITION KEY WITHDRAWAL LOCK

Check ignition key withdrawal lock. (Scheme 55)and (Scheme 56).

Scheme 52

Scheme 53

ON-VEHICLE REPAIRS

Note. Various components may be serviced without transaxle removal. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION .

LOCKING CABLE

Note. Locking cable must always be adjusted in installation position.

Scheme 54

1. Remove rear center console. See «REAR CENTER CONSOLE»(ref-170597-S22561534702005011200000). Move selector lever in "P" position. Place key in ignition and turn ignition to "Off" position. Move steering column to back/down position.
2. Loosen support bracket bolt. Install adjustment gauge (3352 A) between locking lever (1) and locking cable eye (2). (Scheme 57) To compensate for play, pull support bracket up to limit stop in direction of arrow. It must be possible to remove and insert adjustment gauge (3352 A) easily in this position.
3. Tighten support bracket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000). Remove setting bar. Check function of ignition key removal lock. (Scheme 55)and (Scheme 56).

Scheme 55

Scheme 56

Scheme 57

Scheme 58

1. Shift selector lever into "N" position. Switch ignition off. Disconnect hose (5) from air cleaner housing. (Scheme 58)
2. Using a screwdriver, press selector lever cable (1) off lever/selector shaft (6). (Scheme 59) Do not loosen bolt (2). Do not kink selector lever cable.
3. Remove lever/selector shaft (1). (Scheme 60)
4. Loosen both bolts (B). Do not fully unscrew bolts. Install adjustment gauge (T10173) on selector shaft. (Scheme 61) Turn multi-function TR switch (A) until tab of connector (arrow "1") engages in groove of adjustment gauge (T10173).
5. If connector tab cannot engage in groove of adjustment gauge, transmission is no longer in "N" position. If transmission is no longer in "N" position, switch transmission to "N" position by turning adjustment gauge forward or backward, as appropriate, until tab of connector (arrow "1") is able to engage in groove of adjustment gauge (T10173). Turn multi function TR switch (A) slightly, if necessary.
6. Secure adjustment gauge (T10173) on selector shaft with knurled screw (C). (Scheme 61) Tighten both bolts (B) to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000). Remove adjustment gauge from selector shaft.
7. Install lever/selector shaft (1). (Scheme 60) Tighten selector lever-to-selector shaft nuts (3) to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
8. Press selector lever cable (1) onto lever/selector shaft (6). (Scheme 59) It may be necessary to shift lever/selector shaft to right position to be able to press on selector lever cable.
9. Connect hose (5) to air cleaner housing. (Scheme 58) Check setting of selector lever cable, and adjust as necessary. See «SELECTOR LEVER CABLE»(ref-170597-S16863672122005011200000).

Scheme 59

Scheme 60

1. Move selector lever to "P" position. Using open ended 10 mm wrench (2) or similar, pry off selector lever cable (1) from lever/selector shaft (3). (Scheme 62)
2. Press catches on support bracket of selector lever cable together (arrows) and pull selector lever cable out of support bracket/transmission. (Scheme 62) Press selector lever from "P" to "S" position. Check protective sleeve on front of selector lever cable for damage and replace cable, if necessary.
3. Move selector lever to "P" position. Shift mechanism and selector lever cable must move freely. If necessary, replace selector lever cable or service shift mechanism. See «SELECTOR LEVER CABLE»(ref-170597-S16746228502005011200000) under REMOVAL & INSTALLATION. Carefully press selector lever cable onto lever/selector shaft and insert in support bracket/transmission.
4. Move selector lever to "P" position. Loosen bolt (2) at front ball socket of selector lever cable (1). (Scheme 63) Set lever/selector shaft (3) on transmission to "P" position. Detent lever must engage in parking lock gear, both front wheels are locked, and not able to be turned together in one direction. Tighten bolt (2) to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000). Check shift mechanism. See «SHIFT MECHANISM»(ref-170597-S41371128862005011200000) under INSPECTION.

BATTERY DISCONNECT PRECAUTIONS

Note. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

Air Bag

ECM

If connector is disconnected from ECM or battery is disconnected, all adaptation values in control module are erased. To achieve optimal anti-theft protection for vehicle, an anti-theft immobilizer was installed.

ECM Readiness Code

Readiness code must be generated when Engine Control Module (ECM) memory is cleared, battery voltage is disconnected or ECM is disconnected. To generate readiness code, a scan tool must be used.

Power Windows

After connecting battery, completely open and close all power windows.

Radio

Vehicles are equipped with an anti-theft stereo system that requires a code to activate. Record stereo code BEFORE disconnecting negative battery cable. Disconnect negative battery cable. Turn ignition to ON position. Reconnect negative battery cable. Enter code into stereo and reset clock.

Scheme 61

Scheme 62

Scheme 63

1. On vehicles equipped with coded radio, obtain radio code. Remove cover from engine.
2. With ignition switch turned to OFF position, disconnect negative battery cable. Pull intake hose (1) and connector (2) for Mass Air Flow (MAF) sensor. (Scheme 64) Pull secondary air pump hose (3) off air cleaner housing. Remove bolts (4, 5, and 6). Remove complete air cleaner.
3. Using hose clamps (3094), clamp off ATF cooler hoses. (Scheme 65) Disconnect from ATF cooler.
4. Remove ATF cooler (1) from transmission (arrow A). (Scheme 66)
5. When installing ATF cooler (1), seat lug (arrow B) into cutout in transmission housing. (Scheme 66) Insert bolt (arrow A). Tighten to 26 ft. lbs. (36 N.m).
6. Check coolant level in coolant system. See appropriate SPECIFICATIONS & DRIVE BELT ROUTING article in ENGINES.
7. Check ATF level. See «CHECKING FLUID LEVELS»(ref-170597-S16947090572005011200000) under LUBRICATION. Top off as necessary.

Scheme 64

1. Remove oil pan. See «OIL PAN»(ref-170597-S21594399982005012000000).
2. Unscrew bolts for ATF screen (arrows). see scheme 25 Remove ATF screen (A) from valve body.
3. To install, apply a thin coating of ATF to seals around suction collar of ATF screen (rear side). Install ATF screen on valve body and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-170597-S13798279542005011200000).
4. Install oil pan. See «OIL PAN»(ref-170597-S21594399982005012000000).
5. Fill with ATF. See «DRAINING & REFILLING»(ref-170597-S32383465402005011200000). Check ATF level, and top off as necessary. See «CHECKING FLUID LEVELS»(ref-170597-S16947090572005011200000).

Scheme 65

Scheme 66

1. Remove drive axle shaft from transmission flange. See «AXLE SHAFTS - FWD & AWD»(ref-161308) article in DRIVELINE/AXLES.
2. Plug opening in transmission for drive shaft with clean cloth (A). see scheme 26 Place drip tray (V.A.G. 1306) under transmission. Using a commercially available steel drill bit (B), size 2 to 4, drill hole in outer metal ring of shaft sealing ring.
3. Protect housing surface with pad (B) and pry shaft sealing ring out at hole using mandrel (C). see scheme 27 Remove cloth (A), and clean transmission thoroughly. If it was only possible to remove metal ring of shaft sealing ring when prying out, use screwdriver (A) to pry out remainder of shaft sealing ring. (Scheme 67)
4. Installation is reverse of removal procedure. Lightly lubricate outer circumference and sealing lips of sealing ring with ATF. Install new sealing ring by hand. Install straight and press in as far as possible so that shaft sealing ring is held in position in transmission housing.
5. Install thrust piece centrally on shaft sealing ring (A). For left drive flange (Scheme 68) For right drive flange (Scheme 69) Drive NEW sealing ring in up to limit stop of thrust piece, ensuring sealing ring goes on straight.
6. Install drive axle shaft. See «AXLE SHAFTS - FWD & AWD»(ref-161308) article in DRIVELINE/AXLES.
7. With transmission installed, check ATF level, and top off as necessary. See «CHECKING FLUID LEVELS»(ref-170597-S16947090572005011200000) under LUBRICATION.

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

1. On vehicles equipped with coded radio, obtain radio anti-theft code. On all vehicles, turn ignition switch off. Disconnect negative battery cable. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000).
2. Disable air bag and remove driver's airbag unit and steering wheel. See appropriate AIRBAG article in RESTRAINTS.
3. Unclip left dash panel end trim (1). (Scheme 73)
4. Remove screws (2). (Scheme 75) Pull driver's storage compartment (1) out of clips (4). Pull sides of frame outward. Move driver's storage compartment down.
5. Unplug harness connectors (1 and 2) by pressing retainer tabs (arrows). (Scheme 74)
6. Unclip diagnostic connector (6) by squeezing together tabs (5). (Scheme 75)
7. Remove upper steering column cover. see scheme 37and see scheme 38.
8. Remove lower steering column cover. see scheme 39
9. Remove steering wheel adjustment levers. see scheme 40
10. Turn ignition key to "ignition on" position. Move selector lever to "P" position. Pull out clamp (2) of locking cable (3). see scheme 41
11. Pull locking cable out of steering lock (1). Remove selector lever handle. see scheme 49 Remove rear center console. See «REAR CENTER CONSOLE»(ref-170597-S22561534702005011200000).
12. Loosen bolt on support bracket (arrow "A") of locking cable. see scheme 42 Carefully remove locking cable from shift mechanism (arrow "B"), and disengage from locking lever (arrow "C"). Pull locking cable out of instrument panel.
13. To install, route locking cable (arrow) from steering lock, behind wiring harness (1), under footwell vent (2) and carpet (3) to shift mechanism. see scheme 43 Move selector lever to "P" position.
14. Pull locking cable slightly out of cable sleeve and engage in locking lever (arrow "C"). see scheme 42 Engage support bracket of locking cable in selector housing (arrow "B"). Push locking cable into steering lock. see scheme 41 Flattened side of locking cable points downward.
15. Install clamp (2) of locking cable (3) from above. Angled ends of clamp point toward steering lock. Check catches of clamp. Adjust locking cable. See «LOCKING CABLE»(ref-170597-S15076695172005011200000) under ADJUSTMENTS.
16. Check function of ignition key removal lock. (Scheme 55)and (Scheme 56).
17. Install rear center console. See «REAR CENTER CONSOLE»(ref-170597-S22561534702005011200000). Install selector lever handle. see scheme 50
18. Guide holder (3) into mount at pedals. (Scheme 75)
19. Install driver's side storage compartment. Install steering column adjustment levers. see scheme 40
20. Install steering column covers. see scheme 37- see scheme 39.
21. Install steering wheel and airbag. See appropriate AIRBAG article in RESTRAINTS. Reconnect battery ground cable. See «BATTERY DISCONNECT PRECAUTIONS»(ref-170597-S34422722222005011200000). Enter radio anti-theft code, if necessary.

OIL PAN