Audi TT 2000-2006 Repair Manual - Excerpt

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An excerpt from the Audi TT 2000-2006 Repair Manual - 34b DSG transmission. For more information, visit http://www.bentleypublishers.com/audi/tt/2000-2006/Audi-TT-2000-2006-Repair-Manual.html

Transcript of Audi TT 2000-2006 Repair Manual - Excerpt

34b-4

DSG Transmission

Shift Mechanism

SHIFT MECHANISMSelector lever and selector housing assembly1. Gear shift knob See Gear shift knob, removing and installing 2. Trim/locking sleeve Clips into gear shift knob Locks knob to prevent knob from pulling off 3. Bolt Threaded through retaining ring and upper cover into side cover Qty: 8, M4x10 Tighten to 2 Nm (18 in-lb) 4. Retaining ring 5. Upper cover With integral symbol insert Positioned on frame (item 8) (arrows) 6. Side cover Positioned on frame (item 8) (arrows) 7. Printed circuit board Positioned on frame (item 8) (arrows) See Printed circuit board, installed position 8. Frame With locating pins (arrows) Pull 4 integral hooks outward to remove Remove complete with retaining ring, upper cover, side cover, and printed circuit board (items 4, 5, 6, 7) 9. Selector cable Do not bend or kink Do not lubricate cable eye or ball socket See Selector cable, adjusting 10. Nut, self locking Qty: 4 Always replace Tighten to 10 Nm (7 ft-lb) 11. Housing With glued-on gasket 12. Washer 13. Intermediate plate346

A37-0663.tif

14. Bolt Inserted into intermediate plate 15. Shift lock solenoid (N110) With integral tiptronic switch (F189) See Shift lock solenoid, removing and installing 16. Retainer Secures cable 17. Selector mechanism

18. Bolt Qty: 3 Tighten to 6 Nm (53 in-lb) 19. Locking cable Do not bend or kink For ignition key removal lock 20. Steering lock 21. Locking clip Install clip from above Angled ends point towards steering lock

Printed circuit board, installed position A37-0592.tif Position holes on printed circuit board onto front and rear guide pins (arrows) on frame. Ensure wiring harness is properly positioned and that printed circuit board is not deformed.

DSG Transmission 34b-5Shift MechanismShift lock solenoid, removing and installing Disconnect harness connector (B) from shift lock solenoid (N110). Depress retaining tab (A) to rear while simultaneously turning solenoid counter-clockwise (dashed arrow). Pull shift lock solenoid off. A37-0664.tif

Gear shift knob, removing and installingSeveral slightly different style gear shift knobs are used, but all are removed in the same manner.

AT0634b005.tif

With a firm grip, grasp trim/locking sleeve (A) and pull down on shaft (B).

AT0634b004.tif

Pull release button out (A) of shift knob as far as possible and lock in place with a wire clip in the opening on top (C).

AT0634b006.tif

While holding button out, pull up (B) on knob to remove from shaft. If release button slips back into knob, use a pick tool to pull button out and lock in place with wire clip.

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34b-6

DSG TransmissionInstallation is the reverse of removal, noting the following: Install trim/locking sleeve onto shaft. Release button must be pulled out to install knob. Installed position: button points to driver. Slide knob onto shaft and move around to engage mechanism. When knob is felt to engage mechanism, push down fully onto shaft. While holding knob down, grasp trim/locking sleeve, slide up and lock onto knob.

Selector Cable

Backup light and neutral start functionOperation of the backup lights and the ability to allow starter operation in park and neutral positions only, has typically been a direct function of the selector mechanism. DSG transmissions use a combination of selector mechanism (E313) and Mechatronic unit (J743) control to operate relays which enable these functions. A97-00 The 13-fold relay panel is located above the micro central electric panel under the drivers side of the padded dash. Position 11 - Starter interlock relay (J207) Position 13 - Backup light relay (J219)

SELECTOR CABLESelector cable, checking With ignition switched off, disconnect battery ground strap. See 27 Battery, Alternator, Starter. Remove air cleaner assembly. See 03 Maintenance. Shift selector lever into P position. Push circlip (A) upward and remove.

Press selector lever cable off of selector shaft lever (arrow) and place on top to allow free movement of cable and selector mechanism without shifting transmission. NOTE Do not loosen adjustment bolt (B).

A37-0659.tif

Lay selector lever cable aside in such a way that end can move freely. Use care to avoid bending or kinking selector lever cable. Shift selector lever from P to S. Check protective sleeve on selector mechanism (on front of selector lever cable) for damage. Replace cable if damaged.

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DSG Transmission 34b-7Selector Cable Shift selector lever into P position. Selector mechanism and selector lever cable should move smoothly. Replace selector lever cable or service selector mechanism as needed.

With selector lever in P, carefully press selector lever cable back onto selector shaft lever and install circlip (A). Install air cleaner assembly. Connect battery. Check backup light operation.

Selector cable, adjusting With ignition switched off, disconnect battery ground strap. See 27 Battery, Alternator, Starter. Remove air cleaner assembly. See 03 Maintenance. Shift selector lever into P position. Loosen bolt (B).

AT0634b003.tif

Move selector shaft lever on transmission into P position. Turn (rotate) both front wheels in one direction by hand (if lifted) or by pushing vehicle, until detent lever in transmission engages parking lock gear and wheels lock. This will confirm that internal transmission mechanism is fully in park position. NOTE The selector lever must be in P position when the clamping bolt (B) is loosened; if not, adjustment will be incorrect.

Carefully move selector lever slightly forward and backward, without shifting into a different selector lever position, to centralize shift lever. Tighten bolt (B) smoothly and evenly. Tightening torque Bolt, selector cable adjustment 13 Nm (10 ft-lb)

NOTE When tightening bolt (B), make sure the selector lever cable does not move out of position.

Install air cleaner assembly. Connect battery. Functional check selector cable. Check backup light operation.

349

34b-8

DSG TransmissionSelector cable, checking adjustment Depress button on gear shift knob while pulling selector lever back approximately 5 mm (3/16 in) to the rear and out of P position. Do not allow selector lever to be shifted into R. Release selector lever. Selector lever must spring back into P position automatically. If necessary, re-adjust selector cable and/or inspect selector mechanism for free movement.

Selector Cable

Depress button on gear shift knob while pulling selector lever back approximately 5 mm (3/16 in) to the rear and out of N position. Do not allow selector lever to be shifted into D. Release selector lever. Selector lever must spring back into N position automatically. If necessary, re-adjust selector cable and/or inspect selector mechanism for free movement.

Depress button on gear shift knob while pushing selector lever forward approximately 5 mm (3/16 in) to the front and out of N position. Do not allow selector lever to be shifted into R. Release selector lever. Selector lever must spring back into R position automatically. If necessary, re-adjust selector cable and/or inspect selector mechanism for free movement.

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established 1950 Automotive Reference

BentleyPublishers.com

Audi TT Service Manual: 2000-20061.8L turbo, 3.2L including roadster and quattroPrice: $99.95 Bentley Stock Number: AT06 Publication Date: 2006.nov.17 ISBN-10: 0-8376-1500-3 ISBN-13: 978-0-8376-1500-4 Audi of America Lit. No. W42 AUDITT0006SM Softcover, 8 3/8 in. x 11 in. Case quantity: 5 978 pages, 1826 photos, illustrations and diagrams Includes a 32 page color Audi TT Familiarization section

Bentley Publishers is proud to announce the publication of the Audi TT Service Manual: 20002006. This repair manual covers the 2000 through 2006 model year TTs, including the TT Coupe and the TT Roadster. Although the do-it-yourself Audi owner will find this manual indispensable as a source of theory of operation and step-by-step maintenance and repair information, the Audi owner who has no intention of working on his or her car will find that reading and owning this manual will make it possible to discuss repairs more intelligently with a professional technician. Technical Highlights: Covers TT Coupe and Roadster (convertible) models 2000-2006. Maintenance procedures: from oil changes to belt replacement. Engine and cylinder head service, including timing belt replacement for 4-cylinder engines. Removal, installation and testing of Motronic fuel injection system components. Exhaust system component replacement, including Secondary Air Injection system. Drivetrain maintenance, troubleshooting, adjustment and repair, including clutch, gearshift linkage, and drive axles.. Suspension component replacement, including front struts, rear shocks, springs, front stabilizer bar and alignment procedures and specifications. Heating and air conditioning component replacement. Body adjustment and repairs, including front door components, fenders, bumper covers and convertible top replacement. Wiring schematics with fuse/relay locations including an easy-to-use illustrated component locator section. Audi OBD II diagnostic trouble codes, SAE-defined OBD II P-codes, as well as basic scan tool operation. Comprehensive Audi factory tolerances, wear limits, adjustments, and tightening torques. Bentley repair manuals provide the highest level of clarity and comprehensiveness for service and repair procedures. If youre looking for better understanding of your Audi TT, look no further than Bentley.

Bentley technical editors working on a TT Roadster.

Location of ignition components on 3.2L engine