Page 1: Manual Transmission
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Page 3: Table Of Contents
Clutch System, Bleeding ..........permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Information Regarding the Removal and Installation of the Clutch Master or Slave Cylinder with respect to the correctness of information in this document.
Page 4 Transmission, Securing to Assembly Stand ........107 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Transmission, Installing .
Page 5 Specifications ............227 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Fastener Tightening Specifications .
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Page 7: General, Technical Data
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Page 8: General Repair Information
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Page 9 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Apply the sealing compound -AMV 188 200 03- evenly and not with respect to the correctness of information in this document.
Page 10 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Install various bearings (removed tapered roller bearings) into permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 12: Overall Transmission Ratio I, Calculating
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Page 13: Description And Operation
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Page 15: Specifications
♦ Rear final drive allocation Manual transmission Code letters Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Manufactured from 01.08 12.09...
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Page 17: Clutch
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Page 18: Clutch System, Bleeding
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Page 19: Clutch Master Cylinder And Clutch Slave Cylinder, Function Test
Installation of the Clutch Master or Slave Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Cylinder with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 20 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not al switch or drivers who constantly rest their foot on the clutch permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability pedal.
Page 21: Description And Operation
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Page 23: Pedal Assembly, Master Cylinder Assembly Overview
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Page 25: Hydraulics Assembly Overview
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Page 27: Clutch Release Mechanism, Clutch Slave Cylinder Assembly Overview
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Page 28: Sachs Clutch Assembly Overview
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Page 31: Luk Clutch Assembly Overview
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Page 34: Specifications
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Page 35: Removal And Installation
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Page 36: Over-Center Spring
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Page 38: Clutch Pedal
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Page 40: Mounting Bracket
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Page 42: Clutch Position Sensor
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Page 43: Master Cylinder
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Page 45: Slave Cylinder With Release Bearing
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Page 46: Sachs Clutch
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Page 48: Luk Clutch
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Page 49 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not plate, do not clean the pressure plate. This will shorten the permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability service life of the clutch considerably.
Page 50 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Clutch Plate Installation Location with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 51: Special Tools
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Page 53: Controls, Housing
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Page 54: Gear Oil In Bevel Box, Checking
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Page 55: Gear Oil In Bevel Box, Filling
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Page 58: Description And Operation
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Page 60: Shift Knob And Covers Assembly Overview
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Page 62: Shift Lever And Shift Housing For Vehicles To Vin 8J-7-013000 Assembly Overview
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Page 65: Shift Lever And Shift Housing For Vehicles From Vin 8J-7-013001 Assembly Overview
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Page 67: Shift Cable And Selector Cable To Model Year 2007 Assembly Overview
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Page 69: Transmission Shift Lever And Selector Relay Lever To Model Year 2007 Assembly Overview
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Page 71: Shift Cable And Selector Cable From Model Year 2008 Assembly Overview
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Page 75: Shift Mechanism, Adjusting
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Page 77 The cable -B- must be able to move in the cable retainer. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability •...
Page 78: Subframe Mount Assembly Overview
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not operation of the reverse gear lock permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 80 18 - Transmission Bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Transmission with Threaded Inserts (for example HeliCoil) for with respect to the correctness of information in this document.
Page 81: Transmission Overview
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Page 82: Transmission Assembly Overview
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Page 83: Transmission Housing And Shift Mechanism Assembly Overview
❑ 45 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ For selector shaft with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 84 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Allocation of Bolts as Replacement Parts permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 85: Input Shaft, Output Shafts, Differential, Bevel Box And Selector Rods Assembly Overview
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Page 87: Transmission Housing Assembly Overview
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Page 89: Clutch Housing Assembly Overview
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Page 91: Shift Mechanism Assembly Overview, Transmission Side
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Page 92: Shift Forks Assembly Overview
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Page 93: Specifications
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Page 96: Removal And Installation
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Page 97: Selector Mechanism
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Page 100: Shift Cable And Selector Cable
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Page 101 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Vehicles from VIN 8J-7-013001 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 102: Transmission, Removing
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Page 112: Transmission, Transporting
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Pay attention to electromechanical steering gear when lowering with respect to the correctness of information in this document.
Page 113: Transmission, Securing To Assembly Stand
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Page 115 -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Plastic selector relay lever -1- with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 116 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – If equipped, install small cover plate -A- behind the bevel box permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability -arrow- ⇒...
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Page 118 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Install the left and right noise insulation -arrows-.
Page 119: Transmission Mount, Removing
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Page 122: Transmission Mount, Installing
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Page 123: Pendulum Support
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Page 124: Bevel Box, Removing
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Page 128: Bevel Box, Installing
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Page 129: Input Shaft Seal
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Page 130: Selector Shaft Seal
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Page 132: Selector Shaft
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Page 134: Disassembly And Assembly
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Page 137: Transmission Without Circlip A For Cap/Input Shaft
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Page 148: Transmission With Circlip A For The Cap/Input Shaft
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Page 158: Shift Forks
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Page 164: Clutch Housing, Servicing
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Page 166: Special Tools
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Page 183: Gears, Shafts
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Page 185: Description And Operation
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Page 187: Output Shaft For 1St To 4Th Gears Assembly Overview
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Page 189: Output Shaft, 1St To 4Th Gears, Adjusting
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Page 191 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not The following shims are available: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 193: Output Shaft For 5Th/6Th Gear/Reverse Gear Assembly Overview
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ With synchronizer ring permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 194: Output Shaft For 5Th/6Th Gear And Reverse Gear, Adjusting
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Page 198: Disassembly And Assembly
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Page 200: Output Shaft, 1St To 4Th Gears
– Remove the pliers before the roller bearing is installed posi‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability tion.
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Page 208: Output Shaft For 5Th/6Th Gear And Reverse Gear
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Page 212 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Pressing on Locking Collar/Synchronizer Hub for 5th and 6th permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 214: Special Tools
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Page 225: Final Drive, Differential
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Ring for Bevel Box with permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 226: Flange Shaft And Seals On Bevel Box Assembly Overview
❑ Replace if damaged Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 4 - Shaft Seal with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 228: Differential Assembly Overview
⇒ page 239 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ Pressing on with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 230: Adjustment Overview
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not A new differential adjustment is required when the following com‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ponents have been replaced: with respect to the correctness of information in this document.
Page 231: Permitted Unless Authorised By Audi Ag. Audi Ag Does Not Guarantee Or Accept Any Liability
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Page 232: Permitted Unless Authorised By Audi Ag. Audi Ag Does Not Guarantee Or Accept Any Liability
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Page 233: Specifications
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Page 234: Removal And Installation
♦ Pulling Hook -T20143/2- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Sealing grease -G 052 128 A1- with respect to the correctness of information in this document.
Page 235: Shaft Sealing Ring For Bevel Box With Manual Transmission Installed, Replacing
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Page 236: Right Flange Shaft
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not and fill. Refer to permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ⇒ “1.1 Manual Transmission, Checking Gear Oil Level”, page with respect to the correctness of information in this document.
Page 237: Right Flange Shaft Seat On Outer Bevel Box, Replacing
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Page 238: Right Flange Shaft Needle Bearing
Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Remove right flange shaft. Refer to with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 239: Seal Between Transmission And Bevel Box
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – Lightly oil outer circumference of new shaft seal.
Page 240: Bevel Box Drive Flange Seal
♦ Stop Plate -T10108/1- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Tapered Roller Bearing Puller -V.A.G 1582- with respect to the correctness of information in this document.
Page 241 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
Page 242 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability A - Two–arm puller Kukko 20/10 with respect to the correctness of information in this document.
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Page 244: Disassembly And Assembly
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Page 246 – Then press out differential bevel gear axle. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Note with respect to the correctness of information in this document.
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Page 248: Special Tools
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Page 254 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Kukko 45/2 three arm puller permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
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Page 259 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Page 260 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Page 261 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Audi TT 2007 Repair Manual

General, Technical Data

Clutch

Controls, Housing

Gears, Shafts

Final Drive, Differential

Quick Links

Manual Transmission

Need help?

Questions and answers

Related Manuals for Audi TT 2007

Summary of Contents for Audi TT 2007

Table of Contents