Installing gearbox - vehicles with 6-cylinder engine: Audi TT Mk1

🧭 Before you start

Fits: Audi TT Mk1 (8N)

• Opens: clutch fluid
• Renewed: if necessary

Don't miss

• For correct allocation of bolts Parts catalogue
• Support bracket10-222 A must not be removed until all bolts on left and right assembly mountings have been tightened to specified torque. — Remove support bracket.
• Press engine/gearbox assembly towards bulkhead; the bevel box pin must be guided carefully into the propshaft flange when doing this.
• The seal (arrow) in the propshaft flange must not be damaged when removing and installing. If seals are damaged, the propshaft must be renewed. — Secure pendulum support to subframe with new bolts (arrows A).
• Do not press clutch pedal before clutch system has been bled. — Remove hose clamp3094.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of greaseG 000 100 to the splines. It is important to remove excess grease.
2. Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary.
3. Check clutch release bearing with hydraulic actuator for wear and renew if necessary.
4. Check that intermediate plate (top) (2) is correctly positioned on engine.
5. Tilt gearbox to the left by turning spindles of gearbox support3282.

6. Raise gearbox carefully and move to installation position using gearbox support.
7. Push the gearbox over the engine flywheel at the front first (arrow) and then at the bevel box side.
8. Align gearbox with engine and install.
9. Install intermediate plate (bottom) (1).
10. Fit new engine/gearbox securing bolts which are accessible from below. Tightening torques [Note: For correct allocation of bolts Parts catalogue]
11. Screw in bolts for bevel box bracket (1) and (2) only a few turns at this stage.
12. Observe the further tightening sequence:
13. First tighten bolts (1) to 3 Nm. — 3 Nm (2.2 lb-ft)
14. Tighten bolts (2) to 35 Nm. — 35 Nm (26 lb-ft)
15. Tighten bolts (1) to 45 Nm. — 45 Nm (33 lb-ft)
16. Detach gearbox support3282 from gearbox.
17. Fit new engine/gearbox securing bolts which are accessible from above.
18. Use new bolts (1) when installing assembly mounting.
19. Fit gearbox support to gearbox (pendulum support remains removed).
20. Pull gearbox up to gearbox support with spindle on support bracket.
21. ⚠ Before tightening the bolts, the support arm of the gearbox mounting and the gearbox support must be aligned absolutely parallel, otherwise the threads will be damaged. If necessary, push gearbox up at the rear with trolley jack. — Renew bolts (2).
22. Fit support arm of gearbox mounting to gearbox support.
23. ⚠ Support bracket10-222 A must not be removed until all bolts on left and right assembly mountings have been tightened to specified torque. — Remove support bracket.
24. Install subframe as follows:
25. Move drive shafts in installation position and tighten hand-tight.
26. Move subframe into installation position.
27. Fit subframe bolts.
28. Place steering box onto subframe and fit steering box bolts.
29. Secure steering box Running gear, front-wheel drive and four-wheel drive48.
30. Secure subframe with new bolts Running gear, front-wheel drive and four-wheel drive48.
31. Install diagonal struts Running gear, front-wheel drive and four-wheel drive40.
32. Install heat shield for drive shaft (right-side) (arrows).
33. Bolt drive shafts to gearbox flange shafts Running gear, front-wheel drive and four-wheel drive40.
34. Secure pendulum support to gearbox with new bolts (arrows B).
35. Press engine/gearbox assembly towards bulkhead; the bevel box pin must be guided carefully into the propshaft flange when doing this.
36. Slide propshaft onto guide pin without tilting.
37. ⚠ The seal (arrow) in the propshaft flange must not be damaged when removing and installing. If seals are damaged, the propshaft must be renewed. — Secure pendulum support to subframe with new bolts (arrows A).
38. Bolt propshaft with flexible coupling on bevel box flange (arrows)5/6-speed manual gearbox 02M, four-wheel drive / final drive39.
39. Install starter and fit bottom securing bolt; tightening torque .
40. Install exhaust system free of stress 26.
41. Fit secondary air pump bracket (A) at bolt head (2), then tighten bolts (1) and (2).
42. Install tubular cross member (front) General body repairs, exterior50.
43. Close drain plug (1) and fit coolant hose to radiator.
44. Clip in coolant hose (1).
45. Attach power steering pressure pipe.
46. Check gear oil in manual gearbox with bevel box .
47. Install noise insulation panels General body repairs, exterior50.
48. If fitted, install bracket for headlight range control in wheel housing (left-side) Running gear, front-wheel drive and four-wheel drive40.
49. Install top bolt securing starter. Tightening torque
50. Attach electrical connector for reversing light switch F4(arrow).
51. Press slave cylinder pressure hose (1) into hose connector and lock in position with retaining clip.
52. ⚠ Do not press clutch pedal before clutch system has been bled. — Remove hose clamp3094.
53. Fit bracket (2), attach wiring and engage connector in bracket.
54. Fit earth wire (1).
55. Fit selector shaft lever with gear selector cable (B) on selector shaft (tighten nut (arrow 2)).
56. Install relay lever with gate selector cable (A) (fit securing clip (arrow 1)).
57. Tighten nut (arrow 3).
58. Attach cable support bracket to gearbox (arrows).
59. Plug in electrical connector at speedometer sender G22(arrow).
60. Make sure that mountings of engine/gearbox assembly are free of tension when installing 10.

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