5 Box - 02t-0df

Service
Workshop Manual
Audi A1 2011 ➤
5-speed manual gearbox 02T, 0DF
Edition 12.2018
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Audi AG, Ingolstadt D3E802F44C0

Audi A1 2011 ➤
5-speed manual gearbox 02T, 0DF - Edition 12.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Allocation of gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Transmission layout - front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 6
5 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Exploded view - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Exploded view - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Exploded view - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.7 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.8 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.9 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.10 Removing and installing lines for clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.11 Bleeding clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.12 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 44
1.13 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.14 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Exploded view - clutch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Renewing input shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Exploded view - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Exploded view - selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.4 Exploded view - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.5 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.8 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.9 Renewing selector shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.10 Removing and installing selector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Contents i
Audi A1 2011 ➤
2.3 Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2 Draining and filling gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6 Securing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.2 Exploded view - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.3 Exploded view - gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4 Exploded view - input shaft, output shafts, differential and selector rods . . . . . . . . . . . . . . 103
7.5 Exploded view - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.6 Exploded view - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.7 Servicing selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.8 Removing and installing angled rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.9 Removing and installing 5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.10 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.1 Exploded view - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.2 Exploded view - gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.3 Removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.4 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Exploded view - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Renewing bearing mounting with grooved ball bearings for input and output shafts . . . . . . 137
1.3 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.1 Exploded view - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

1 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Overview of fitting locations - oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Renewing oil seal (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.3 Renewing oil seal (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.1 Exploded view - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.4 Removing and installing flange shaft (left-side) - manual gearbox 02T . . . . . . . . . . . . . . . . 190
2.5 Removing and installing flange shaft (right-side) - manual gearbox 02T . . . . . . . . . . . . . . 192
ii Contents
Audi A1 2011 ➤
00 – Technical data
1 Identification
(ARL006180; Edition 12.2018)
⇒ “1.1 Gearbox identification”, page 1
1.1 Gearbox identification

⇒ “1.1.1 Gearbox identification - manual gearbox 02T”,
page 1
⇒ “1.1.2 Gearbox identification - manual gearbox 0DF”,
page 2
1.1.1 Gearbox identification - manual gearbox

02T
The 5-speed manual gearbox 02T is installed in the Audi A1 2011
► ⇒ “2.1 Allocation of gearbox to engine”, page 4 .
Location on gearbox
♦ Code letters and date of manufacture -arrow 1-
♦ Manual gearbox 02T -arrow 2-
Manual gearbox 02T -arrow 2-
1. Identification 1
Audi A1 2011 ➤
Code letters and production date of gearbox -arrow-

Example: LGQ 28 06 0
I I I I
Code letters Day Month Year of manufac‐
ture (2010)
Additional data depend on manufacture.
Note
The gearbox code letters can also be found on the vehicle data
sticker.
1.1.2 Gearbox identification - manual gearbox

0DF
The 5-speed manual gearbox 0DF is installed in the Audi A1 2011
► ⇒ “2.1 Allocation of gearbox to engine”, page 4 .
Location on gearbox
♦ Manual gearbox 0DF -arrow 1-
♦ Code letters and date of manufacture -arrow 2-
Manual gearbox 0DF -arrow 1-
2 Rep. gr.00 - Technical data

Audi A1 2011 ➤
Code letters and date of manufacture of gearbox -arrow 2-

Example: NXG 27 03 15
I I I I
Code letters Day Month Year of manufac‐
ture (2015)
Additional data depend on manufacture.
Note
The gearbox code letters can also be found on the vehicle data
sticker.
1. Identification 3
Audi A1 2011 ➤
2 Technical data
⇒ “2.1 Allocation of gearbox to engine”, page 4
⇒ “2.2 Capacities”, page 4
2.1 Allocation of gearbox to engine

Manual gearbox 5-speed 02T
Code letters LGQ
Manufactured from 06.10
to
Allocation Model Audi A1 2011 ►
Engine 1.2 ltr. - 63 kW TFSI
Ratio Final drive 58 : 16 = 3.625
Z1 : Z2
The following data can be found in the ⇒ Electronic parts catalogue
♦ Individual gear ratios
♦ Allocation of drive shaft flanges
♦ Allocation of clutch type
Manual gearbox 5-speed 0DF

Code letters QTS
Manufactured from 01.15
to
Allocation Model Audi A1 2011 ►
Engine 1.0 ltr. - 70 kW TFSI
Ratio Final drive 58 : 16 = 3.625
Z1 : Z2
The following data can be found in the ⇒ Electronic parts catalogue
♦ Individual gear ratios
♦ Allocation of drive shaft flanges
♦ Allocation of clutch type
2.2 Capacities
Manual gearbox 5-speed 02T 5-speed 0DF
Code letters LGQ QTS
Capacity 2.0 ltr. 2.1 ltr.
♦ Gear oil specifications ⇒ Electronic parts catalogue

Audi A1 2011 ➤
3 Transmission layout
⇒ “3.1 Transmission layout - front-wheel drive”, page 5
3.1 Transmission layout - front-wheel drive
Note
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive
❑ Not used
3. Transmission layout 5
Audi A1 2011 ➤
4 Safety precautions
⇒ “4.1 Safety precautions when working on vehicles with start/
stop system”, page 6
4.1 Safety precautions when working on ve‐

hicles with start/stop system
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (indicated by
a message in the instrument cluster), the engine may start
automatically if it needs to.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).

Audi A1 2011 ➤
5 Repair instructions
⇒ “5.1 General repair instructions”, page 7
⇒ “5.2 Contact corrosion”, page 12
5.1 General repair instructions

Proper tools and the maximum possible care and cleanliness are
essential for satisfactory repairs to the transmission units. The
usual basic safety precautions also naturally apply when carrying
out repair work.
A number of generally applicable instructions for the various re‐
pair procedures - which were previously repeated at numerous
places in the Workshop Manual - are summarised here. They ap‐
ply to the work described in this Manual.
Special tools
♦ For a complete list of special tools used in this Workshop
Manual ⇒ Workshop equipment and special tools .
Gearbox
♦ When installing the gearbox, ensure that the dowel sleeves
between the engine and the gearbox are correctly located.
♦ Allocate bolts and other components according to ⇒ Elec‐
tronic parts catalogue .
♦ Clean contact surfaces when assembling mounting brackets
and waxed components. The contact surfaces must be free of
wax and grease.
♦ Thoroughly clean all joints and connections and the surround‐
ing areas before disconnecting.
♦ When installing a new gearbox, check the oil level and fill up
with oil if necessary ⇒ page 48 .
♦ Capacities ⇒ page 4 , specifications ⇒ Electronic parts cata‐
logue .
Sealant
♦ Thoroughly clean joint surfaces on gearbox housing etc. be‐
fore applying sealing paste.
♦ Apply sealing paste - AMV 188 200 03- evenly and not too
thick.
♦ Breather holes must remain free of sealing paste.
5. Repair instructions 7
Audi A1 2011 ➤
Oil seals, seals, O-rings and gaskets

♦ Always renew O-rings, oil seals and gaskets after removal.
♦ 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.
♦ Before installing oil seals, lightly oil the outer circumference of
the seal and fill the space between the sealing lips -arrow-
about half full with grease - G 052 128 A1- .
♦ The open side of the oil seal should face the side containing
the fluid.
♦ When installing a new oil seal, position the seal in the housing
so that the sealing lip does not contact the shaft in the same
place as the old seal (make use of installation depth toleran‐
ces).
♦ Lightly lubricate O-rings with oil before installation to prevent
them being trapped during assembly.
♦ Check oil level after installing new gaskets, O-rings and oil
seals ⇒ page 96 .
Locking elements
♦ To facilitate assembly, use circlip pliers - VAS 5503A- .

♦ Do not over-stretch circlips.
♦ Installation position for some circlips: the circlip is fitted so that
the narrow part of the gap is at the top. This also gives the
pliers a better grip when removing and installing.
♦ Always renew circlips which have been damaged or over-
stretched.
♦ Circlips must be properly seated in the base of the groove.

Audi A1 2011 ➤
♦ Renew spring pins. Position: the slit -A- should be in line with
the line of force -arrow-.
Audi A1 2011 ➤
Nuts, bolts
♦ Loosen the nuts and bolts in reverse sequence to the specified
tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Parts which are particularly sensitive (e.g. clutch pressure
plate) must be kept straight. Loosen and tighten bolts and nuts
in stages and in diagonal sequence.
♦ Always renew self-locking nuts and bolts.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned (using a tap or similar). Oth‐
erwise there is a danger of the bolts shearing off the next time
they are removed.
♦ For all threaded connections, ensure that (where applicable)
the contact surfaces and the nuts and bolts are not coated with
wax until after assembly is completed.
Bearings
♦ Install new tapered roller bearings as supplied; do not lubricate
additionally with oil.
♦ Lubricate all bearings (except tapered roller bearings) with
gear oil before installing in gearbox.
♦ Use inductive heater - VAS 6414- to heat inner races of ta‐
pered roller bearings to approx. 100°C before installing. Press
home onto stop when installing so there is no axial clearance.
♦ Do not interchange inner or outer races of bearings of the
same size.
♦ Always renew the tapered roller bearings on one shaft togeth‐
er and use new bearings from a single manufacturer.
♦ Install needle bearings so the lettering (side with thicker metal)
faces towards the installing tool.
Shims
♦ Use a micrometer to measure the shims at several points.
Tolerance variations make it possible to obtain the exact shim
thickness required.
♦ Check for burrs and damage. Install only shims which are in
perfect condition.
♦ Install only shims which are in perfect condition.
Synchro-rings

Audi A1 2011 ➤
♦ Do not interchange synchro-rings. When reusing always fit to

the same selector gear.
♦ Check for wear; renew if necessary.
♦ Check the grooves -arrow 1- on synchro-ring -A- and on inner
ring for wear (flattened sections in grooves).
♦ Make sure that the coating of coated synchro-rings is not dam‐
aged.
♦ If an intermediate ring -B- is fitted, check the outer contact
surface -arrow 2- and inner contact surface -arrow 3- of the
intermediate ring for »scoring«, »visible traces of wear« and
»blue discolouration (caused by overheating)«.
♦ Check cone on selector gear for scoring and visible traces of
wear.
♦ Lubricate synchro-rings with gear oil before installing.
Gear wheels
♦ Clean before pressing on.
♦ Use inductive heater - VAS 6414- to heat to approx. 100°C
before installing. Press home onto stop when installing so
there is no axial clearance.
Selector gears and locking collars
♦ After installing, check 1st to 5th selector gears for minimal axial
play and freedom of movement.
♦ Abnormal wear on synchro-ring or selector gear:

A - Worn chamfer on dog teeth of synchro-ring or selector gear.
♦ In comparison: intact synchro-ring or selector gear:

B - Intact chamfer on dog teeth of synchro-ring or selector gear.
Audi A1 2011 ➤
♦ Abnormal wear on locking collar:

C - Worn chamfer on internal splines of locking collar.
♦ In comparison: intact locking collar:

D - Intact chamfer on internal splines of locking collar.
Clutch mechanism, clutch
♦ Before renewing the clutch master cylinder or slave cylinder
on the assumption that it is defective, you must first carry out
the appropriate function check ⇒ page 44 .
♦ When removing gearbox, remove clutch slave cylinder without
disconnecting pipes.
♦ Do not depress the clutch pedal after removing the clutch slave
cylinder if the hydraulic pipe is still connected. Otherwise the
piston will be pressed out of the clutch slave cylinder.
♦ If the clutch pedal does not return to its initial position after
releasing it (clutch pedal in rest position), you must bleed the
clutch system (further measures ⇒ page 44 ).
♦ After installing the slave cylinder, carefully press the clutch
pedal. If you feel an unusually strong point of resistance when
pressing the clutch pedal, you must not press it down further.
The plunger of the slave cylinder is likely to have been guided
past the clutch release lever. The slave cylinder would then be
destroyed once pedal force exceeds approx. 300 N.
♦ Ensure that the pressure plate is kept straight: loosen and
tighten bolts in a diagonal sequence and in several gradual
stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing,
flywheel and parts of the engine facing the gearbox in order to
prevent odour.
♦ Only blow out dual-mass flywheel with compressed air.
5.2 Contact corrosion

The gearbox housing and clutch housing are made of an alumi‐
nium or magnesium alloy.
Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
In addition, rubber components, plastic components and adhe‐
sives are made of non-conductive material.
If you are not sure whether used parts can be re-installed, always
fit new parts ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.

Audi A1 2011 ➤
♦ We recommend the use of accessories approved by Audi.

♦ Damage caused by contact corrosion is not covered by war‐
ranty.
Audi A1 2011 ➤
6 Electrical components
⇒ “6.1 Overview of fitting locations - electrical components”, page
14
6.1 Overview of fitting locations - electrical

components
Clutch position sender - G476-
Fitting location: the clutch position sender is attached to the clutch
master cylinder.
⇒ “1.13 Removing and installing clutch position sender G476 ”,
page 45
Reversing light switch - F4- / gearbox neutral position sender -

G701-
Fitting location: behind starter on gearbox
1 - Reversing light switch - F4-
3 - Gearbox neutral position sender - G701-
⇒ “7.4 Exploded view - input shaft, output shafts, differential and
selector rods”, page 103

Audi A1 2011 ➤
30 – Clutch
1 Clutch mechanism
⇒ “1.1 Exploded view - pedal cluster”, page 15
⇒ “1.2 Exploded view - clutch hydraulics”, page 19
⇒ “1.3 Exploded view - clutch release mechanism”, page 21
⇒ “1.4 Removing and installing clutch pedal”, page 22
⇒ “1.5 Removing and installing over-centre spring”, page 28
⇒ “1.6 Removing and installing mounting bracket”, page 30
⇒ “1.7 Removing and installing bearing bush”, page 33
⇒ “1.8 Removing and installing clutch master cylinder”,
page 34
⇒ “1.9 Removing and installing clutch slave cylinder”, page 39
⇒ “1.10 Removing and installing lines for clutch hydraulics”, page
41
⇒ “1.11 Bleeding clutch hydraulics”, page 42
⇒ “1.12 Checking clutch master cylinder and clutch slave cylin‐
der”, page 44
⇒ “1.13 Removing and installing clutch position sender G476 ”,
page 45
⇒ “1.14 Servicing clutch release mechanism”, page 46
1.1 Exploded view - pedal cluster

⇒ “1.1.1 Exploded view - pedal cluster, vehicles up to model year
2014”, page 15
⇒ “1.1.2 Exploded view - pedal cluster, vehicles from model year
2015 onwards”, page 18
1.1.1 Exploded view - pedal cluster, vehicles up to model year 2014
1. Clutch mechanism 15
Audi A1 2011 ➤
1 - Clutch pedal
❑ Removing and installing
with over-centre spring
⇒ page 22
with extension spring
⇒ page 24
2 - Support
❑ Renew only when clutch
master cylinder has
been removed
❑ Removing ⇒ page 17
❑ Pressing on
⇒ page 17
3 - Clutch master cylinder
⇒ page 34
4 - Gasket
❑ Renew
❑ Glue onto clutch master
cylinder
5 - Clutch position sender -
G476-
⇒ page 45
❑ Checking in Guided
Fault Finding ⇒ ve‐
hicle diagnostic tester
6 - Pivot pin
❑ Cannot be removed
without being damaged
❑ Always renew
7 - Plenum chamber partition panel
❑ With mounting for mounting bracket and master cylinder
8 - Bush
❑ For top drilling in mounting bracket
❑ Bushes for bottom drilling in mounting bracket are installed in master cylinder
9 - Nut
❑ 25 Nm
❑ 3x
❑ Self-locking
❑ Renew
10 - Crash bar
❑ Secured to steering column
❑ Different versions available; for correct version refer to ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Central tube for dash panel;
Exploded view - central tube for dash panel
11 - Bolt
❑ A nut is fitted on some versions ⇒ Electronic parts catalogue
❑ Tightening torque ⇒ General body repairs, interior; Rep. gr. 70 ; Central tube for dash panel; Exploded
view - central tube for dash panel
16 Rep. gr.30 - Clutch

Audi A1 2011 ➤
12 - Mounting bracket
❑ Removing and installing with clutch master cylinder ⇒ page 34
❑ Removing and installing without clutch master cylinder ⇒ page 30
13 - Stop
❑ For clutch pedal
14 - Over-centre spring
❑ An extension spring or an over-centre spring is installed depending on the equipment version
❑ Select correct components from ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ page 22
15 - Bearing bushes
16 - Extension spring with vibration damper
❑ An extension spring or an over-centre spring is installed depending on the equipment version
❑ Select correct components from ⇒ Electronic parts catalogue
❑ Engaged on mounting bracket ⇒ Item 12 (page 17) and at clutch pedal ⇒ Item 1 (page 16)
17 - Cap
Removing retaining clip

– Lever off retaining clip -A- -arrow-.
Pressing on retaining clip

– Carefully press retaining clip -A- onto operating rod for clutch
master cylinder using punch - 2074- .
Audi A1 2011 ➤
Removing and installing extension spring

– Insert vibration damper so that 2nd spring coil -right arrow- is
at recess -left arrow- (in illustration) of vibration damper.
1.1.2 Exploded view - pedal cluster, vehicles from model year 2015 onwards
1 - Bearing bush
2 - Over-centre spring
⇒ page 28
3 - Pivot pin
❑ Cannot be removed
without being damaged
⇒ page 36
bearing bush
⇒ page 33
5 - Gasket
❑ Renew
❑ Glue onto clutch master
cylinder
6 - Plenum chamber partition
panel
❑ With mounting for
mounting bracket and
master cylinder
7 - Clutch position sender -
G476-
⇒ page 45
8 - Bush
❑ For top drilling in mount‐
ing bracket
❑ Bushes for bottom drill‐
ing in mounting bracket
are installed in clutch master cylinder
9 - Mounting bracket
10 - Nut
❑ Self-locking
❑ Renew after removing
❑ 3x

Audi A1 2011 ➤
❑ 25 Nm
11 - Stop
12 - Bearing bush
13 - Clutch pedal
14 - Locking pin
15 - Cap
1.2 Exploded view - clutch hydraulics
Note
The installation position on a left-hand drive vehicle is shown as an example.
1 - Bolt
❑ 2x
❑ 20 Nm
2 - Clutch slave cylinder
⇒ page 39
3 - Gearbox
4 - Bleeder screw
❑ Bleeding clutch system
⇒ page 42
❑ 6 Nm
5 - Dust cap
6 - Retaining clip
❑ To remove and install
pipe/hose assembly,
pull out clip as far as it
will go
7 - Brake fluid reservoir
8 - Seal
❑ Seals must be fitted in
supply hose
❑ Not available separately
❑ Renew supply hose
-item 9- if damaged
9 - Supply hose
10 - Seal
❑ Seals must be fitted in
supply hose
❑ Not available separately
❑ Renew supply hose
-item 9- if damaged
Audi A1 2011 ➤

❑ Different versions available; for correct version refer to ⇒ Electronic parts catalogue
12 - Seal or O-ring
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Renew seal or O-ring if damaged
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 20
❑ For correct version, refer to ⇒ Electronic parts catalogue
13 - Pipe/hose assembly
❑ Disconnecting from clutch master cylinder and clutch slave cylinder ⇒ page 21
14 - Bracket
❑ For pipe/hose assembly
15 - Seal or O-ring
❑ Push onto pipe connection
❑ Lubricate with brake fluid before installing
❑ Renew seal or O-ring if damaged
❑ Whether a seal or an O-ring is used depends on the type of connection ⇒ page 20
16 - Retaining clip
❑ To remove and install pipe/hose assembly, pull out retaining clip as far as it will go
O-rings or seals for pipe/hose assemblies

Item Type of connection
-1- Connection with annular groove -arrow 1-
-2- Connection with shoulder -arrow 2-
-3- Connection with shoulder -arrow 2- and annular
groove -arrow 3-
• Connection with annular groove -arrow 1- and -arrow 3-:
seal / O-ring must be inserted in groove.

Audi A1 2011 ➤
Disconnecting and connecting pipe/hose assembly from/to clutch

master cylinder/clutch slave cylinder
– To remove, release retaining clip -3- with a screwdriver and
disconnect pipe/hose assembly -1- from clutch master cylin‐
der/slave cylinder -4-.
Note
Renew damaged seals or O-rings -2-.
– Press pipe/hose assembly -1- into connection on clutch slave

cylinder or master cylinder -4- so that retaining clip -3- snaps
into place.
– Pull on pipe to check that it is secure.
1.3 Exploded view - clutch release mechanism
1 - Release bearing
❑ Remove and install to‐
gether with release lev‐
er ⇒ Item 3 (page 21)
and guide sleeve
⇒ Item 5 (page 21)
⇒ page 46
❑ Do not wash out bear‐
ing; wipe clean only
❑ Renew bearing if noisy
❑ Lubricate surfaces
which contact release
lever with grease, e.g. -
G 000 100-
2 - Bolt
❑ 5 Nm +90°
❑ Renew
3 - Clutch release lever
gether with release
bearing -item 1- and
guide sleeve -item 5-
⇒ page 46
❑ Remove existing grease
❑ Lubricate surface which
contacts ball-head pin
with MoS2 grease
4 - Retaining spring
❑ Secure to clutch release
lever
5 - Guide sleeve
gether with release
bearing -item 1- and re‐
lease lever ⇒ Item 3 (page 21) ⇒ page 46
Audi A1 2011 ➤
6 - Ball-head pin
❑ 20 Nm
❑ Remove existing grease from contact surface of release lever
❑ Lubricate with grease -G 000 100-
7 - Oil seal
❑ For input shaft
❑ Renewing ⇒ page 51
8 - Gearbox housing
9 - Bolts
❑ Tightening torque ⇒ Item 1 (page 19)
10 - Clutch slave cylinder
❑ Lubricate end of plunger with MoS2 grease
1.4 Removing and installing clutch pedal

⇒ “1.4.1 Removing and installing clutch pedal with over-centre
spring - vehicles up to model year 2014”, page 22
⇒ “1.4.2 Removing and installing clutch pedal with extension
spring - vehicles up to model year 2014”, page 24
⇒ “1.4.3 Removing and installing clutch pedal - vehicles from
model year 2015 onwards”, page 27
1.4.1 Removing and installing clutch pedal

with over-centre spring - vehicles up to
model year 2014
Note
Pivot pin for clutch pedal cannot be removed without being dam‐
aged.
Special tools and workshop equipment required

♦ Pliers - T10005-
Removing
Note
aged.

Audi A1 2011 ➤
– Remove dash panel cover (driver side) ⇒ General body re‐

pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing dash panel cover (driver
side) .
– Remove crash bar ⇒ General body repairs, interior; Rep. gr.
70 ; Central tube for dash panel; Exploded view - central tube
for dash panel .
– To release operating rod for clutch master cylinder, pull clutch
pedal slightly towards passenger compartment.
– Press both sides of retaining clip inwards using pliers -
T10005- -arrows-.
– Using 8 mm Allen key -item 1-, turn pivot pin for clutch pedal
anti-clockwise -arrow- until ears -B- are horizontal.
Note
♦ Retainers -A- will be destroyed when you do this.

♦ Renew pivot pin.
– Move clutch pedal back and forth to pull out pivot pin.
– Remove over-centre spring and (if necessary) clutch pedal.
Installing
Installation is carried out in reverse sequence; note the following:
Note
Renew pivot pin.
– Bring clutch pedal into position at clutch master cylinder.

• The retaining clip -2- must be fitted on the master cylinder op‐
erating rod -1-.
– Press on clutch pedal so that retaining clip snaps into place in
mounting on clutch pedal -3-.
– Working sideways from below, insert over-centre spring into

mounting bracket at point -A- beside operating rod of clutch
master cylinder and beside clutch pedal.
• The bearing recess -arrow- for the actuator on the clutch pedal
must be vertical.
Audi A1 2011 ➤
– Attach over-centre spring to actuator on clutch pedal -arrow-.
– Press clutch pedal slightly and slide in new pivot pin.

clockwise -arrow- until ears -A- are vertical.
• Retainers -B- should engage audibly.
– Install crash bar ⇒ General body repairs, interior; Rep. gr. 70 ;
Central tube for dash panel; Exploded view - central tube for
dash panel .
– Install dash panel cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Storage compartments/covers/trim pan‐
els; Removing and installing dash panel cover (driver side) .
Tightening torques
♦ ⇒ “1.1 Exploded view - pedal cluster”, page 15
1.4.2 Removing and installing clutch pedal

with extension spring - vehicles up to
model year 2014
Note
aged.

♦ Hook - 3438-

Audi A1 2011 ➤
♦ Pliers - T10005-
Removing
Note
aged.

side) .
for dash panel .
– Disengage extension spring using hook - 3438- .
Note
Right side of illustration -arrows- is only relevant for installation.

T10005- -arrows-.
Audi A1 2011 ➤
anti-clockwise -arrow- until ears -B- are horizontal.
Note
♦ Retainers -A- will be destroyed when you do this.

– Remove clutch pedal.
Installing
Note

♦ Grease mountings for extension spring.

erating rod -1-.
– Insert new pivot pin in mounting bracket and clutch pedal.

clockwise -arrow- until ears -A- are vertical.
• Retainers -B- should engage audibly.
– Engage clutch pedal at mounting on master cylinder operating
rod.
– Hook in extension spring.

– Insert vibration damper so that 2nd spring coil -right arrow- is
at recess -left arrow- (in illustration) of vibration damper.
dash panel .
Tightening torques

Audi A1 2011 ➤
1.4.3 Removing and installing clutch pedal -

vehicles from model year 2015 onwards
Note
aged.
Removing
side) .
– Remove bolt -2-.
– Detach intermediate steering shaft -1- from steering column
-arrow- and place to one side.
for dash panel .
– Remove locking pin -3- of operating rod for clutch master cyl‐
inder; to do so, release catch using an 8 mm socket -item 1-.
– Using 8 mm Allen key, turn pivot pin -3- for clutch pedal anti-
clockwise until arrows on mounting bracket -2- and pivot pin
are in line with each other, as shown in illustration.
Note
This will damage the retainers -1, 4- irreparably.
– Remove clutch pedal.
Installing
Installation is carried out in reverse order; note the following:
• Renew pivot pin and locking pin.
Audi A1 2011 ➤
– Move clutch pedal into installation position and slide in new

pivot pin -3-.
– Using 8 mm Allen key, turn pivot pin for clutch pedal clockwise
until retainers -1, 4- engage audibly.
• Arrows on mounting bracket -1- must be offset, as shown in
illustration.
– Press clutch pedal until operating rod -2- for clutch master cyl‐
inder has reached installation position.
– Press in new locking pin -3- so that it engages audibly.
Note
Disregard -item 1- and -arrow-.

dash panel .
– Install intermediate steering shaft ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and instal‐
ling intermediate steering shaft .
1.5 Removing and installing over-centre

spring
⇒ “1.5.1 Removing and installing over-centre spring - vehicles up
to model year 2014”, page 28
⇒ “1.5.2 Removing and installing over-centre spring - vehicles
from model year 2015 onwards”, page 28
1.5.1 Removing and installing over-centre

spring - vehicles up to model year 2014
Note
If the over-centre spring is being removed on its own, the clutch

pedal does not have to be separated from the clutch master cyl‐
inder
⇒ “1.4.1 Removing and installing clutch pedal with over-centre
spring - vehicles up to model year 2014”, page 22 .
1.5.2 Removing and installing over-centre

spring - vehicles from model year 2015
onwards
Removing

Audi A1 2011 ➤

side) .
for dash panel .
– Swivel clutch pedal towards rear and remove over-centre
spring.
Installing
Note
Renew locking pin.
– Working sideways from below, insert over-centre spring into

mounting bracket at point -A- beside operating rod of clutch
master cylinder and beside clutch pedal.
• Bearing recess -arrow- for actuator lug of clutch pedal must be
vertical.
– Attach over-centre spring to mounting lug on clutch pedal

-arrow-.
Audi A1 2011 ➤
Note

dash panel .
1.6 Removing and installing mounting

bracket
⇒ “1.6.1 Removing and installing mounting bracket - vehicles up
to model year 2014”, page 30
⇒ “1.6.2 Removing and installing mounting bracket - vehicles from
model year 2015 onwards”, page 32
1.6.1 Removing and installing mounting

bracket - vehicles up to model year 2014
♦ Pliers - T10005-
Removing
side) .
for dash panel .

Audi A1 2011 ➤

T10005- -arrows-.
– Unscrew nuts -1 and 2-.

– Carefully remove mounting bracket -3- (to do this, get a sec‐
ond mechanic to counterhold clutch master cylinder until it is
disengaged from mounting bracket).
Installing
Note
Renew self-locking nuts.

erating rod -1-.
– Press on clutch pedal so that retaining clip snaps into place in
mounting on clutch pedal -3-.
dash panel .
Tightening torques
Audi A1 2011 ➤
1.6.2 Removing and installing mounting

bracket - vehicles from model year 2015
onwards
Removing
side) .
for dash panel .

– Carefully remove mounting bracket -3- (to do this, get a sec‐
ond mechanic to counterhold clutch master cylinder until it is
disengaged from mounting bracket).
Installing
Note
Renew self-locking nuts and locking pin.
– Bring mounting bracket into position at clutch master cylinder

and secure it.

Audi A1 2011 ➤
Note

dash panel .
Tightening torques
♦ ⇒ “1.1.2 Exploded view - pedal cluster, vehicles from model
year 2015 onwards”, page 18
1.7 Removing and installing bearing bush

Removing
side) .
for dash panel .
– Swivel clutch pedal towards rear.
Audi A1 2011 ➤
– Turn plunger of clutch master cylinder so that recesses -1- and

pin -2- are visible.
• Recesses -1- and pin -2- point in the same direction.
– Remove bearing bush -A- from recesses -1-.
Installing
– Turn plunger of clutch master cylinder so that recesses -1- and
pin -2- are visible.
• Recesses -1- and pin -2- point in the same direction.
– Insert bearing bush -A- into recesses -1- and pivot into posi‐
tion.
– Install over-centre spring ⇒ page 28 .
1.8 Removing and installing clutch master

cylinder
⇒ “1.8.1 Removing and installing clutch master cylinder - vehicles
up to model year 2014”, page 34
⇒ “1.8.2 Removing and installing clutch master cylinder - vehicles
from model year 2015 onwards”, page 36
1.8.1 Removing and installing clutch master

cylinder - vehicles up to model year
2014
♦ Hose clamps up to 25 mm - 3094-

Audi A1 2011 ➤
♦ Sealing tool - T10249-
Removing
– Remove air cleaner housing ⇒ Rep. gr. 24 ; Air cleaner; Re‐
moving and installing air cleaner housing .
Note
♦ Make sure brake fluid does not come into contact with longi‐
tudinal member or gearbox when performing the following
operations. If it does, clean affected area thoroughly.
♦ Place a cloth underneath to catch escaping brake fluid.
– Using hose clamp - 3094- , clamp off supply hose to clutch

master cylinder.
– Disconnect supply hose -1- from clutch master cylinder and

plug hose using sealing tool - T10249/1- .
– Release retaining clip -2- with a screwdriver and disconnect
pipe/hose assembly -3- from clutch master cylinder.
– Unclip clutch position sender - G476- -arrows A, B- and place
it to one side with electrical connector attached.
side) .
for dash panel .
Audi A1 2011 ➤
Note
When working in the footwell, put cloths on the floor covering to

protect it from possible brake fluid spills.

– Remove mounting bracket -3- with clutch master cylinder.
– Detach clutch master cylinder from mounting bracket.
Installing
Note
– Push pipe/hose assembly onto connection on clutch master

cylinder so that retaining clip snaps into place.
– Pull on pipe to check that it is secure.
dash panel .
– Bleed clutch system ⇒ page 42 .
– Install clutch position sender - G476- ⇒ page 45 .
– Install air cleaner housing ⇒ Rep. gr. 24 ; Air cleaner; Re‐
Tightening torques
1.8.2 Removing and installing clutch master

cylinder - vehicles from model year 2015
onwards

Audi A1 2011 ➤
♦ Sealing tool - T10249-
Removing
– Remove engine control unit - J623- from bracket and tie to one
side ⇒ Rep. gr. 23 ; Engine control unit; Removing and in‐
stalling engine control unit - J623- .
Note
– Using hose clamp -3094- , clamp off supply hose to clutch

master cylinder.
Note
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp -3094- , the supply hose must
be returned to its original shape.
– Disconnect supply hose -1- from clutch master cylinder and

plug hose using sealing tool - T10249/1- .
pipe/hose assembly -3- from clutch master cylinder.
– Unclip clutch position sender - G476- -arrows A, B- and place
it to one side with electrical connector attached.
side) .
Audi A1 2011 ➤

for dash panel .
Note
When working in the footwell, put cloths on the floor covering to

protect it from possible brake fluid spills.

– Remove mounting bracket -3- with clutch master cylinder.
– Detach clutch master cylinder from mounting bracket.
Installing
Note
– Clip clutch master cylinder into mounting bracket.

– Bring mounting bracket -3- and clutch master cylinder into in‐
stallation position and tighten nuts -1, 2-.

Audi A1 2011 ➤
Note

dash panel .
– Connect pipe/hose assembly ⇒ page 21 .
– Install engine control unit - J623- ⇒ Rep. gr. 23 ; Engine con‐
trol unit; Removing and installing engine control unit - J623- .
Tightening torques
♦ ⇒ “1.1.2 Exploded view - pedal cluster, vehicles from model
year 2015 onwards”, page 18
1.9 Removing and installing clutch slave

cylinder
Removing
Note
♦ If you suspect a defective clutch slave cylinder, perform func‐

tion test prior to renewing ⇒ page 44 .
♦ If the slave cylinder is removed from gearbox with the pipe/
hose assembly still attached, make sure you do not press the
clutch pedal. Otherwise, the piston will be pressed out of the
slave cylinder and will be damaged irreparably.
Audi A1 2011 ➤
Vehicles with 1.0 ltr. engine:

– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
All vehicles (continued):
– Clamp off hose on pipe/hose assembly between clutch master
cylinder and slave cylinder using hose clamp - 3094- .
– Remove bolts -arrows- and detach clutch slave cylinder -1-.
Note
♦ Make sure that no brake fluid escapes onto the gearbox. If it

does, clean affected area thoroughly.

pipe/hose assembly -1- from connection -4-.
Note
Disregard -item 2-.
Caution
Risk of brake fluid escaping.

♦ Do not operate clutch pedal with slave cylinder removed.
Installing

Audi A1 2011 ➤
– Connect pipe/hose assembly -B- to clutch slave cylinder -A-.

– Lubricate end of plunger of clutch slave cylinder -A- with
MoS2 grease.
– Install clutch slave cylinder and tighten bolts -arrows- to speci‐
fied torque.
Tightening torques
♦ ⇒ “1.2 Exploded view - clutch hydraulics”, page 19
1.10 Removing and installing lines for clutch

hydraulics
Removing
Vehicles from model year 2015 onwards:
Audi A1 2011 ➤
Note
– Using hose clamp -3094- , clamp off supply hose to clutch

master cylinder.
Note
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp -3094- , the supply hose must
be returned to its original shape.

pipe/hose assembly -1- from connection -4-.
– Detach pipe/hose assembly from bracket and remove.
Caution
Risk of brake fluid escaping.

Installing
– Connect pipe/hose assembly to clutch master cylinder and
clutch slave cylinder ⇒ page 21 .
1.11 Bleeding clutch hydraulics
Note
♦ The clutch system must be bled after performing work on the

hydraulic clutch mechanism.
♦ In the following steps make sure that no brake fluid escapes
onto the longitudinal member or onto the gearbox below.
♦ Before bleeding clutch system, top up brake fluid reservoir to
“max.” marking with brake fluid.
♦ The brake fluid in the clutch system should be changed at the
same intervals as the brake fluid in the brake system ⇒ Main‐
tenance ; Booklet 819 ; Description of work; Brake fluid:
changing (every 2 years) .

Audi A1 2011 ➤

♦ Brake filling and bleeding equipment - VAS 5234-
♦ Brake fluid specification ⇒ Electronic parts catalogue .

Procedure
– Pull clutch pedal back to rest position.
– Connect up brake filling and bleeding equipment - VAS 5234- .
– Remove protective cap and connect 670 mm bleeder hose -
V.A.G 1238 B3- to bleeder connection -arrow-.
– Connect bleeder hose to collector bottle of brake bleeding unit.
– Switch on brake bleeding unit.
♦ Operating pressure 2.0 bar
– Open bleeder screw.
– Bleed off about 100 cm3 of brake fluid.
– Close bleeder screw.
– Rapidly pump clutch pedal through full range of travel 10 to 15
times.
– Open bleeder screw once again.
– Bleed off a further 50 cm3 of brake fluid.
– Tighten bleeder screw, disconnect bleeder hose and fit pro‐
tective cap.
– Detach brake filling and bleeding equipment - VAS 5234- from
brake fluid reservoir.
– Depress clutch pedal several times after bleeding process is
completed.
– Repeat bleeding procedure if necessary.
Tightening torques
♦ ⇒ “1.2 Exploded view - clutch hydraulics”, page 19
Audi A1 2011 ➤
1.12 Checking clutch master cylinder and

clutch slave cylinder
Before you renew the clutch master cylinder or slave cylinder you
must - in the case of the following faults - first carry out the ap‐
propriate checks.
Noises when operating the clutch:
♦ First check whether any noise is coming from the over-centre
spring.
♦ If you hear a noise, remove over-centre spring and repeat
check.
♦ Renew relevant component.
After releasing clutch pedal it still remains pressed / does not re‐
turn to its initial position.
♦ Check whether the clutch pedal returns all the way to its initial
position, thereby uncovering the vent opening in the master
cylinder.
♦ The vent opening is integrated in the clutch master cylinder. It
is not visible from the outside.
♦ The vent opening must be uncovered, otherwise the perma‐
nent self-bleeding function for the hydraulic clutch system will
no longer be effective.
♦ Make the customer aware that the driver must NOT rest his/
her foot on the clutch pedal for long periods of time. This could
impair the self-bleeding function of the clutch system as the
vent opening in the master cylinder can no longer function.
♦ The self-bleeding function of the clutch system can be im‐
paired if the footwell trim or floor mats get trapped, if the clutch
pedal switch jams or if the driver rests his foot on the clutch
pedal for long periods of time.
Check the complete hydraulic system for leaks.
♦ Check brake fluid level in brake fluid reservoir.
♦ Check clutch master cylinder and slave cylinder as well as the
pipe/hose assembly including connections for external leaks
(visual inspection).
♦ If you identify any leaks you must renew the leaking compo‐
nent.
♦ Bleed clutch system ⇒ page 42 .
Pedal forces:
♦ Approx. 140 N for complete service life of the clutch
High pedal force:
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 48 .
Clutch does not disengage or does not disengage fully:
♦ Air in hydraulic system: bleed clutch system ⇒ page 42 and
check hydraulic system for external and internal leaks.
♦ Clutch plate does not move smoothly on input shaft splines
(due to corrosion or dirt, etc.)
♦ Foreign body in clutch system
♦ Mechanical fault on pressure plate/clutch plate ⇒ page 48 .
♦ Wrong components were installed when carrying out repair
work (e.g. clutch plate, clutch pressure plate and dual-mass

Audi A1 2011 ➤
flywheel are not from the same manufacturer); allocation ⇒

Electronic parts catalogue .
♦ Components were forgotten when carrying out repair work
(e.g. intermediate plate or dowel sleeves).
♦ Clutch plate was installed incorrectly when carrying out repair
work.
1.13 Removing and installing clutch position

sender - G476-
Removing
Vehicles from model year 2015 onwards:
– Unclip clutch position sender - G476- -arrows A, B-.
– Unplug electrical connector and remove clutch position sender
- G476- .
Note
Disregard -items 1, 2, 3-.
Installing
– Fit clutch position sender - G476- all the way onto clutch mas‐
ter cylinder (electrical connector should be plugged in before‐
hand).
• Clutch position sender should click into place -arrow A-.
– Check by pulling clutch position sender -arrow B-.
Audi A1 2011 ➤
1.14 Servicing clutch release mechanism

Removing
• Gearbox removed
– Unhook spring -arrow- from clutch release lever.
– Remove bolts -1- and -2-.
– Remove release lever with release bearing and guide sleeve.
– Rotate guide sleeve -1- approx. 90° -arrow-.

– Press down the two retainer tabs -4- and pull release bearing
-3- off release lever -2-.
Installing
Note
Lubricate surface on release lever which contacts ball-head pin

with MoS2 grease.
Tightening torques
♦ ⇒ “1.3 Exploded view - clutch release mechanism”, page 21

Audi A1 2011 ➤
2 Clutch
⇒ “2.1 Exploded view - clutch unit”, page 47
⇒ “2.2 Removing and installing clutch”, page 48
⇒ “2.3 Renewing input shaft oil seal”, page 51
2.1 Exploded view - clutch unit
1 - Flywheel
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel
❑ Ensure that dowel pins
fit tightly
❑ Contact surface for
clutch plate must be free
of grooves, oil and
grease
2 - Clutch plate
⇒ page 48
❑ For correct version, re‐
fer to ⇒ Electronic parts
catalogue
❑ Installation position:
spring cage faces pres‐
sure plate
3 - Clutch pressure plate
⇒ page 48
❑ Checking ends of dia‐
phragm spring
⇒ page 48
❑ Checking spring con‐
nections and rivets
⇒ page 48
catalogue
4 - Bolt
❑ M6 - 13 Nm
❑ M7 - 20 Nm
❑ Loosen and tighten gradually in diagonal sequence and in small steps
2. Clutch 47
Audi A1 2011 ➤
Checking ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring
-arrows- is permissible.
Checking springs and riveting

I - Springs OK
• Slight kinking on the outside -arrows A- is normal on produc‐
tion parts.
II - Springs damaged
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.
– Check spring connections between clutch pressure plate and

cover for cracks and make sure rivet fastenings are seated
tightly.
• Renew clutch pressure plate if spring connections are dam‐
aged or rivets are loose -arrows-.
2.2 Removing and installing clutch


Audi A1 2011 ➤
♦ Counterhold tool - 3067-
♦ Centring mandrel - 3190 A-
♦ Centring mandrel - T10086-
♦ Grease for clutch plate splines - G 000 100-

Removing
• Gearbox removed
– Insert counterhold tool - 3067- to unscrew bolts.
– Loosen bolts in small steps and in diagonal sequence.
– Take off clutch pressure plate and clutch plate.
Installing
2. Clutch 49
Audi A1 2011 ➤
Note
♦ Refer to general repair instructions ⇒ page 7 .

♦ The clutch plate, clutch pressure plate and dual-mass flywheel
must be from the same manufacturer.
♦ Select the correct clutch plate and pressure plate according to
engine code ⇒ Electronic parts catalogue .
♦ Renew clutch plate and pressure plate if riveted fastening is
damaged or loose.
♦ 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 grease for clutch plate splines - G 000 100- to the
splines. Then move clutch plate backwards and forwards on
input shaft until hub moves freely on shaft. Remove any ex‐
cess grease.
♦ Clutch pressure plates have an anti-corrosion coating and are
greased. With the exception of the friction surface for the
clutch plate, the pressure plate must not be cleaned. Other‐
wise, the service life of the clutch will be considerably reduced.
♦ The friction surface of the pressure plate and the dual-mass
flywheel must be cleaned (degreased) thoroughly.
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in area of clutch and parts of the engine facing the gearbox
in order to prevent odours.
♦ Important: different diameters -arrow- in crankshaft!
♦ For engines with smaller centring diameter in crankshaft
-arrow- or engines with needle bearing -arrow- in crankshaft:
use centring mandrel - T10086- ⇒ page 51 .
♦ For engines with larger centring diameter in crankshaft
-arrow-: use centring mandrel - 3190 A- ⇒ page 51 .
♦ Installation position of clutch plate: protruding spring cage /
marking “Getriebeseite” (gearbox side), if provided, faces to‐
wards pressure plate.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert bolts.
♦ Check that dowel sleeves for centralising engine/gearbox are
in the cylinder block; install if necessary.
♦ If the dowel sleeves are not fitted, this will lead to gear-change
problems, clutch malfunction and in some cases gearbox
noise (gears will make rattling noises).

Audi A1 2011 ➤
Crankshaft with large centring diameter

– Reverse position of counter-hold tool - 3067- when installing.
– Position clutch pressure plate on dowel pins.
– Use centring mandrel - 3190 A- to centralise clutch plate.
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with clutch pressure plate.
– Tighten bolts in small steps and in diagonal sequence to avoid
damaging centring holes in pressure plate and dowel pins on
flywheel.
Crankshaft with small centring diameter

– Reverse position of counter-hold tool - 3067- when installing.
– Position clutch pressure plate on dowel pins.
– Use centring mandrel - T10086- to centralise clutch plate.
– Screw in all 6 bolts evenly by hand until bolt heads make con‐
tact with clutch pressure plate.
– Tighten bolts in small steps and in diagonal sequence to avoid
damaging centring holes in clutch pressure plate and dowel
pins on flywheel.
Tightening torques
♦ ⇒ “2.1 Exploded view - clutch unit”, page 47
2.3 Renewing input shaft oil seal

♦ Extractor tool - T20143/2-
♦ Thrust piece - T40008-
♦ Sealing grease - G 052 128 A1-
2. Clutch 51
Audi A1 2011 ➤
Procedure
• Gearbox removed
– Remove release bearing ⇒ page 46 .
– Pry out oil seal using extractor tool - T20143/2- .
Note
Take care not to damage contact surface for oil seal on input
shaft.
– Clean contact surface and sealing surface.
– Pack space between sealing lip and dust lip -arrow- half full
with sealing grease - G 052 128 A1- .
– Drive in new oil seal onto stop (take care to keep oil seal
straight).
– Install release bearing ⇒ page 46 .

Audi A1 2011 ➤
34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Overview - selector mechanism”, page 53
⇒ “1.2 Exploded view - gear knob and cover”, page 55
⇒ “1.3 Exploded view - selector cables”, page 56
⇒ “1.4 Exploded view - selector mechanism”, page 60
⇒ “1.5 Removing and installing gear knob”, page 61
⇒ “1.6 Removing and installing selector mechanism”, page 62
⇒ “1.7 Adjusting selector mechanism”, page 65
⇒ “1.8 Dismantling and assembling selector mechanism”,
page 67
⇒ “1.9 Renewing selector shaft oil seal”, page 71
⇒ “1.10 Removing and installing selector cable”, page 72
1.1 Overview - selector mechanism

Gear selection movement -black arrow-
Gate selection movement -white arrow-
1. Selector mechanism 53
Audi A1 2011 ➤
1 - Gearbox selector lever

❑ With damper weight
2 - Gear selector cable
❑ For gear selection
movement
3 - Selector mechanism
4 - Gate selector cable
❑ For gate selection
movement
5 - Gate relay lever
54 Rep. gr.34 - Controls, housing

Audi A1 2011 ➤
1.2 Exploded view - gear knob and cover
1 - Gear lever
2 - Clip
❑ Must be the same as
original equipment ⇒
Electronic parts cata‐
logue
3 - Trim frame
⇒ General body repairs,
interior; Rep. gr. 68 ;
Centre console; Re‐
moving and installing
trim panel for centre
console
4 - Gear knob
❑ With gear lever boot
⇒ page 61
Audi A1 2011 ➤
1.3 Exploded view - selector cables
Note
Lubricate all bearings and moving surfaces with grease - G 000 450 02- .

❑ Detaching and securing
at gearbox selector lev‐
er ⇒ page 58
⇒ page 72
❑ Adjusting ⇒ page 65
⇒ page 72
❑ Adjusting ⇒ page 65
3 - Bush
❑ If damaged, renew gate
selector cable
4 - Retaining clips
❑ Renew
❑ Take care not to dam‐
age selector cables
when removing.
5 - Selector housing
6 - Cable support bracket
7 - Grommet
8 - Bush
9 - Bolt
❑ 20 Nm
10 - Cable end-piece
❑ Secures gate selector
cable to gate relay lever
❑ Allocation ⇒ page 57
❑ Detaching from gate se‐
lector cable ⇒ page 58
❑ Levering off gate relay lever ⇒ page 59
❑ Pressing onto gate relay lever ⇒ page 59
11 - Securing clip
❑ Renew
12 - Cable end-piece
❑ Secures gear selector cable to gearbox selector lever
❑ Allocation ⇒ page 57
❑ Detaching from gear selector cable ⇒ page 58
13 - Nut
❑ 20 Nm
❑ Self-locking

Audi A1 2011 ➤
❑ Renew
❑ With damper weight
❑ Fitting ⇒ page 57
❑ Installation position ⇒ page 58
❑ After installing, adjust selector mechanism ⇒ page 65
15 - Slide block
❑ Detaching and securing gate relay lever at gearbox selector lever ⇒ page 59
❑ Lubricate all bearings and moving surfaces with grease - G 000 450 02- .
17 - Clip
❑ For gate relay lever
Identification of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece for: Dimension “a”
-1- Gear selector cable to gearbox selector lever 8.5 mm
-2- Gate selector cable to gate relay lever 10 mm
Installing gearbox selector lever

– When installing gearbox selector lever, make sure that the gap
in the splines -arrow A- aligns with the wider spline -arrow B-
on the selector shaft.
Audi A1 2011 ➤
Installation position: gearbox selector lever/gate relay lever

- Locates in guide rail of gearbox selector lever via slide block
-arrow-.
- With damper weight
Detaching cable end-pieces from gear selector cable and gate

selector cable
– Pull locking mechanism forwards -arrow 1- onto stop and then
turn to left -arrow 2- to lock.
– Take cable -B- out of cable end-piece -A-.
Detaching and securing gear selector cable at gearbox selector

lever
Detaching
– Lift tab on securing clip -3- for gear selector cable and detach
securing clip from gearbox selector lever -1-.
– Detach gear selector cable -2- from pin -arrow-.
Securing
Note
♦ Renew securing clip for gear selector cable.

♦ Apply a small amount of grease - G 000 450 02- to pin
-arrow-.
– Push gear selector cable -2- onto gearbox selector lever -1-
and secure with securing clip -3-.

Audi A1 2011 ➤
Detaching and securing gate relay lever at gearbox selector lever

Detaching
– Remove clip -arrow 1- and take off gate relay lever together
with cable end-piece.
• The gate relay lever must be removed before detaching the
cable end-piece ⇒ page 59 .
Securing
Note
Lubricate all bearings and moving surfaces with grease - G 000

450 02- .
– Insert gate relay lever with cable end-piece as far as stop.

– Press on clip -arrow 1-, making sure it engages securely.
Note
-Arrow 2- can be disregarded.
Levering cable end-piece for gate selector cable off gate relay
lever
• Gate relay lever removed
– Apply plain slot screwdriver -A- between bush -B- and gate
relay lever.
Pressing cable end-piece for gate selector cable onto gate relay
lever
• Gate relay lever removed
• Press on cable end-piece only at bush -arrow-.
• Cable end-piece must move freely on gate relay lever.
• Cable end-piece must be behind detent.
– Ensure that components engage securely.
Audi A1 2011 ➤
1.4 Exploded view - selector mechanism
Note
Lubricate bearings and moving surfaces with grease - G 000 450 02- .
1 - Floor plate
❑ Bend tabs open to re‐
move
❑ Renew
2 - Gasket
❑ Renew
3 - Bush
❑ Fitted in gate selector
cable
❑ Renew gate selector ca‐
ble if bush is damaged
4 - Retaining clips
❑ Renew
❑ Lever off gate selector
lever
❑ Press onto gate selector
lever inside selector
mechanism
❑ Installation position
⇒ page 53
❑ Lever off gear lever
guide
❑ Press onto gear lever
guide inside selector
mechanism
⇒ page 53
7 - Gear lever guide
8 - Bearing shell
❑ Will be damaged during removal
❑ Renew
9 - Spring
10 - Securing clip
11 - Damper
12 - Nut
❑ 4x
❑ M6 - 8 Nm
❑ M8 - 20 Nm
13 - Gasket
❑ Between selector housing and floor

Audi A1 2011 ➤
❑ Renew
❑ Self-adhesive
❑ Glue onto selector housing
14 - Selector housing
❑ With spring and gate selector lever
❑ Spring and gate selector lever cannot be removed
15 - Damping washer
❑ Push onto gear lever as far as stop
16 - Gear lever
❑ Can be removed and installed without removing gear lever guide ⇒ Item 7 (page 60)
Removing and installing securing clip

– Hold gear lever -2- firmly.
– Push bush -3- in direction of -arrow-.
– Detach securing clip -1-.
1.5 Removing and installing gear knob

♦ Removal wedge - 3409-
Audi A1 2011 ➤
♦ Hose clip pliers - V.A.G 1275-
Removing
– Using removal wedge - 3409- , lift up gear lever boot -1- (as
indicated by -arrows-) and turn inside out over gear knob.
– Open clip -arrow- and pull off gear knob together with boot.
Installing
Note
Secure gear knob with the correct clip (as original equipment);
refer to ⇒ Electronic parts catalogue .
– Push gear knob together with boot onto gear lever as far as
stop.
– Secure gear knob to gear lever with clip -arrow-, using hose
clip pliers - V.A.G 1275- .
1.6 Removing and installing selector mech‐

anism
Removing
– Remove gear knob with gear lever boot ⇒ page 61 .

Audi A1 2011 ➤
– Remove centre console ⇒ General body repairs, interior; Rep.

gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove nuts -arrows- securing selector housing to body.
Vehicles up to model year 2014:
– Remove securing clip -2-.

– Pull gear selector cable -1- off gearbox selector lever -4-.
Note
Disregard -item 3-.
• To avoid damage to the gate selector cable, the cable end-

piece must be separated from the gate selector cable before
removal.
– Press gate relay lever towards front -arrow 3-.
Audi A1 2011 ➤
– Remove bolts -arrows- for cable support bracket -1-.

– Remove heat shield in centre tunnel ⇒ General body repairs,
exterior; Rep. gr. 66 ; Strips / trim panels / extensions; Explo‐
ded view - heat shield .
– Swing down selector housing and remove together with ca‐
bles.
Installing selector mechanism

• Cables from selector mechanism to gearbox must run parallel.
– Insert selector mechanism and tighten nuts -arrows-.
– Apply a small amount of grease - G 000 450 02- to pin

-arrow- of gearbox selector lever -1-.
– Push gear selector cable -2- onto pin -arrow- and secure with
new securing clip -3-.
– Insert gate selector cable in cable end-piece on gate relay
lever.

Audi A1 2011 ➤
– Secure cable support bracket to gearbox -arrows-.

– Adjust selector mechanism ⇒ page 65 .
– Install heat shield in centre tunnel ⇒ General body repairs,
exterior; Rep. gr. 66 ; Strips / trim panels / extensions; Explo‐
ded view - heat shield .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Install gear knob with gear lever boot ⇒ page 61 .
Tightening torques
♦ ⇒ “1.4 Exploded view - selector mechanism”, page 60
1.7 Adjusting selector mechanism

♦ Removal wedge - 3409-
♦ Locking pin - T10027A-
Adjustment conditions
• Gear selector linkage must be in proper condition and undam‐
aged.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox in neutral.
Audi A1 2011 ➤
Adjusting
– Using removal wedge - 3409- , lift up gear lever boot -1- (as
indicated by -arrows-) and turn inside out over gear knob.
– Open ashtray (if fitted).
– With gearbox in neutral, move gear lever to the left into 1st/
2nd gear gate.
– If fitted, pull noise insulation slightly to one side.

– Fix gear lever in position with locking pin - T10027A- .
Note
The noise insulation panels are removed to give a better illustra‐

tion.

Release cable end-pieces for gear selector cable and gate se‐
lector cable as follows:
– Push locking sleeves on gear selector cable and gate selector
cable forward as far as they will go -arrow 1-.
– Turn locking sleeve as far as stop in direction of -arrow 2- so
that it engages.
• It should now be possible to move the cables in the cable end-
pieces.
• Gearbox in neutral.
Lock selector shaft as follows:

– Push gearbox selector lever down into 1st/2nd gear gate
-arrow 1-. At the same time, turn angled rod -A- in direction of
-arrow 2- until it engages in selector shaft.
• The selector shaft is then locked and can no longer be moved.
– Ensure that the gear selector cable and the gate selector cable
are located free of tension in the cable end-pieces.

Audi A1 2011 ➤
– Turn locking sleeves on gear selector cable and gate selector

cable as far as they will go -arrows-.
• The spring presses the locking sleeve back into the original
position.
Note
Cable adjustment is now complete.
– Turn angled rod -A- back to original position in direction of

-arrow-.
– Pull locking pin - T10027A- out of selector mechanism.
Checking adjustment
• With the gearbox in neutral, the gear lever should rest in the
3rd/4th gear gate.
– Press clutch pedal.
– Select all gears several times. Pay particular attention to the
operation of the reverse gear locking mechanism.
• The gear lever should return by itself from the reverse gear
gate to the 3rd / 4th gear gate.
If the gear lever sticks or baulks repeatedly when engaging a
gear, perform the adjustment procedure again ⇒ page 65 .
– Install gear lever boot.
1.8 Dismantling and assembling selector

mechanism
♦ Press tool - VW 412-
Audi A1 2011 ➤
♦ Adapters - 10 - 222 A /25-
♦ Assembly tool - T10178-
♦ Release tool - T10236-
♦ Wedge - T10357-
♦ Counter-support Kukko series 16

Audi A1 2011 ➤
Dismantling
• Selector mechanism removed ⇒ page 62 .
– Open out tabs -arrows- all round with screwdriver and remove
floor plate.
– Remove gasket.
– Detach retaining clip -2-.

– Press off gear selector cable -1- using release tool - T10236- .
Note
Disregard items -3 and 4-.
– Hold gear lever -3- firmly.

– Push spring -1- in direction of -arrow-.
– Detach securing clip -2-.
– Remove spring.
– Press arm -A- of spring to side until it is located next to damper

-arrow-.
– Move gear lever to side and remove damper.
Audi A1 2011 ➤
Note
A second mechanic is required for the following step.
– Working from below, release all four retaining lugs -arrows- on

ball socket by applying a small screwdriver at each lug.
– At the same time press gear lever out of selector housing to‐
gether with ball socket and gear lever guide.
– Press ball socket -2- off ball -1- in gear lever guide.
– To do so, pull ball socket upwards -arrow A- and turn ball
socket in direction of -arrow B- to release it from gear lever
guide.
Assembling
Assembly is performed in reverse sequence; note the following:
Note
♦ Renew seals.
♦ Lubricate bearings and moving surfaces with grease - G 000
450 02- .
– First fit ball socket over ball in gear lever guide and then press
ball socket into selector housing until retaining lugs -arrows-
snap into place.
– Press gear selector cable -1- onto gearbox selector lever.

– Secure gear selector cable with retaining clip -2-.
Note
Disregard items -3 and 4-.

Audi A1 2011 ➤
Fitting floor plate

– Fit gasket onto floor plate.
Caution
Risk of damage to selector housing and floor plate.

♦ Apply only light pressure when pre-tensioning selector
housing.
– Secure selector mechanism and floor plate using tools, as

shown in illustration.
A - Counter-support, e.g. Kukko series 16
– Lever tabs -arrows- of floor plate over rim of selector housing
on both sides using wedge - T10357- .
– Install selector mechanism ⇒ page 64 .
1.9 Renewing selector shaft oil seal

♦ Tube - VW 423-
♦ Extractor tool - T20143/1-
Procedure
Audi A1 2011 ➤

– Detach gear selector cable from gearbox selector lever -B-.
– Remove gate relay lever -A- from gearbox together with cable
end-piece ⇒ page 59 .
– Remove gearbox selector lever -B- by removing nut
-arrow 2-.
– Pry out oil seal using extractor lever - T20143/1- .
– Drive in oil seal using tube - VW 423- .

The remaining installation steps are carried out in reverse se‐
quence; note the following:
– Install gearbox selector lever and gate relay lever
⇒ page 56 .
Note
The gearbox selector lever can only be installed in one position.

Tightening torques
♦ ⇒ “1.3 Exploded view - selector cables”, page 56
1.10 Removing and installing selector cable

Removing
– Remove selector mechanism ⇒ page 62 .
– Open out tabs -arrows- all round with screwdriver and remove
floor plate.
– Remove gasket.

Audi A1 2011 ➤
– Detach retaining clips -2, 3-.

– Press off gear selector cable -1- and gate selector cable -4-
using a screwdriver.
Release cable end-pieces -A- for gate selector cable and gear
selector cable -B- as follows:
– Push locking sleeve forwards as far as stop -arrow 1-.
– Turn locking sleeve clockwise as far as stop -arrow 2- so that
it engages.
– Detach cable end-pieces from selector cables.
– Remove retaining clips -1- and -2-.

– Detach cable support bracket from selector cables.
Installing
Note
Renew gate selector cable if bush ⇒ Item 3 (page 56) is damaged.
– Fit gasket and install floor plate -arrows- ⇒ page 71 .

– Install selector mechanism ⇒ page 62 .
Audi A1 2011 ➤
2 Removing and installing gearbox

⇒ “2.1 Removing gearbox”, page 74
⇒ “2.2 Installing gearbox”, page 87
⇒ “2.3 Tightening torques for gearbox”, page 89
2.1 Removing gearbox

⇒ “2.1.1 Removing gearbox - vehicles with 1.0 ltr. engine”,
page 74
⇒ “2.1.2 Removing gearbox - vehicles with 1.2 ltr. engine”,
page 79
2.1.1 Removing gearbox - vehicles with 1.0 ltr.

engine
♦ Extension -2024A/1- of lifting tackle - 2024A-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/53-
♦ Engine and gearbox jack - VAS 6931-

Audi A1 2011 ➤
Procedure
Note
Fit all cable ties in the original positions when installing.

• To prevent damage to gate selector cable, cable end-piece
must be detached from gate selector cable before removing.

– Remove nut -3- and detach gearbox selector lever.
– Unscrew bolts -arrows-, remove cable support bracket -1- and

place to one side together with cables.
2. Removing and installing gearbox 75

Audi A1 2011 ➤
– Remove bolts -arrows-, detach clutch slave cylinder -1- and

place to one side. Do not disconnect pipes.
Caution
Risk of irreparable damage to clutch slave cylinder.

– Unplug electrical connector -2-.

– Detach cover for B+ wire -3-.
– Remove nut and move B+ wire clear.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Remove wheel housing liner (front left) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (front) .
Vehicles with start/stop system:

– Unplug electrical connector -3- at gearbox neutral position
sender - G701- .
– Unplug electrical connector -1- at reversing light switch - F4- .
– Remove nut -2- and detach bracket for electrical wiring.
– Remove bolt (bottom) and detach starter.
– If bolted on: Detach drive shafts (left and right) from gearbox.
To do so, remove bolts -arrows-.

Audi A1 2011 ➤
– Remove nuts -arrows- securing swivel joint on both sides.

– If fitted, unscrew nut on bracket for front left vehicle level send‐
er - G78- .
– Disengage swivel joint (both sides) from wishbone.
– Swivel suspension strut (both sides) outwards and support

with extension -2024A/1- , as shown in illustration.
WARNING
Risk of accidents if components of support are loose

♦ Secure retaining pin and swivel joint with locking pin
-arrow- and nut -1-.
– If inserted in gearbox: Carefully pry drive shaft off joint pin

(have a second mechanic hold the drive shaft to prevent it from
dropping).
– Tie up drive shafts (left and right).
Note
Take care not to damage the surface coating of the drive shaft.
– Remove flange shaft (right-side) ⇒ page 192 .
WARNING
Risk of accident.
♦ Do NOT loosen bolted connection -1-.
– Remove bolts -arrows- and detach pendulum support.

Audi A1 2011 ➤
– Loosen nuts -arrows- and move clamp towards rear.
– Remove bolts -2 and 3- (accessible from above).

– Support engine in installation position ⇒ Rep. gr. 10 ; As‐
sembly mountings; Supporting engine in installation position .
– Remove bolts -arrows- securing gearbox mounting.
– Lower engine/gearbox assembly using spindle of support

bracket - 10 - 222 A- until distance -a- is obtained between
gearbox support and gearbox mounting.
• Dimension -a- = 50 mm

Audi A1 2011 ➤
– Remove bolts -arrows- and detach gearbox support -A-.
To remove gearbox 02T, set up gearbox support - 3282- with ad‐

justment plate - 3282/53- .
– Insert gearbox support - 3282- in engine and gearbox jack -
VAS 6931- .
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Secure support elements as illustrated on adjustment plate.
– Place engine and gearbox jack - VAS 6931- underneath ve‐
hicle.
• The arrow symbol on the adjustment plate points in the direc‐
tion of travel.
– Align adjustment plate - 3282/53- parallel to gearbox and at‐
tach support elements to gearbox.
– Remove bolts -1, 6, 7, 8, 9- securing gearbox to engine.

– Press gearbox off dowel sleeves.
– Detach gearbox from engine.
– While lowering gearbox, adjust position of gearbox using spin‐
dles on gearbox support - 3282- .
2.1.2 Removing gearbox - vehicles with 1.2 ltr. engine

Audi A1 2011 ➤
Special tools and workshop

equipment required
♦ Support bracket - 10 - 222 A-

♦ Adapters - 10 - 222 A /19-
♦ Extension -2024 A/1- of lifting tackle - 2024 A-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
♦ Engine and gearbox jack - VAS 6931- or -V.A.G 1383 A-
♦ Engine support (basic set) - T40091-

Audi A1 2011 ➤
Procedure
Note
Fit all cable ties in the original positions when installing.
Caution
When disconnecting the battery there is a risk of irreparable

damage to electronic components.
♦ Observe notes on procedure for disconnecting the battery.
– With ignition switched off, disconnect battery earth wire and

remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Release retainers -arrows A- and lift out side panel for battery
tray -arrow B-.
– Remove bolt -3- and nuts -1 and 2- and detach battery tray.
• To prevent damage to gate selector cable, cable end-piece

must be detached from gate selector cable before removing.

Audi A1 2011 ➤

– Remove nut -3- and detach gearbox selector lever.
– Unscrew bolts -arrows-, remove cable support bracket -1- and

place to one side together with cables.
– Remove bolts -arrows-, detach clutch slave cylinder -1- and

place to one side. Do not disconnect pipes.
Caution
Risk of irreparable damage to clutch slave cylinder.

– Unplug electrical connector -2-.

– Detach cover for B+ wire -3-.
– Remove nut and move B+ wire clear.
insulation .

Audi A1 2011 ➤
Vehicles with start/stop system:

– Unplug electrical connector -3- at gearbox neutral position
sender - G701- .
– Unplug electrical connector -1- at reversing light switch - F4- .
– Remove nut -2- and detach bracket for electrical wiring.
– Remove bolt (bottom) and detach starter.
– If bolted on: Detach drive shafts (left and right) from gearbox.
To do so, remove bolts -arrows-.
– Remove nuts -arrows- securing swivel joint on both sides.

er - G78- .
– Pull swivel joint (left-side) off wishbone.
Note
When removing and installing, take care not to damage the rubber
boot of the swivel joint. The boot should be protected against
damage if necessary.
– If inserted in gearbox: Press drive shafts (left and right) off

gearbox using assembly lever -1-.
– Pivot suspension strut outwards and at the same time guide
drive shaft out of gearbox.

Audi A1 2011 ➤
– Support suspension strut (left and right) with extension -2024

A /1- , as shown in illustration.
WARNING

– Tie up drive shaft.
Note
WARNING
Risk of accident.
♦ Do NOT loosen bolted connection -1-.
– Remove bolts -arrows- and detach pendulum support.
– Loosen nuts -arrows- and move clamp towards rear.
– Remove bolts -1- and -2- (accessible from above).

Audi A1 2011 ➤
– Set up support bracket - 10 - 222 A- on wing mounting flanges,

as shown in illustration.
– Engage hook of spindle - 10 - 222 A /11- in engine lifting eye
(left-side).
– Take up weight of engine with spindle; do not lift.
– Remove bolts -arrows- securing gearbox mounting.
– Lower engine/gearbox assembly using spindle of support

bracket - 10 - 222 A- until distance -a- is obtained between
gearbox support and gearbox mounting.
• Dimension -a- = 50 mm
– Remove bolts -arrows- and detach gearbox support -A-.

Audi A1 2011 ➤
To remove gearbox 02T, set up gearbox support - 3282- with ad‐

justment plate - 3282/31- .
– Insert gearbox support - 3282- in engine and gearbox jack -
V.A.G 1383 A- .
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Bolt on support elements -A-, as illustrated on adjustment
plate.
– Place engine and gearbox jack - V.A.G 1383 A- underneath
vehicle.
• The arrow symbol -B- on the adjustment plate points in the
direction of travel.
– Align adjustment plate - 3282/31- parallel to gearbox and lock

safety support on gearbox.
Note
Disregard -arrow-.
– Remove bolts -arrows- and detach cover plate -1-.
– Remove remaining engine/gearbox securing bolts -5- and

-8-.
– Press gearbox off dowel sleeves.
– Detach gearbox from engine.

Audi A1 2011 ➤
– Press engine forward slightly.

– Carefully lower gearbox using engine and gearbox jack -
V.A.G 1383 A- and ensure sufficient clearance between
sleeve -1- and clutch pressure plate -arrow- to prevent dam‐
age.
– While lowering gearbox, adjust position of gearbox using spin‐
dles on gearbox support - 3282- .
2.2 Installing gearbox

Installation is carried out in the reverse order; note the following:
Note
♦ Renew bolts which are tightened by turning through a speci‐

fied angle.
♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Fit all cable ties in the original positions when installing.
♦ 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 grease for clutch plate splines - G 000 100- to the
splines. Then move clutch plate backwards and forwards on
input shaft until hub moves freely on shaft. It is important to
remove excess grease.

Audi A1 2011 ➤
– Check that dowel sleeves -B- for centralising engine/gearbox

are in the cylinder block; install any missing dowel sleeves.
Caution
If the dowel sleeves -arrows B- are not fitted, this will lead to
gear-change problems, clutch malfunction and in some cases
gearbox noise (gears will make rattling noises).
– Make sure that the intermediate plate is engaged on the seal‐

ing flange -arrow A- and fitted on the dowel sleeves
-arrows B-.
– Check clutch release bearing for wear and renew if necessary.
– Lubricate surface which contacts ball-head pin with grease,
e.g. -G 000 100-
– Place engine and gearbox jack - V.A.G 1383 A- underneath
vehicle.
• The arrow symbol on the adjustment plate points in the direc‐
tion of travel.
– Remove flange shaft (right-side) when installing a new gear‐
box or exchange gearbox.
– Check oil seal for flange shaft (right-side) for leakage and re‐
new if necessary ⇒ page 161 .
– Carefully raise gearbox using engine and gearbox jack - V.A.G
1383 A- .
Vehicles up to model year 2014:

– When doing so, ensure sufficient clearance between sleeve
-1- and pressure plate -arrow- to prevent damage.
– Bring gearbox into position.
– Install bottom engine/gearbox securing bolts.
– Detach gearbox support - 3282- with adjustment plate -
328253- from gearbox after bolting gearbox and engine to‐
gether.
– Install gearbox support -A- ⇒ page 91 .

– Install top engine/gearbox securing bolts.
– Raise engine/gearbox assembly via spindle of support bracket
- 10 - 222 A- .

Audi A1 2011 ➤
– Align engine/gearbox assembly in installation position. To do

so, raise engine/gearbox until gearbox support makes full con‐
tact with gearbox mounting.
Caution
Bolts must be fitted straight to avoid damage to threads in

gearbox support.
♦ Gearbox support and support arm of gearbox mounting
must be perfectly parallel to each other before screwing in
bolts -arrows-.
– Bolt gearbox support to gearbox mounting ⇒ page 91 .
WARNING
Risk of accident.
♦ Do not remove support bracket - 10 - 222 A- until all bolts
securing the left-hand engine/gearbox mounting have
been tightened to the specified torque.
– Install pendulum support ⇒ Rep. gr. 10 ; Assembly mountings;

Removing and installing pendulum support .
– Install flange shaft (right-side) ⇒ page 192 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Exploded view - drive shaft .
– Install clutch slave cylinder ⇒ page 39 .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Ex‐
ploded view - starter .
– Adjust selector mechanism ⇒ page 65 .
– Check oil level in gearbox and top up with gear oil if necessary
⇒ page 96 .
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Exploded view - battery .
2.3 Tightening torques for gearbox
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gear oil may be used,
but do not use lubricants containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: ± 15 %

Audi A1 2011 ➤
Securing manual gearbox 02T to 1.2 ltr. engine

Item Bolt Nm
1 M12x65 80
21) M12x140 80
3 M12x80 80
4 M10x50 40
A Dowel sleeves for centralising
• 1) Also secures starter.
Securing manual gearbox 0DF to 1.0 ltr. engine

Item Bolt Nm
1, 9 M12x70 80
2, 3 M12x60 80
4, 5 1) M12x150 80
6, 7, 8 M10x55 40
A Dowel sleeves for centralising
• 1) Also secures starter.

Audi A1 2011 ➤
3 Assembly mountings
⇒ “3.1 Exploded view - assembly mountings”, page 91
3.1 Exploded view - assembly mountings

⇒ “3.1.1 Exploded view - assembly mountings, vehicles with 1.0
ltr. engine”, page 91
⇒ “3.1.2 Exploded view - assembly mountings, vehicles with 1.2
ltr. engine”, page 93
3.1.1 Exploded view - assembly mountings, vehicles with 1.0 ltr. engine
1 - Engine support
2 - Bolt
❑ Tightening torque ⇒
Rep. gr. 10 ; Assembly
mountings; Exploded
view - assembly mount‐
ings
3 - Engine mounting
⇒ Rep. gr. 10 ; Assem‐
bly mountings; Remov‐
ing and installing engine
mounting
4 - Bolt
mountings; Exploded
ings
5 - Centre hex stud
❑ 30 Nm +90°
6 - Bolt
mountings; Exploded
ings
7 - Pendulum support
ing and installing pendu‐
lum support
8 - Bolt
❑ Tightening torque ⇒ Rep. gr. 10 ; Assembly mountings; Exploded view - assembly mountings
9 - Bolt
10 - Bolt
❑ 40 Nm +90°
❑ Renew
3. Assembly mountings 91
Audi A1 2011 ➤
11 - Gearbox mounting
❑ With support arm
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing gearbox mounting
12 - Gearbox support
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Exploded view - assembly mountings
13 - Bolt
❑ 40 Nm +90°
❑ Renew
14 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 92
Gearbox mounting - tightening torque and sequence
Note
Renew bolts which are tightened by turning through a specified

angle.
– Tighten bolts in 3 stages in the sequence shown:

Stage Bolts Tightening torque/angle specification
1. -A, B, C- Screw in by hand until contact is made
2. -A, B, C- 50 Nm
3. -A, B, C- Turn 90° further

Audi A1 2011 ➤
3.1.2 Exploded view - assembly mountings, vehicles with 1.2 ltr. engine
1 - Engine support
2 - Bolt
mountings; Exploded
ings
3 - Engine mounting
ing and installing engine
mounting
4 - Bolt
mountings; Exploded
ings
5 - Support arm
6 - Nut
❑ Only loosen this part if
engine mounting
-item 3- is to be renewed
mountings; Exploded
ings
7 - Threaded pin
mountings; Exploded
ings
8 - Bolt
9 - Pendulum support
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing pendulum support
10 - Bolt
11 - Bolt
12 - Bolt
❑ 40 Nm +90°
❑ Renew
13 - Bolt
❑ Renew
14 - Gearbox mounting
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing gearbox mounting
3. Assembly mountings 93
Audi A1 2011 ➤
15 - Gearbox support
❑ Removing and installing ⇒ Rep. gr. 10 ; Assembly mountings; Exploded view - assembly mountings
16 - Bolt
❑ 40 Nm +90°
❑ Renew
17 - Bolt
❑ Renew

Audi A1 2011 ➤
4 Transporting gearbox
♦ Gearbox lifting tackle - 3336-
♦ Workshop hoist - VAS 6100-
Procedure
– Bolt gearbox lifting tackle - 3336- to clutch housing.

– Set support arm on sliding bracket by means of locking pin
-arrow-.
• Number of holes visible = 6
– Lift gearbox with workshop hoist - VAS 6100- and gearbox lift‐
ing tackle - 3336- .
4. Transporting gearbox 95
Audi A1 2011 ➤
5 Gear oil
⇒ “5.1 Checking gear oil level”, page 96
⇒ “5.2 Draining and filling gear oil”, page 96
5.1 Checking gear oil level

♦ Socket - 3357-
or
♦ 17 mm socket (hexagon key)
Procedure
– Drive vehicle onto a four-column lifting platform or over an in‐
spection pit (vehicle must be horizontal).
insulation .
– Remove oil filler plug -arrow-.
• Specification: oil level up to bottom lip of filler hole
– Top up gear oil if necessary. Specifications ⇒ Electronic parts
catalogue
– Tighten oil filler plug -arrow- to specified torque.
Tightening torques
♦ ⇒ Fig. ““Different versions of oil filler/oil drain plug”“ ,
page 126
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
5.2 Draining and filling gear oil


Audi A1 2011 ➤
♦ Used oil collection and extraction unit - VAS 6622A-
♦ Gear oil specifications ⇒ Electronic parts catalogue

Draining
– Drive vehicle onto a four-column lifting platform or over an in‐
spection pit (vehicle must be horizontal).
insulation .
– Place used oil collection and extraction unit - VAS 6622A- be‐
low gearbox.
– Unscrew oil drain plug ⇒ Item 3 (page 103) and allow gear oil
to drain.
– Tighten oil drain plug to specified torque.
Filling
– Unscrew oil filler plug -arrow-.
– Fill up gear oil to bottom lip of filler hole.
– Screw in oil filler plug -arrow-.
– Start engine and let gearbox turn in neutral for approx. 2 mi‐
nutes.
– Switch off engine and remove oil filler plug.
– Top up gear oil again to bottom lip of filler hole.
– Tighten plug -arrow- to specified torque.
Tightening torques
♦ ⇒ Fig. ““Different versions of oil filler/oil drain plug”“ ,
page 126
5. Gear oil 97
Audi A1 2011 ➤
6 Securing to engine and gearbox sup‐

port
♦ Gearbox support - 3221A-
♦ Engine and gearbox support - VAS 6095- or support clamp -

VW 313-
Preparing gearbox support - 3221- for manual gearbox 02T:

The old gearbox support - 3221- can be converted into gearbox
support - 3221A- as follows:
– Make an additional ∅ 11 mm drilling -arrow- in gearbox sup‐
port - 3221- according to dimensions shown (dimensions in
mm).
Note
This drilling is already present on gearbox support - 3221A- .
Preparing gearbox support - 3221A- for manual gearbox 0DF:

– Make two additional ∅ 11 mm drillings -arrows- in gearbox
support - 3221A- according to dimensions shown (dimensions
in mm).

Audi A1 2011 ➤
Manual gearbox 02T

– Bolt gearbox support - 3221- / -3221A- to gearbox housing
-arrows-, as shown in illustration.
Manual gearbox 0DF

– Bolt gearbox support - 3221A- to gearbox housing -arrows- as
shown in illustration.
6. Securing to engine and gearbox support 99

Audi A1 2011 ➤
7 Dismantling and assembling gearbox

⇒ “7.1 Schematic overview - gearbox”, page 100
⇒ “7.2 Exploded view - gearbox”, page 101
⇒ “7.3 Exploded view - gearbox housing cover”, page 102
⇒ “7.4 Exploded view - input shaft, output shafts, differential and
selector rods”, page 103
⇒ “7.5 Exploded view - selector forks”, page 105
⇒ “7.6 Exploded view - selector unit”, page 106
⇒ “7.7 Servicing selector forks”, page 107
⇒ “7.8 Removing and installing angled rod”, page 110
⇒ “7.9 Removing and installing 5th gear”, page 111
⇒ “7.10 Dismantling and assembling gearbox”, page 113
7.1 Schematic overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Gearbox housing cover
7 - Gearbox housing
8 - Reverse gear wheel
❑ Selector forks
10 - Clutch housing
11 - Input shaft
12 - Output shaft
13 - Differential

Audi A1 2011 ➤
7.2 Exploded view - gearbox

Sequence for dismantling and assembling ⇒ page 113
I - Gearbox housing cover and

5th gear
❑ Exploded view
⇒ page 102
II - Clutch housing
❑ Exploded view
⇒ page 124
⇒ page 128
III - Input shaft, output shaft,
differential, selector mecha‐
nism and selector forks
❑ Exploded view
⇒ page 103
⇒ page 113
7. Dismantling and assembling gearbox 101

Audi A1 2011 ➤
7.3 Exploded view - gearbox housing cover
1 - Gearbox housing
❑ Servicing ⇒ page 125
2 - 5th gear wheel
large collar faces gear‐
box housing cover
⇒ page 111
3 - Circlip
❑ Renew
❑ Determining thickness
⇒ page 113
4 - Gasket
5 - Gearbox housing cover
Note
If the gearbox housing cover is in‐

stalled with the gearbox in the vehi‐
cle, check and top up oil
⇒ page 96 .
6 - Bolt
❑ Renew
❑ 5 Nm +90°
7 - Circlip
❑ Renew
⇒ page 113
8 - Synchro-hub with locking
collar and check ring for 5th
gear
❑ Dismantling and assembling
9 - 5th gear synchro-ring
10 - 5th speed selector gear
11 - Needle bearing
❑ For 5th gear
12 - 5th gear selector fork
❑ Dismantling and assembling ⇒ page 105
13 - Pivot pin
❑ For 5th gear selector fork

Audi A1 2011 ➤
7.4 Exploded view - input shaft, output shafts, differential and selector rods
Note
Securing gearbox to assembly stand ⇒ page 98
1 - Differential
⇒ page 113
❑ Dismantling and assem‐
bling ⇒ page 166
2 - Gearbox housing
3 - Oil drain plug
❑ Tightening torque
⇒ page 126
4 - Flange shaft with spring
❑ Only for manual gear‐
box 02T
⇒ page 190
❑ Assembling
⇒ page 166
5 - Countersunk bolt
box 02T
6 - Bolt
❑ Secures bearing mount‐
ing with grooved ball
bearings for input and
output shafts
❑ Self-locking
❑ Renew
❑ 5 Nm +90°
7 - Hexagon flange nut
❑ 23 Nm
❑ For selector mechanism ⇒ Item 17 (page 104)
❑ Self-locking
❑ Renew
8 - O-ring
❑ Renew
9 - Pivot pin
10 - Bolt
❑ Renew
❑ 5 Nm +90°
11 - Selector shaft with selector mechanism cover
❑ Selector unit

Audi A1 2011 ➤

12 - Bolt
❑ Renew
❑ 5 Nm +90°
13 - Bolt
❑ 6 Nm
14 - Gearbox neutral position sender - G701-
❑ For vehicles with start/stop system
15 - Reversing light switch - F4-
❑ 20 Nm
❑ With captive seal; seal does not have to be renewed
16 - Seal
❑ Captive seal; does not have to be renewed
❑ Selector forks
18 - Input and output shafts with bearing mounting for grooved ball bearings
❑ If bearing mounting is separated from gearbox housing, it must always be renewed
❑ Pressing bearing mounting on and off ⇒ page 137
❑ Dismantling and assembling input shaft ⇒ page 135
❑ Dismantling and assembling output shaft ⇒ page 148
19 - Reverse gear shaft
20 - Reverse gear wheel
21 - Bolt
❑ For reverse gear shaft
❑ Renew
❑ M6 - 5 Nm + 90°
❑ M8 - 25 Nm + 45°

Audi A1 2011 ➤
7.5 Exploded view - selector forks
Note
The selector fork cluster ( ⇒ Item 1 (page 105) ) does not have to be dismantled in order to remove and install
the detent segments, clamping washers and angular contact ball bearings.
1 - Selector fork cluster with

selector plates
2 - 3rd/4th gear detent seg‐
ment
❑ Identification
⇒ page 108
❑ Detent segment should
turn freely after installa‐
tion.
❑ Separate detent seg‐
ments are fitted in some
gearboxes ⇒ page 109
❑ Identification
⇒ page 109
3 - Angular contact ball bearing
❑ 4x
❑ Pressing inner race into
outer race ⇒ page 110
❑ Installing ⇒ page 110
4 - Clamping washer
❑ Renew
5 - 1st/2nd gear detent seg‐
ment
❑ Identification
⇒ page 108
❑ The segment must ro‐
tate freely after installing
the lock washer
❑ Selector fork with detent
segment ⇒ page 109
6 - 5th gear selector fork with detent segments
❑ Detent segments are inseparably joined with selector fork
❑ Identification ⇒ page 108
7 - Pivot pin
❑ For 5th gear selector fork

Audi A1 2011 ➤
7.6 Exploded view - selector unit
1 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ page 134
❑ Driving in ⇒ page 134
2 - Angled rod
❑ For adjusting selector
mechanism ⇒ page 65
⇒ page 110
3 - Selector shaft with selector
mechanism cover
❑ Selector unit
❑ Renew together
4 - Bolt
❑ Renew
❑ 5 Nm +90°
5 - Oil seal
6 - Cap
❑ For gearbox breather
7 - Bolt
❑ Renew
❑ 5 Nm +90°

Audi A1 2011 ➤
7.7 Servicing selector forks

equipment required
♦ Thrust plate - VW 402-

♦ Thrust piece -3290/1- from assembly tool - 3290-
♦ Assembly tool - 3301-
♦ Thrust piece - VW 431-
♦ Spacer sleeve - VW 472/2-
♦ Drift - 10 - 206-

Audi A1 2011 ➤
♦ Assembly mandrel - 10 - 508-

♦ Removal lever - 80 - 200-
♦ Tensioning device - 2070-
Identification of detent segments and 5th gear selector fork with

detent segments
Dimension -a-
1 - Detent segments 1st/2nd gear = 10.2 mm
2 - Detent segment 3rd/4th gear = 78.6 mm
3 - 5th/6th gear selector fork with detent segments = 79.5 mm

Audi A1 2011 ➤
Separate detent segments for 3rd/4th gear -A-

Detent segments should turn freely after installation.
Identification of separate detent segments for 3rd/4th gear

1- Short detent segment for 3rd/4th gear -a- = 10.2 mm
2- Long detent segment for 3rd/4th gear -a- = 10.2 mm
1st/2nd gear selector fork with detent segments

Distance -a- = 75 mm
Removing lock washer

– Secure selector fork in vice with protective jaw covers -B-.
– Lever off lock washer -A- in direction of -arrow-.

Audi A1 2011 ➤
Installing lock washer

– Press lock washer into groove on detent segment using socket
attachment.
A - Socket (10 mm)
B - Protective jaw covers
Note
Detent segment should turn freely after lock washer is installed.
Removing angular contact ball bearing
Note
Do not bend selector forks when removing and installing the ball
bearing.
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage positively in outer race.
Pulling angular contact ball bearing into selector fork (insert onto
stop)
Recess in thrust piece - 3290/1- points towards ball bearing.
7.8 Removing and installing angled rod


Audi A1 2011 ➤
♦ Tube - T10203-
Removing
– Remove outer part of angled rod -A-.
– Carefully lever out angled rod with a screwdriver -arrow-.
Installing
– Drive angled rod into selector mechanism cover with tube -
T10203- .
• Installation position: Marking -1- should coincide with marking
-2- on selector mechanism cover.
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Exploded view - battery .
7.9 Removing and installing 5th gear
Note
The gearbox housing cover and 5th gear can also be removed
without removing the gearbox from the vehicle. The gearbox oil
must be drained off for this operation. The following instructions
describe removal and installation with the gearbox removed from
the vehicle.

Audi A1 2011 ➤
Removing
• Gearbox removed
– Secure gearbox to assembly stand ⇒ page 98 .
– Unbolt gearbox housing cover -arrow-.
– Pull out pivot pin -1- for 5th gear selector fork -2- and remove
selector fork.
– Remove circlip -3- for 5th gear synchro-hub.
– Remove circlip -4- for 5th gear wheel.
– Take off selector gear, locking collar with synchro-hub, and
gear wheel.
Installing
– Check synchro-ring for wear ⇒ page 144 .
– Fit 5th gear wheel -1-.
• Installation position of 5th gear wheel: the large collar
-arrow- points to the gearbox housing cover.
– Install the following components in the sequence indicated:

1 - Needle bearing for 5th speed selector gear
4 - 5th gear synchro-hub with locking collar and check ring

Audi A1 2011 ➤
– Fit 5th gear selector fork -2- and slide pivot pin -1- in onto stop
in direction of -arrow-.
– Determine thickness of new circlips -arrow- for input shaft -3-
and output shaft -4-.
– Determine the thickest circlip that will just fit and install it. For
part number, refer to ⇒ Electronic parts catalogue .
The following circlips are available:
Circlip thickness (mm)
2.00 2.10 2.20
– Install gearbox housing cover.
Note
If the gearbox cover is installed with the gearbox in the vehicle,

fill up with gear oil and check oil level ⇒ page 96 .
Tightening torques
♦ ⇒ “7.3 Exploded view - gearbox housing cover”, page 102
7.10 Dismantling and assembling gearbox

Audi A1 2011 ➤

equipment required

♦ Tube - VW 422-
♦ Guide pin - T10079-

Audi A1 2011 ➤

♦ Thrust block - T10083-
♦ Thrust plate - T10084 A-

Audi A1 2011 ➤
Dismantling gearbox
• Gearbox removed
low gearbox.
– Drain off gear oil.
– Unbolt gearbox housing cover -arrow-.
– Pull out pivot pin -1- for 5th gear selector fork -2- and remove
selector fork.
– Remove circlip -3- for 5th gear synchro-hub.
– Remove circlip -4- for 5th gear wheel.
– Take off synchro-hub for 5th gear, selector gear and 5th gear
wheel.
– Unscrew securing bolts -A- for bearing mounting for input and
output shafts.
– Unscrew hexagon flange nut -B- for selector mechanism (re‐
verse gear wheel mounting).
Manual gearbox 02T:
– Remove flange shaft -C- (see next illustration).
– Remove securing bolt for flange shaft (left-side); to do so,

screw two bolts into flange and counterhold flange shaft with
suitable lever.
– Pull out flange shaft together with spring, thrust washer and
tapered ring.

Audi A1 2011 ➤
– Turn gearbox on assembly stand so that clutch housing faces

upwards.
– Remove securing bolt for flange shaft (right-side); to do so,
tyre iron or other suitable lever.
tapered ring.
Continued for all gearboxes:

– Remove all 18 bolts -arrow- securing clutch housing.

– Carefully remove clutch housing by levering alternately at the
protruding webs on the housing, taking care not to damage the
sealing surfaces.
Caution
Make sure you keep clutch housing straight to avoid damaging

roller bearings and bearing seat on input and output shafts.

Audi A1 2011 ➤
– Remove differential -A- from gearbox housing.
– Gearbox for vehicles with start/stop system: remove gearbox

neutral position sender - G701- -arrow-.
– Remove selector shaft with selector mechanism cover -A-. To

do so, move selector shaft into neutral position. Then remove
bolts -arrows- and pull selector mechanism cover and selector
shaft out of gearbox housing.
– Remove pivot pins -B- from top of gearbox.
– Unscrew reversing light switch - F4- -item C-.
– Remove bolt -A- securing reverse gear shaft.

– Remove pivot pins -B- from gearbox underside.
Note
Do not remove cover plate -arrow- when dismantling gearbox.

Audi A1 2011 ➤
– Press out input and output shafts together with bearing mount‐
ing, selector mechanism (selector forks) and reverse gear
wheel.
Note
♦ Place gearbox housing on thrust plates - VW 401- and -

VW 402- so that dowel sleeves in gearbox housing are not
damaged.
♦ Make sure components do not drop out when being removed
(get help from a second person if necessary).
– Press input and output shaft out of bearing mounting with

grooved ball bearings ⇒ page 137 .
Note
The bearing mounting must always be renewed if it is separated

from the gearbox housing.
Assembling gearbox
• Bearing mounting with grooved ball bearings has been re‐
newed ⇒ page 137
– Place the pre-assembled input shaft -2- and output shaft -1-
with bearing mounting for grooved ball bearings in thrust piece
- T10085- .
– Insert selector mechanism (selector forks) -4- in locking collars
on shafts.
– Fit reverse gear shaft -3- with reverse gear wheel.
– Screw guide pin - T10079- onto threaded pin (reverse gear
mounting) -arrow-.

Audi A1 2011 ➤
– Insert assembled components into gearbox housing, running

guide pin - T10079- into gearbox housing through hole for se‐
lector mechanism mounting.
– Unscrew guide pin - T10079- .
– Check that selector forks engage correctly in locking collars
before pressing in bearing mounting.
– Carefully press in bearing mounting together with input and

output shafts as far as the stop.
– Secure bearing mounting lightly with bolt tightened finger-tight.
– Screw in bolt -A- for reverse gear shaft.

– Install pivot pins -B- on underside of gearbox.
– Screw in reversing light switch - F4- -item C-.

– Align selector mechanism and install pivot pins -B- on top of
gearbox.
– Set selector plates in neutral position.
– Clean sealing surfaces; they must be free from oil and grease.
– Apply sealing paste - AMV 188 200 03- evenly to sealing sur‐
face.
– Install selector shaft with selector mechanism cover -A-. Then
tighten bolts -arrows-.

Audi A1 2011 ➤
– Gearbox for vehicles with start/stop system: fit gearbox neutral

position sender - G701- -arrow- and tighten securing bolt to
specified torque ⇒ Item 13 (page 104) .
– Using new bolts -A-, secure bearing mounting for input and
output shafts.
Note
Tighten the bolts in stages to the specified torque in diagonal se‐

quence, starting in the centre.
– Tighten hexagon flange nut -B- for selector mechanism (se‐

lector forks).
– Engage all gears to check function.
– Install differential -A-.

face.
– When installing housing, rotate input shaft by hand to enable
bearing to slide easily onto its seat.
– Tighten gearbox housing bolts -arrow- diagonally in stages.

– Turn gearbox on assembly stand so that gearbox housing
faces upwards.

Audi A1 2011 ➤
– Fit 5th gear wheel -1-.

• Installation position of 5th gear wheel: the large collar
-arrow- points to the gearbox housing cover.
– Install the following components in the sequence indicated:

1 - Needle bearing for 5th speed selector gear
4 - 5th gear synchro-hub with locking collar and check ring
– Fit 5th gear selector fork -2- and slide pivot pin -1- in onto stop
in direction of -arrow-.
– Determine thickness of new circlips -arrow- for input shaft -3-
and output shaft -4-.
– Determine the thickest circlip that will just fit and install it. For
part number, refer to ⇒ Electronic parts catalogue .
Circlip thickness (mm)
2.00 2.10 2.20

Audi A1 2011 ➤
– Install gearbox housing cover -arrow-.
Manual gearbox 02T:

– Install both flange shafts with springs, thrust washers and ta‐
pered rings (press in towards gearbox housing and tighten
bolts).
– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 46 .
– Fill up oil in gearbox and check oil level ⇒ page 96 .
Tightening torques
♦ ⇒ “7.3 Exploded view - gearbox housing cover”, page 102
♦ ⇒ “8.1 Exploded view - clutch housing”, page 124
♦ ⇒ “7.4 Exploded view - input shaft, output shafts, differential
and selector rods”, page 103

Audi A1 2011 ➤
8 Gearbox housing, clutch housing

⇒ “8.1 Exploded view - clutch housing”, page 124
⇒ “8.2 Exploded view - gearbox housing and clutch housing”,
page 125
⇒ “8.3 Removing and installing clutch housing”, page 128
⇒ “8.4 Servicing gearbox housing and clutch housing”,
page 130
8.1 Exploded view - clutch housing
box 02T
❑ When installing, push
flange shaft in towards
gearbox
2 - Flange shaft with spring
box 02T
⇒ page 157
❑ Assembling
⇒ page 166
3 - Bolt
❑ Renew
❑ 5 Nm +90°
4 - Clutch housing
5 - Gearbox housing
6 - Clutch release lever
❑ With guide sleeve and
release bearing
⇒ page 46
7 - Bolt

Audi A1 2011 ➤
8.2 Exploded view - gearbox housing and

clutch housing
⇒ “8.2.1 Exploded view - gearbox housing and clutch housing,
manual gearbox 02T”, page 125
⇒ “8.2.2 Exploded view - gearbox housing and clutch housing,
manual gearbox 0DF”, page 127
8.2.1 Exploded view - gearbox housing and clutch housing, manual gearbox 02T
1 - Sleeve
2 - Dowel sleeve
3 - Magnet
❑ Held in place by joint
surface of housing
4 - Sealing cap
❑ Apply sealing paste -
AMV 188 200 03- before
installing.
5 - Circlip
❑ Fit in groove on roller
bearing
6 - Circlip
❑ Fit in groove on roller
bearing
7 - Roller bearing
❑ For input shaft
❑ Pulling out ⇒ page 134
❑ Pressing in
⇒ page 134
8 - Roller bearing
❑ For output shaft
❑ Pressing in
⇒ page 134
9 - Clutch housing
❑ If renewed: adjust differential ⇒ page 182
10 - Input shaft oil seal
❑ Lever out with screwdriver
11 - Ball-head pin
❑ 20 Nm
❑ Lubricate with MoS2 grease
12 - Oil seal for flange shaft (right-side)
8. Gearbox housing, clutch housing 125

Audi A1 2011 ➤
13 - Sleeve
❑ For oil seal
❑ Drawing in ⇒ page 133
14 - Oil filler plug
❑ Tightening torque ⇒ page 126
15 - Shim S2
❑ For differential
❑ Determining thickness ⇒ page 182
16 - Tapered roller bearing outer race
❑ Pulling out and pressing in ⇒ page 166
17 - Bolt
❑ 5 Nm +90°
❑ Renew
19 - Shim S1
❑ Not fitted on this gearbox version
20 - Dowel sleeve
21 - Gearbox housing
22 - Oil drain plug
23 - Oil seal for flange shaft (left-side)
Different versions of oil filler/oil drain plug

I - Oil filler/oil drain plug with multi-point socket - 25 Nm
II - Oil filler/oil drain plug with hexagon socket - 30 Nm

Audi A1 2011 ➤
8.2.2 Exploded view - gearbox housing and clutch housing, manual gearbox 0DF
1 - Clutch housing
❑ If renewed: adjust differ‐
ential ⇒ page 182
2 - Input shaft oil seal
❑ Lever out with screw‐
driver
3 - Ball-head pin
❑ 20 Nm
❑ Lubricate with MoS2
grease
4 - Oil seal for stub shaft (right-
side)
5 - Oil filler plug
⇒ page 126
6 - O-ring
❑ Renew
7 - Plug
8 - Bolt
❑ 5 Nm +90°
❑ Renew
9 - Shim
⇒ page 182
10 - Oil deflector ring
11 - Tapered roller bearing out‐
er race
12 - Bolt
❑ 5 Nm +90°
❑ Renew
14 - Dowel sleeve
16 - Oil drain plug

Audi A1 2011 ➤
17 - Oil seal for stub shaft (left-side)

18 - Sleeve
19 - Magnet
❑ Held in place by joint surface of housing
20 - Sealing cap
❑ Apply sealing paste - AMV 188 200 03- before installing.
21 - Circlip
❑ Fit in groove on roller bearing ⇒ Item 22 (page 128)
22 - Roller bearing
❑ For output shaft
❑ Pressing in ⇒ page 134
23 - Circlip
❑ Fit in groove on roller bearing ⇒ Item 24 (page 128)
24 - Roller bearing
❑ For input shaft
8.3 Removing and installing clutch housing


Audi A1 2011 ➤
Removing
• Gearbox removed
low gearbox.
– Drain off gear oil.
Manual gearbox 02T:

– Remove right flange shaft securing bolt; to do so, screw two
bolts into flange and counterhold flange shaft with tyre iron or
other suitable lever.
tapered ring.
– Turn gearbox on assembly stand so that clutch housing faces
upwards.
– Remove all 18 bolts -arrow- securing clutch housing.

– Carefully remove clutch housing by levering alternately at the
protruding webs on the housing, taking care not to damage the
sealing surfaces.

Audi A1 2011 ➤
Installing
• Differential -A- installed
face.
– When installing housing, rotate input shaft by hand to enable
bearing to slide easily onto its seat.
– Tighten gearbox housing bolts -arrow- diagonally in stages.

Manual gearbox 02T:
– Push flange shaft in towards gearbox together with spring,
thrust washer and tapered ring, and tighten bolt.
– Install release lever with release bearing and guide sleeve
⇒ page 46 .
– Fill up oil in gearbox and check oil level ⇒ page 96 .
Tightening torques
8.4 Servicing gearbox housing and clutch housing

Audi A1 2011 ➤

equipment required
♦ Press tool - VW 408 A-

♦ Centring mandrel - 12 - 551-
♦ Thrust piece - 30 - 555-
♦ Threaded rod from assembly device - 3066-
♦ Thrust piece - 3124-

Audi A1 2011 ➤

♦ Tube - VW 415 A-
♦ Tube - VW 516-
♦ -1- Kukko 21/3 internal puller
♦ -2- Kukko 18/1 puller
♦ -3- Kukko 17/1 splitter
♦ -4- Kukko 22/1 counter-support

Audi A1 2011 ➤
♦ Socket - 3357-
♦ Thrust piece -
T40008-
Driving in input shaft oil

seal so it is flush
Pulling out oil seal sleeve

– Apply spacer sleeve - VW 472/2- and press tool - 30 - 555- to
differential.
A - Puller , e.g. -Kukko 18/1-
B - Splitter 12...75 mm , e.g. -Kukko 17/1-
Drawing in oil seal sleeve

A - Screw threaded rod from assembly device - 3066- into threa‐
ded piece in differential.
B - M12 nut with washer
– Turn nut -B- and pull sleeve in onto stop with thrust piece -
3124- .
Note
If gearbox has been dismantled, press in sleeve onto stop using

thrust piece - 3124- .

Audi A1 2011 ➤
Driving out selector shaft sleeve -A-
Driving in selector shaft sleeve -A-
Pulling roller bearing out of clutch housing

– When pulling out, compress circlip -arrow- for roller bearing
using pliers -C-.
A - Counter-support , e.g. -Kukko 22/1-
B - Internal puller 30 ... 37 mm , e.g. -Kukko 21/5-
Pressing roller bearing into clutch housing

– Support clutch housing using tube - VW 415 A- (not visible in
illustration) directly under bearing mounting.
– When pressing in, compress circlip -arrow- for roller bearing
using pliers -A-.
– Remove the pliers before the roller bearing is in its final posi‐
tion.
♦ The circlip must engage in the groove in the clutch housing.

Audi A1 2011 ➤
35 – Gears, shafts
1 Input shaft
⇒ “1.1 Exploded view - input shaft”, page 135
⇒ “1.2 Renewing bearing mounting with grooved ball bearings for
input and output shafts”, page 137
⇒ “1.3 Dismantling and assembling input shaft”, page 138
1.1 Exploded view - input shaft
Note
♦ Refer to ⇒ Electronic parts catalogue and technical data when installing new gear wheels or a new input
shaft.
♦ Pressing input and output shaft out of bearing mounting and grooved ball bearings ⇒ page 137
♦ Lubricate all bearings, selector gears and synchro-rings on input shaft with gear oil before installing.
♦ Do not interchange synchro-rings. When re-using synchro-rings, always fit on the same selector gear.
1 - Circlip
❑ Renew
⇒ page 113
2 - Locking collar with synchro-
hub for 5th gear
⇒ page 111
❑ Dismantling and assem‐
bling ⇒ page 146
⇒ page 111
❑ Checking for wear
⇒ page 144
⇒ page 111
5 - Needle bearing
❑ For 5th gear
⇒ page 111
❑ Renew together with
sleeve
6 - Sleeve
❑ For 5th gear needle
bearing
❑ Renew together with
❑ Press off with bearing
mounting/grooved ball
bearing ⇒ page 137 .
1. Input shaft 135

Audi A1 2011 ➤
❑ Pressing on ⇒ page 138

7 - Gearbox housing
8 - Bearing mounting with grooved ball bearings
❑ Only renew grooved ball bearings together with bearing mounting.
❑ If bearing mounting is separated from gearbox housing, it must always be renewed
❑ Pressing off and on ⇒ page 137
9 - Input shaft
10 - Needle bearing
❑ For 3rd gear
11 - 3rd speed selector gear
12 - 3rd gear synchro-ring
❑ Checking for wear ⇒ page 144
13 - Locking collar with synchro-hub for 3rd and 4th gear
❑ Press off with 3rd speed selector gear ⇒ page 142
❑ Dismantling ⇒ page 143
❑ Installation position: Locking collar/synchro-hub ⇒ page 144
❑ Assembling ⇒ page 144
16 - Sleeve
❑ For 4th gear needle bearing
❑ Renew together with needle bearing ⇒ Item 17 (page 136)
❑ Pressing off ⇒ page 142
17 - Needle bearing
❑ For 4th gear
❑ Renew together with ⇒ Item 16 (page 136)
18 - Thrust washer
19 - Inner race for roller bearing
❑ Pressing off ⇒ page 142
❑ Can also be pulled off ⇒ page 143
20 - Circlip
❑ Renew
21 - Roller bearing
❑ With circlip
❑ Installation position: Circlip in bearing faces towards input shaft
22 - Clutch housing
23 - Spring
❑ Installation position: angled end of spring must locate in one of the locking pieces.
136 Rep. gr.35 - Gears, shafts

Audi A1 2011 ➤
24 - Locking collar for 3rd and 4th gear

❑ Installation position: Locking collar/synchro-hub ⇒ page 144
25 - Synchro-hub for 3rd and 4th gear
26 - Locking pieces
❑ 3x
27 - Spring
❑ Installation position: angled end of spring must locate in one of the locking pieces.
28 - Locking pieces (3x)
29 - 5th gear synchro-hub
30 - 5th gear locking collar
31 - Check ring
❑ Prevents locking pieces from moving out
1.2 Renewing bearing mounting with

grooved ball bearings for input and out‐
put shafts
Pressing off bearing mounting and grooved ball bearings
– Slide locking collar for 1st and 2nd gear onto 2nd gear.
– Slide in thrust plate - T10084 A- from the side until it contacts
input shaft.
– Insert centring pins in thrust piece - T10081- into bores in input
and output shafts.
Note
Make sure components do not drop out when being removed (get
help from a second person if necessary).
– Press input and output shafts out of bearing mounting.

– Take out bearing mounting.
– Dismantle input shaft if necessary ⇒ page 135 .
– Dismantle output shaft if necessary ⇒ page 148 .
Pressing bearing mounting with grooved ball bearings onto input
and output shafts
1. Input shaft 137

Audi A1 2011 ➤
Note
♦ Due to differences in the height of the teeth (dimension -a-),

the output shafts of different gearboxes differ in length (shown
here with shafts installed).
♦ To ensure that the bearing mounting is pressed evenly onto
the shafts, the shafts must always be fitted evenly in the thrust
block - T10083- .
♦ It may be necessary to fit a washer - T10083/1- (3 mm thick)
in the hole provided for the input shaft ⇒ page 138 .
♦ Dimension -a- on teeth of output shaft must therefore be
measured.
Dimension -a- = 30.6 mm

Insert washer - T10083/1- ⇒ next illustration.
Inserting washer - T10083/1-
– Heat bearing mounting to about 100°C
WARNING
Wear protective gloves.
– Press on bearing mounting with grooved ball bearings.
Pressing on sleeve -A- for 5th gear needle bearing
1.3 Dismantling and assembling input shaft

Audi A1 2011 ➤

equipment required

♦ Tube - VW 415 A-
♦ Tube - VW 422-
1. Input shaft 139

Audi A1 2011 ➤

♦ Tube - VW 516-
♦ Extension - 30 - 23-
♦ Drift sleeve - 30 - 100-

Audi A1 2011 ➤
♦ Tube - 2010-
♦ Thrust block - T10083-
♦ Washer - T10083/1-
♦ Thrust plate - T10084A-
♦ -1- Internal puller , e.g. -Kukko 21/5-
♦ -4- Counter support , e.g. -Kukko 22/2-
♦ -2- Puller , e.g. -Kukko 18/1-
♦ -3- Splitter 12...75 mm , e.g. -Kukko 17/1-
♦ -Feeler gauge-
1. Input shaft 141

Audi A1 2011 ➤
♦ Circlip pliers - VAS 5503-
Dismantling
– Press off bearing mounting and grooved ball bearings
⇒ page 137 .
– Remove circlip -arrow- with circlip pliers - VAS 5503- .
Press off roller bearing inner race together with: thrust washer,
4th speed selector gear with needle bearing, locking collar and
synchro-hub for 3rd and 4th gear and 3rd speed selector gear.

Audi A1 2011 ➤
– Remove components from input shaft in the sequence indica‐

ted -1 ... 10-.
Roller bearing inner race can also be pulled off with 4th speed
selector gear only.
– First remove circlip using circlip pliers - VAS 5503- .
– Clamp splitter -B- behind driving teeth (not dog teeth) on 4th
gear.
A - Puller , e.g. -Kukko 18/1-
B - Splitter 12...75 mm , e.g. -Kukko 17/1-
C - Protective jaw covers
Dismantling and assembling locking collar and synchro-hub for

3rd and 4th gears
1- Spring
2- Locking collar
3- Synchro-hub
4- Locking piece
– Slide locking collar over synchro-hub.
The deeper recesses -arrow A- for the locking pieces in the syn‐
chro-hub must align with the recesses -arrow B- in the locking
collar.
1. Input shaft 143

Audi A1 2011 ➤
Installation position of 3rd and 4th gear locking collar and syn‐
chro-hub
If there is a groove on the top -arrow-, this points towards 4th gear.
The high collar faces towards 3rd gear.
Assembling locking collar with synchro-hub for 3rd and 4th gears
– Fit locking pieces in the smaller slots -arrows- and install
springs so they are offset 120°.
• Angled end of spring must locate in one of the locking pieces.
Checking 3rd, 4th and 5th gear synchro-rings for wear

Gap -a- Installation depth Wear limit
3rd, 4th and 5th 1.1 … 1.7 mm 0.5 mm
gear
Pressing on 3rd and 4th gear synchro-hub with locking collar

If there is a groove on the top of the synchro-hub, this points to‐
wards 4th gear.
High collar of synchro-hub faces towards 3rd gear.

Audi A1 2011 ➤
Pressing on sleeve -A- for 4th gear needle bearing

– After pressing on sleeve -A-, install 4th gear needle bearing,
synchro-ring with selector gear for 4th gear and thrust washer.
Pressing on roller bearing inner race -A-
Determining thickness of circlip

– Insert a 2.0 mm thick circlip -A- in groove on input shaft and
press upwards -arrow-.
– Measure gap between inner race -B- and fitted circlip -A- using
feeler gauge -C-.
– Remove circlip fitted for measurement.
– Select circlip from table.
Note
Select correct circlips from ⇒ Electronic parts catalogue (ETKA) .

Measured value Circlip thickness Axial clearance
(mm) (mm) (mm)
0.05 … 0.14 2.0 0.05 … 0.15
0.15 … 0.24 2.1 0.05 … 0.15
0.25 … 0.34 2.2 0.05 … 0.15
0.35 … 0.44 2.3 0.05 … 0.15
0.45 … 0.51 2.4 0.05 … 0.10
1. Input shaft 145

Audi A1 2011 ➤
Detaching check ring

– Unclip hooks -A- of check ring from synchro-hub using a
screwdriver.
Dismantling and assembling 5th gear locking collar and synchro-

hub
1 - Spring
2 - Locking piece
3 - Synchro-hub
• Installation position: the groove on the top -arrow A- and the
higher collar -arrow B- on the synchro-hub face towards 5th
gear.
4 - Locking collar
5 - Check ring
Assembling 5th gear locking collar/synchro-hub
– Slide locking collar over synchro-hub.
• Installation position: the smaller slots -arrow C- for the locking
pieces in the synchro-hub should be in line with the slots
-arrow D- in the locking collar.
– Insert locking pieces in the deeper slots -arrows- and install

springs off-set by 120°. Angled end of spring must locate in
hollow locking piece.

Audi A1 2011 ➤
Installing check ring

– Push check ring onto tube - 2010- .
– Insert check ring together with tube - 2010- into 5th gear syn‐
chro-hub/locking collar (observe installation position
⇒ page 146 ).
• Hooks -arrow 1- engage in slots -arrow 2- for locking pieces in
synchro-hub.
– Push check ring downwards until hooks engage.
– Pull off tube - 2010- .
1. Input shaft 147

Audi A1 2011 ➤
2 Output shaft
⇒ “2.1 Exploded view - output shaft”, page 148
⇒ “2.2 Dismantling and assembling output shaft”, page 151
2.1 Exploded view - output shaft
Note
♦ Refer to ⇒ Electronic parts catalogue and technical data when installing new gear wheels or a new output
shaft.
♦ Pressing input and output shaft out of bearing mounting and grooved ball bearings ⇒ page 137
♦ Lubricate all bearings, selector gears and synchro-rings on output shaft with gear oil before installing.
♦ Do not interchange synchro-rings. When re-using synchro-rings, always fit on the same selector gear.
1 - Roller bearing
❑ With circlip
⇒ page 130
❑ Installation position: cir‐
clip in bearing faces out‐
put shaft
2 - Output shaft
❑ With inner race for roller
bearing (depending on
version)
❑ Inner race cannot be re‐
moved from output shaft
❑ Check bearing seat /
bearing inner race for
scoring or other damage
❑ If you detect scoring or
other damage to the
bearing seat / inner
race, renew both output
shaft and roller bearing
3 - 4th gear wheel
Collar faces 3rd gear
⇒ page 150
⇒ page 151
4 - Circlip
5 - Circlip
6 - 3rd gear wheel
Collar faces 4th gear
⇒ page 150
7 - Circlip
8 - Needle bearing
❑ For 2nd gear

Audi A1 2011 ➤
9 - 2nd speed selector gear

10 - Inner ring for 2nd gear
11 - Outer ring for 2nd gear
❑ Renew if scored or if there are visible traces of wear
12 - 2nd gear synchro-ring
13 - Locking collar with synchro-hub for 1st and 2nd gear
14 - Circlip
15 - 1st gear synchro-ring
16 - Outer ring for 1st gear
❑ Renew if scored or if there are visible traces of wear
17 - Inner ring for 1st gear
❑ Check lugs for scoring
18 - Needle bearing
❑ For 1st gear
19 - 1st speed selector gear
20 - Spring
21 - Locking collar for 1st and 2nd gear
22 - Synchro-hub for 1st and 2nd gear
23 - Locking pieces
❑ 3x
24 - Spring
2. Output shaft 149

Audi A1 2011 ➤
Installation position of 3rd and 4th gear wheel

Installation position of 4th gear wheel -A-:
• Collar -arrow 1- faces 3rd gear wheel -B-.
Installation position of 3rd gear wheel -B-:
• Collar -arrow 2- faces 4th gear wheel -A-.
Checking 1st and 2nd gear inner ring for wear

– Press inner ring onto cone on selector gear and measure gap
-a- using a feeler gauge.
1st and 2nd gear 0.75 … 1.25 mm 0.3 mm
Checking 1st and 2nd gear synchro-ring for wear

– Press synchro-ring, outer ring and inner ring against cone on
selector gear and measure gap -a- using a feeler gauge.
1st and 2nd gear 1.2 … 1.8 mm 0.5 mm
Dismantling and assembling 1st and 2nd gear locking collar and
synchro-hub
– Take off springs -1- before dismantling.
1 - Spring
2 - Locking collar
3 - Synchro-hub
4 - Locking piece
– To assemble, slide locking collar over synchro-hub.
Installation position:
• After assembly, the groove on the top -arrow A- and the higher
shoulder -arrow B- on the synchro-hub will face towards the
external splines on the locking collar -arrow C-.
• The deeper recesses -arrow D- for the locking pieces in the
synchro-hub must align with the recesses -arrow E- in the
locking collar.

Audi A1 2011 ➤
– Insert locking pieces in deeper recesses -arrows- and install

springs so they are offset 120°.
• Angled end of spring must locate in one of the locking pieces.
2.2 Dismantling and assembling output shaft

equipment required

2. Output shaft 151

Audi A1 2011 ➤
Dismantling
• Output shaft removed ⇒ page 137
– Remove following components from output shaft:
2 - Needle bearing for 1st gear
WARNING
Prevent circlip from springing off suddenly.
– Push circlip -1- out of groove.

A - Protective glove
– Press off 2nd speed selector gear and locking collar/synchro-

hub together.

Audi A1 2011 ➤
– Remove following components from output shaft:

1 - Locking collar with synchro-hub for 1st and 2nd gear
2 - 2nd gear synchro-ring
3 - Outer ring for 2nd gear
4 - Inner ring for 2nd gear
5 - 2nd speed selector gear
6 - Needle bearing for 2nd gear
– Remove circlip -1- using circlip pliers - VAS 5503- .

– Take off 3rd gear wheel -item 2-.
– Remove circlips -3- and -4- with circlip pliers - VAS 5503- .
– Remove 4th gear wheel -Item 5- from output shaft.
Assembling
– Checking synchro-rings for wear ⇒ page 150 .
– Fit 4th gear wheel -A- onto output shaft.
• Collar -arrow 1- faces 3rd gear wheel -B-.
– Fit circlips -2- and -3-.
– Fit 3rd gear wheel -B- onto output shaft.
• Collar -arrow 2- faces 4th gear wheel -A-.
– Fit circlip -1-.
2. Output shaft 153

Audi A1 2011 ➤
– Install needle bearing and 2nd speed selector gear on output

shaft.
– Place inner ring -A- on 2nd speed selector gear.
• Angled coupling lugs -arrows 1- point towards outer ring -B-.
– Fit outer ring -B-.
• Coupling lugs -arrows 2- engage in slots -arrows 3- on selector
gear.
– Fit synchro-ring -C-.
• Slots -arrows 4- engage on coupling lugs -arrows 1- on inner
ring -A-.
– Fit locking collar/synchro-hub -3- on output shaft.

• Splines on locking collar face towards 2nd gear.
– Rotate synchro-ring -1- so that coupling lugs on synchro-ring
are in line with free slots in synchro-hub -2- -arrows-.
– Press 1st and 2nd gear locking collar/synchro-hub onto output

shaft.
– After installing, check clearance of synchro-hub by turning 2nd
speed selector gear backwards and forwards.
• 2nd speed selector gear should turn freely in both directions.

Audi A1 2011 ➤
– Fit circlip.
– Fit following components on output shaft:

2 - Needle bearing for 1st gear
– Fit 1st gear synchro-ring in locking collar/synchro-hub.

Fit outer ring for 1st gear.
• Coupling lugs -arrows- face towards locking collar/synchro-
hub.
Fit inner ring for 1st gear -A-.

• Coupling lugs -arrows 1- must locate in slots -arrows 2- in
synchro-ring -B-.
2. Output shaft 155

Audi A1 2011 ➤
– Fit 1st speed selector gear.

• Rotate selector gear so that coupling lugs on outer ring engage
in slots in selector gear -arrows- (selector gear will then slide
down visibly).

Audi A1 2011 ➤
39 – Final drive - differential

1 Oil seals
⇒ “1.1 Overview of fitting locations - oil seals”, page 157
⇒ “1.2 Renewing oil seal (left-side)”, page 157
⇒ “1.3 Renewing oil seal (right-side)”, page 161
1.1 Overview of fitting locations - oil seals
1 - Oil seal
❑ For input shaft
2 - Oil seal (right-side)
❑ Renewing on manual
gearbox 02T
⇒ page 161
gearbox 0DF
⇒ page 163
3 - Oil seal (left-side)
gearbox 02T
⇒ page 157
gearbox 0DF
⇒ page 159
4 - Oil seal
1.2 Renewing oil seal (left-side)

⇒ “1.2.1 Renewing oil seal (left-side) - manual gearbox 02T”, page
157
⇒ “1.2.2 Renewing oil seal (left-side) - manual gearbox 0DF”,
page 159
1.2.1 Renewing oil seal (left-side) - manual

gearbox 02T
1. Oil seals 157

Audi A1 2011 ➤
♦ Multi-purpose tool - VW 771-
♦ Extractor hook -VW 771/37-

Procedure
– Remove flange shaft (left-side) ⇒ page 190 .
– Pull out flange shaft oil seal using multi-purpose tool - VW 771-
and extractor hook -VW 771/37- .
– Clean installation area for oil seal.
158 Rep. gr.39 - Final drive - differential

Audi A1 2011 ➤
– Lightly oil outer circumference of oil seal and drive in onto stop
using thrust piece - T10082- , ensuring oil seal is kept straight.
– Install flange shaft (left-side) ⇒ page 190 .
1.2.2 Renewing oil seal (left-side) - manual

gearbox 0DF
1. Oil seals 159

Audi A1 2011 ➤

Procedure
– Remove nuts -arrows- securing swivel joint (left-side).
er - G78- .
Note
– Press drive shaft (left-side) off gearbox using assembly lever

-1-.
– Pivot suspension strut (left-side) outwards and at the same
time guide drive shaft out of gearbox.
Note

Audi A1 2011 ➤
– Install drive shaft (left-side; inserted in gearbox) ⇒ Running

gear, front-wheel drive and four-wheel drive; Rep. gr. 40 ;
Drive shaft; Removing and installing drive shaft .
1.3 Renewing oil seal (right-side)

⇒ “1.3.1 Renewing oil seal (right-side) - manual gearbox 02T”,
page 161
⇒ “1.3.2 Renewing oil seal (right-side) - manual gearbox 0DF”,
page 163
1.3.1 Renewing oil seal (right-side) - manual

gearbox 02T
1. Oil seals 161

Audi A1 2011 ➤
♦ Extension -2024A/1- of lifting tackle - 2024A-
♦ Drift sleeve - 3158-

Audi A1 2011 ➤
Procedure
– Install flange shaft (right-side) ⇒ page 192 .
1.3.2 Renewing oil seal (right-side) - manual

gearbox 0DF
1. Oil seals 163

Audi A1 2011 ➤

Procedure
– Unscrew nuts -arrows- for swivel joint (right-side).
Note
– Press drive shaft (right-side) off gearbox using assembly lever

-1-.
– Pivot suspension strut (right-side) outwards and at the same
time guide drive shaft out of gearbox.
Note

Audi A1 2011 ➤
– Install drive shaft (right-side; inserted in gearbox) ⇒ Running

gear, front-wheel drive and four-wheel drive; Rep. gr. 40 ;
Drive shaft; Removing and installing drive shaft .
1. Oil seals 165

Audi A1 2011 ➤
2 Differential
⇒ “2.1 Exploded view - differential”, page 166
⇒ “2.2 Dismantling and assembling differential”, page 170
⇒ “2.3 Adjusting differential”, page 182
⇒ “2.4 Removing and installing flange shaft (left-side) - manual
gearbox 02T”, page 190
⇒ “2.5 Removing and installing flange shaft (right-side) - manual
gearbox 02T”, page 192
2.1 Exploded view - differential

⇒ “2.1.1 Exploded view - differential, manual gearbox 02T”, page
166
⇒ “2.1.2 Exploded view - differential, manual gearbox 0DF”, page
169
2.1.1 Exploded view - differential, manual gearbox 02T
Note
♦ Heat tapered roller bearing inner race to 100° C before installing.

♦ Always renew both tapered roller bearings together.
♦ Adjust differential if tapered roller bearings, differential cage, gearbox housing or clutch housing are renewed
⇒ page 182 .

Audi A1 2011 ➤
❑ 25 Nm
❑ Screws into threaded
piece
2 - Flange shaft (right-side)
❑ Do not interchange; left
and right flange shafts
are different
catalogue
3 - Spring for flange shaft
❑ Installed behind flange
shafts
4 - Thrust washer
❑ Installation position: lip
faces spring
5 - Tapered ring
Taper towards differen‐
tial cage
6 - Circlip
❑ Holds tapered ring,
thrust washer and
spring in position when
flange shaft is removed
7 - Sun wheel
8 - Threaded piece
9 - Differential pinion pin
❑ To remove, shear off spring pin ⇒ Item 18 (page 168) ⇒ page 175
10 - Planet pinion
11 - One-piece thrust washer
❑ Lubricate with gear oil before installing
12 - Flange shaft (left-side)
❑ With dust plate
❑ Do not interchange; left and right flange shafts are different
13 - Oil seal for flange shaft (left-side)
❑ Different diameters for left and right
❑ Can be renewed with gearbox in vehicle ⇒ page 157
14 - Shim S1
❑ Not fitted on this gearbox version
2. Differential 167
Audi A1 2011 ➤

16 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 174
17 - Differential cage
❑ With final drive gear
18 - Clamping sleeve
❑ Secures differential pinion pin
❑ Is sheared off on removal ⇒ page 175
❑ Pressing out ⇒ page 174
21 - Shim S2
22 - Oil seal for flange shaft (right-side)
❑ Different diameters for left and right
❑ Can be renewed with gearbox in vehicle ⇒ page 161
24 - Clutch housing

Audi A1 2011 ➤
2.1.2 Exploded view - differential, manual gearbox 0DF
1 - Sun wheel
2 - Differential pinion pin
❑ To remove, shear off
spring pin
⇒ page 181
3 - Planet pinion
4 - One-piece thrust washer
❑ Lubricate with gear oil
before installing
5 - Oil seal
catalogue
6 - Retaining plate
⇒ page 180
7 - Tapered roller bearing outer
race
❑ Pressing in
⇒ page 180
8 - Tapered roller bearing inner
race
❑ Pressing on
⇒ page 182
9 - Differential cage
❑ With final drive gear
10 - Clamping sleeve
❑ Secures differential pinion pin
❑ Is sheared off on removal ⇒ page 175
❑ Pressing out ⇒ page 174
13 - Shim S2
2. Differential 169
Audi A1 2011 ➤
15 - Clutch housing
2.2 Dismantling and assembling differential

⇒ “2.2.1 Dismantling and assembling differential - manual gear‐
box 02T”, page 170
⇒ “2.2.2 Dismantling and assembling differential - manual gear‐
box 0DF”, page 176
2.2.1 Dismantling and assembling differential - manual gearbox 02T

equipment required

♦ Tube - VW 418 A-

Audi A1 2011 ➤
♦ Installing sleeve - VW 455-

♦ Thrust pad - VW 510-
♦ Tube - 30 - 14-
♦ Tube - 2040-
2. Differential 171
Audi A1 2011 ➤
♦ Counterhold tool - 3067-

♦ Tube - 3259-
♦ Wheel bearing tube - 3345-
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Adapter - V.A.G 1582/4-

Audi A1 2011 ➤
♦ Thrust plate - 30 - 205-

♦ Torque wrench - V.A.G 1331- (5 ... 50 Nm)
♦ Adapter - V.A.G 1582/3-
Pulling tapered roller bearing outer race out of gearbox housing
A - Counter-support , e.g. -Kukko 22/2-
– Clamp internal puller firmly under tapered roller bearing outer
race.
2. Differential 173
Audi A1 2011 ➤
Pressing tapered roller bearing outer race into gearbox housing

– Support gearbox housing with tube - 3259- directly below
bearing mounting.
Pulling off tapered roller bearing inner race

– Before fitting puller, position spacer sleeve - VW 472/2- and
thrust piece - 3002- on differential cage.
Pressing on tapered roller bearing inner race
WARNING
– Heat tapered roller bearing inner race to approx. 100°C before

pressing on.
– Support opposite side of inner race using installing sleeve -
VW 455- .
Pressing tapered roller bearing outer race -A- out of clutch hous‐
ing

Audi A1 2011 ➤
Pressing tapered roller bearing outer race into clutch housing

– Support clutch housing with tube for wheel bearing - 3345-
directly below bearing mounting.

WARNING

pressing on.
Pressing out differential pinion pin

The spring pin is sheared off when it is pressed out.
– Drive the remaining part of the spring pin out of the differential
cage.
2. Differential 175
Audi A1 2011 ➤
Installing differential bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert planet pinions (180° apart) and pivot into position.
– Push differential pinion pin -arrow A- in as far as first planet
pinion.
– Fit threaded pieces -arrows B- in sun wheels.
• Installation position: Stepped shoulder towards sun wheel
– Drive differential pinion pin into final position and secure with
spring pin.
2.2.2 Dismantling and assembling differential - manual gearbox 0DF

equipment required

♦ Press tool - VW 408A-

Audi A1 2011 ➤
♦ Tube - VW 418A-
♦ Installing sleeve - VW 455-

♦ Tube - 30-14-
♦ Tube - 2040-
2. Differential 177
Audi A1 2011 ➤

♦ Tube - 3259-
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Adapter - VAG 1582/3-
♦ Adapter - VAG 1582/4-

Audi A1 2011 ➤
♦ Thrust plate - 30-205-

♦ Drift sleeve - 40-21-
♦ Torque wrench - V.A.G 1331- (5 ... 50 Nm)
Pulling tapered roller bearing outer race out of gearbox housing
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 46 … 58 mm, e.g. Kukko 21/7
– Clamp internal puller firmly under tapered roller bearing outer
race.
2. Differential 179
Audi A1 2011 ➤
Installing a new retaining plate

• Installation position: Collar -arrow- points away from housing
-A-.
Pressing tapered roller bearing outer race into gearbox housing

– Support gearbox housing with press tool - VW 442- , tube -
3259- and tube - 30-14- directly below bearing mounting.
Pressing tapered roller bearing outer race -A- out of clutch hous‐
ing
Pressing tapered roller bearing outer race into clutch housing

– Support clutch housing with tube for wheel bearing - 3345-
directly below bearing mounting.

Audi A1 2011 ➤

Note
The procedure for pulling tapered roller bearing inner races off
the differential cage is the same for both bearings.
WARNING

pressing on.
VW 455- .
Pressing out differential pinion pin

The spring pin is sheared off when it is pressed out.
– Drive remaining part of spring pin out of differential cage.

2. Differential 181
Audi A1 2011 ➤
WARNING

pressing on.
VW 455- .
Installing differential bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Fit both sun wheels.
– Hold upper sun wheel in position.
– Insert planet pinions (180° apart) and pivot into position.
– Drive differential pinion pin -arrow- into final position and se‐
cure with spring pin.
2.3 Adjusting differential

⇒ “2.3.1 Adjusting differential - manual gearbox 02T”, page 182
⇒ “2.3.2 Adjusting differential - manual gearbox 0DF”,
page 186
2.3.1 Adjusting differential - manual gearbox

02T
The differential must be readjusted when the following compo‐
nents have been renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
♦ Tapered roller bearings for differential

Audi A1 2011 ➤

equipment required
♦ End plate - VW 385/17-

♦ Universal dial gauge bracket - VW 387-
2. Differential 183
Audi A1 2011 ➤

♦ Tube - 30 - 14-
♦ Tube - 2040-
♦ Tube - 3259-

Audi A1 2011 ➤

♦ Dial gauge - VAS 6080-
♦ Dial gauge extension, 30 mm
Procedure
– Drive tapered roller bearing outer race into gearbox housing.
– Press tapered roller bearing outer race without shim into clutch
housing.
– Install differential in gearbox housing.
– Install clutch housing and tighten 5 bolts to 5 Nm.
– Set up measuring tool and dial gauge (3 mm measuring range,

dial gauge extension -A- approx. 30 mm).
– Preload dial gauge to 1 mm and set to “0”.
– Move differential up and down and note play indicated on dial
gauge (in this example: 0.50 mm).
Determining thickness of shim S2
The specified bearing preload is achieved by adding a constant
value (0.35 mm) to the measured value to obtain the required
thickness for S2.
Example:
Measured value 0.50 mm
+ Preload (constant value) 0.35 mm
Thickness of shim = 0.85 mm
2. Differential 185
Audi A1 2011 ➤
– Take off clutch housing and press out tapered roller bearing
outer race -A-.
– Fit shim S2 of determined thickness (in example, 0.85 mm).
For part number, refer to ⇒ Electronic parts catalogue .
– Press tapered roller bearing outer race into clutch housing
again.
The following shims are available:
Thickness of shims in mm 1)
0.65 0.85 1.05 1.25
0.70 0.90 1.10 1.30
0.75 0.95 1.15 1.35
0.80 1.00 1.20 1.40
1) Different shim thicknesses make it possible to obtain the exact shim thickness
required; if necessary, fit 2 shims.
– Install clutch housing and tighten bolts to final torque.

Tightening torques
2.3.2 Adjusting differential - manual gearbox

0DF
The differential must be readjusted when the following compo‐
nents have been renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
♦ Tapered roller bearings for differential

Audi A1 2011 ➤

equipment required
♦ End plate - VW 385/17-

♦ Universal dial gauge bracket - VW 387-
♦ Press tool - VW 408A-
2. Differential 187
Audi A1 2011 ➤

♦ Tube - 30-14-
♦ Tube - 2040-
♦ Tube - 3259-
♦ Thrust piece - VW442-

Audi A1 2011 ➤
♦ Dial gauge - VAS 6080-
♦ Dial gauge extension, 30 mm

Procedure
• Sealing surfaces of clutch and gearbox housings must be free
of sealant.
• Both tapered roller bearing inner races have been pressed
onto differential cage ⇒ page 181 .
• New retaining plate has been inserted in gearbox housing
⇒ page 180 .
– Drive tapered roller bearing outer race into gearbox housing
⇒ page 180 .
2. Differential 189
Audi A1 2011 ➤
– Press tapered roller bearing outer race without shim and with‐
out retaining plate into clutch housing ⇒ page 180 .
– Install differential in gearbox housing.
– Install clutch housing and tighten 5 bolts to 5 Nm.
– Set up measuring tool and dial gauge (3 mm measuring range,

dial gauge extension -A- approx. 30 mm).
– Preload dial gauge to 1 mm and set to “0”.
– Move differential up and down and note play indicated on dial
gauge (in this example: 1.30 mm).
Determining thickness of shim S2
The specified bearing preload is obtained by adding a constant
figure (0.35 mm) to the reading indicated.
Example:
Measured value 1.30 mm
+ Preload (constant value) 0.35 mm
Thickness of shim S2 = 1.65 mm
The following shims are available:

Thickness of shim S2 2) in mm
0.65 0.85 1.05 1.25
0.70 0.90 1.10 1.30
0.75 0.95 1.15 1.35
0.80 1.00 1.20 1.40
2) Different shim thicknesses make it possible to obtain the exact shim thickness
required; if necessary, fit 2 shims.
– Take off clutch housing and press out tapered roller bearing
outer race -A-.
– Insert new retaining plate in clutch housing ⇒ page 180 .
– Fit shim S2 of determined thickness (in example, 1.65 mm).
For part number, refer to ⇒ Electronic parts catalogue .
– Press tapered roller bearing outer race into clutch housing
again ⇒ page 180 .
– Install clutch housing and tighten bolts to final torque.
Tightening torques
2.4 Removing and installing flange shaft

(left-side) - manual gearbox 02T

Audi A1 2011 ➤
♦ Extension -2024 A /1-
Removing
• Gearbox in vehicle
insulation .
– Unbolt drive shaft (left-side) from flange shaft on gearbox.
– Remove nuts -arrows- securing swivel joint (left-side).

er - G78- .
– Disengage swivel joint (left-side) from wishbone.
2. Differential 191
Audi A1 2011 ➤
– Swing suspension strut (left-side) outwards and support with

extension -2024 A /1- as shown in illustration.
WARNING

– Tie up drive shaft (left-side).
Note
– Remove bolt -arrow- securing flange shaft (left-side). To do so,

suitable lever.
tapered ring.
Installing
– Push flange shaft in against spring pressure and secure with
bolt.
Tightening torques
♦ ⇒ “2.1 Exploded view - differential”, page 166
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Lower wish‐
bone, swivel joint; Exploded view - lower wishbone, swivel joint
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
2.5 Removing and installing flange shaft

(right-side) - manual gearbox 02T
Removing
• Gearbox in vehicle
insulation .

Audi A1 2011 ➤
– Unbolt drive shaft (right-side) from flange shaft of gearbox.

– Tie up drive shaft (right-side).
Note
– Remove bolt -arrow- securing flange shaft (right-side). To do

so, screw 2 bolts into flange and counterhold flange shaft with
suitable lever.
tapered ring.
Installing
– Push flange shaft in against spring pressure and secure with
bolt.
Tightening torques
♦ ⇒ “2.1 Exploded view - differential”, page 166
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft
2. Differential 193

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Service

Service Department. Technical Information

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Copyright © 2018 Audi AG, Ingolstadt D3E802F44C0

2.3 Tightening torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

1.1 Gearbox identification

1.1.1 Gearbox identification - manual gearbox

Manual gearbox 02T -arrow 2-

Code letters and production date of gearbox -arrow-

1.1.2 Gearbox identification - manual gearbox

Manual gearbox 0DF -arrow 1-

2 Rep. gr.00 - Technical data

Code letters and date of manufacture of gearbox -arrow 2-

2.1 Allocation of gearbox to engine

Manual gearbox 5-speed 0DF

4 Rep. gr.00 - Technical data

3.1 Transmission layout - front-wheel drive

-Arrows- point in direction of travel.

4.1 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

6 Rep. gr.00 - Technical data

5.1 General repair instructions

Oil seals, seals, O-rings and gaskets

♦ To facilitate assembly, use circlip pliers - VAS 5503A- .

8 Rep. gr.00 - Technical data

10 Rep. gr.00 - Technical data

♦ Do not interchange synchro-rings. When reusing always fit to

♦ Abnormal wear on synchro-ring or selector gear:

♦ In comparison: intact synchro-ring or selector gear:

♦ Abnormal wear on locking collar:

♦ In comparison: intact locking collar:

5.2 Contact corrosion

12 Rep. gr.00 - Technical data

♦ We recommend the use of accessories approved by Audi.

6.1 Overview of fitting locations - electrical

Reversing light switch - F4- / gearbox neutral position sender -

14 Rep. gr.00 - Technical data

1.1 Exploded view - pedal cluster

1.1.1 Exploded view - pedal cluster, vehicles up to model year 2014

16 Rep. gr.30 - Clutch

Removing retaining clip

Pressing on retaining clip

Removing and installing extension spring

18 Rep. gr.30 - Clutch

1.2 Exploded view - clutch hydraulics

The installation position on a left-hand drive vehicle is shown as an example.

11 - Clutch master cylinder

O-rings or seals for pipe/hose assemblies

20 Rep. gr.30 - Clutch

Disconnecting and connecting pipe/hose assembly from/to clutch

Renew damaged seals or O-rings -2-.

– Press pipe/hose assembly -1- into connection on clutch slave

1.3 Exploded view - clutch release mechanism

1.4 Removing and installing clutch pedal

1.4.1 Removing and installing clutch pedal

Special tools and workshop equipment required

22 Rep. gr.30 - Clutch