Audi TT 15 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive
Edition 07.2003
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
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 © 2010 Audi AG, Ingolstadt A0057005620
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Securing subframe to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Repairing damaged threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Disposal of fluid-filled components to meet environmental requirements . . . . . . . . . . . . . . 4
4.1 Releasing gas in front gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Releasing gas in rear gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Draining power steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Checking shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Leaks at shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Noises from shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Checking shock absorbers when removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.4 Testing shock absorbers on shock tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Subframe: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Repairing threads in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Vehicle level sender in vehicles with automatic headlight range control . . . . . . . . . . . . . . 17
1.5 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Removing and installing wishbone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.8 Renewing wishbone bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.9 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.10 Renewing subframe bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Wheel bearing: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Drive shaft / wheel hub splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Removing and installing front wheel bearing with wheel bearing housing installed . . . . . . 38
2.4 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Removing and installing front wheel bearing with wheel bearing housing removed . . . . . . 46
3 Suspension strut: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.1 Removing and installing suspension strut/coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1 Removing and installing drive shaft (version with bolted flange on inner joint) . . . . . . . . . . 57
4.2 Removing and installing drive shaft (version with splines on inner joint) . . . . . . . . . . . . . . 58
4.3 Servicing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.5 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.6 Servicing drive shaft with triple roller inner joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.7 Servicing drive shaft with triple roller joint AAR 3300i (bolted flange / splines on inner joint)
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1 Servicing rear axle (front-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.1 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.2 Rear axle beam: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.3 Removing and installing bonded rubber bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Contents i
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
1.4 Removing and installing shock absorber/spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Shock absorbers: exploded view (front-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . 93
1.6 Vehicle level sender in vehicles with automatic headlight range control . . . . . . . . . . . . . . 95
2 Servicing wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.1 Servicing wheel bearing, front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.2 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3 Servicing rear axle (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.1 Rear axle for four-wheel drive: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.2 Removing and installing diagonal strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.3 Removing and installing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.4 Removing and installing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.5 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.7 Springs and shock absorbers: exploded view (four-wheel drive vehicles) . . . . . . . . . . . . . . 109
4 Trailing arm and transverse links: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 Ball joint replaced by bonded rubber bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.2 Vehicle level sender in vehicles with automatic headlight range control . . . . . . . . . . . . . . 112
4.3 Removing and installing wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.4 Removing and installing trailing arm bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5 Removing and installing ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.6 Removing and installing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.7 Removing and installing transverse links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5 Subframe with final drive: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.1 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2 Removing and installing subframe bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.3 Removing and installing bonded rubber bushes for final drive . . . . . . . . . . . . . . . . . . . . . . 137
6 Servicing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.1 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2 Servicing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1 Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.2 Light-alloy wheel (6-spoke design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Light-alloy wheel (5-arm design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.4 Balancing wheels on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.5 Instructions for changing/fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.2 Wheel alignment specifications for vehicles with standard running gear (G17, G78, G79, G91,
G97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.3 Wheel alignment specifications for vehicles with sports running gear (PQZ, G98) . . . . . . 152
2.4 Test requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.5 Measurement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.6 Checking camber at rear wheels (front-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . 155
2.7 Adjusting camber at rear wheels (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 155
2.8 Centralising toe setting at rear wheels (front-wheel drive vehicles) . . . . . . . . . . . . . . . . . . 156
2.9 Adjusting toe setting at rear wheels (four-wheel drive vehicles) . . . . . . . . . . . . . . . . . . . . 156
2.10 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.11 Adjusting toe setting at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1 Steering column and steering wheel with airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.2 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
ii Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
1.3 Safety precautions when working on airbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.4 Removing and installing airbag module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.5 Steps required after servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.6 Removing and installing steering wheel with airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.7 Removing and installing return spring with slip ring and steering angle sender G85 . . . . 161
1.8 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.9 Removing and installing ignition lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2 Power steering box: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.1 Vehicles with front-wheel drive/four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.2 Removing and installing track rod ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.3 Removing and installing power steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.4 Servicing power steering box (ZF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.5 Adjusting power steering box (ZF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3 Power steering pump: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.1 Bottom-mounted power steering pump: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.2 Pressure switch for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.3 Checking pressure switch for power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.4 Checking delivery pressure of power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.5 Power steering fluid reservoir: exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4 Removing and installing power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.1 Vehicles with bottom-mounted pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Contents iii
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
iv Contents
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
00 – Technical data
1 Technical data
1.1 Running gear
Audi TT 1999 ➤
Front axle
Torsion beam axle with separate
spring-and-shock-absorber arrange‐
Front-wheel drive Four-wheel drive
MacPherson struts with bottom wishbones, subframe, anti-roll bar
Trailing arms and double transverse
links with separate spring-and-shock-
ment, tubular anti-roll bar
absorber arrangement, subframe, an‐
ti-roll bar
Wheelbase
2)
Front / rear track
mm 2425.7 2429.7
mm 1530.5 / 1513 1530.5 / 1500
(wheels with 31 mm rim
offset 1))
1) On vehicles with 225/45 R 17 tyres on wheels with 32 mm rim offset the track
widths are 2 mm less.
2) Wheelbase and track widths have a tolerance of ± 6 mm
1.2 Steering
Steering box Power-assisted, maintenance-free rack-and-pinion steering
No. of turns from lock to
lock
Maximum steering an‐
gle at inside wheel
Turning circle diameter approx. 10.5 m
Front-wheel drive Four-wheel drive
2.75
37°54′
1. Technical data 1
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
2 General notes:
Load-bearing components or parts of the suspension must not be
welded or straightened.
The wheel bearings must not be subjected to load when the 12point nuts have been loosened.
If the wheel bearings are subjected to the full weight of the vehicle
they will be overloaded, resulting in reduced service life. There‐
fore please note the following:
– Lift vehicle far enough to relieve load on front wheels.
– Loosen 12-point nut or flange bolt.
Never move vehicles after the drive shafts have been removed;
this will result in wheel bearing damage. If the vehicle does have
to be moved, always note the following points:
– Fit an outer joint in place of the drive shaft.
– Secure the outer joint by tightening to the torque specified for
the drive shaft.
Bonded rubber bushes can only be turned to a limited extent. The
bolt connections on the suspension links should therefore only be
tightened when the vehicle is standing on the ground.
If the wheel alignment has to be checked and adjusted at a later
stage, all bolts and nuts which need to be slackened to make ad‐
justments should initially only be tightened to the specified torque
figure. After wheel alignment has been checked and adjusted,
bolts and nuts must then be fully tightened by turning them
through the specified angle.
Caution
All bolts and nuts must be fully tightened according to specifi‐
cations before the vehicle is driven on public roads.
2 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
3 Securing subframe to body
3.1 Repairing damaged threads
Damaged threads can be repaired with wire inserts (Helicoil).
For information on which threads can be repaired please refer to
the exploded views of components.
Metal particles remaining in the vehicle body must be embedded
in wax.
Audi TT 1999 ➤
3. Securing subframe to body 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
4 Disposal of fluid-filled components to
meet environmental requirements
4.1 Releasing gas in front gas-filled shock absorbers
A - Releasing gas by drilling
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.
Caution
Safety goggles must be worn when drilling.
– Drill a 3 mm ∅ hole -arrow A- through outer tube of shock ab‐
sorber.
Note!
Gas will escape during drilling.
– Continue drilling until inner tube is penetrated (approx. 25 mm
deep).
– Drill a second 6 mm ∅ hole -arrow B- through outer and inner
tubes of shock absorber.
– Hold shock absorber over a drip tray and move piston rod up
and down several times through entire stroke until no more oil
comes out.
B - Opening shock absorber with pipe cutter
Caution
Safety goggles must be worn while drilling and cutting.
– Drill a 3 mm ∅ hole -arrow- through outer tube of shock ab‐
sorber, or saw through side of tube.
Note!
Gas will escape when drilling or sawing.
– Apply pipe cutter (e.g. Stahlwille Express 150/3) as shown in
illustration and cut through outer tube.
– Pull the piston rod upwards, at the same time holding the inner
tube securely with pliers and pressing it downwards, so that it
remains in the outer tube when the piston rod is slowly pulled
upwards.
– Pull piston rod off inner tube.
– Drain shock absorber tube.
4 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
4.2 Releasing gas in rear gas-filled shock absorbers
A - Releasing gas by drilling
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.
Caution
Safety goggles must be worn when drilling.
– Drill a 3 mm ∅ hole -arrow A- through outer tube of shock ab‐
sorber.
Note!
Gas will escape during drilling.
– Continue drilling until inner tube is penetrated (approx. 25 mm
deep).
– Drill a second 6 mm ∅ hole -arrow B- through outer and inner
tubes of shock absorber.
– Hold shock absorber over a drip tray and move piston rod up
and down several times through entire stroke until no more oil
comes out.
Audi TT 1999 ➤
B - Opening shock absorber with pipe cutter
Caution
Safety goggles must be worn while drilling and cutting.
– Drill a 3 mm ∅ hole -arrow- through outer tube of shock ab‐
sorber, or saw through side of tube.
Note!
Gas will escape when drilling or sawing.
– Apply pipe cutter (e.g. Stahlwille Express 150/3) as shown in
illustration and cut through outer tube.
– Pull the piston rod upwards, at the same time holding the inner
tube securely with pliers and pressing it downwards, so that it
remains in the outer tube when the piston rod is slowly pulled
upwards.
– Pull piston rod off inner tube.
– Drain shock absorber tube.
4. Disposal of fluid-filled components to meet environmental requirements 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
4.3 Draining power steering box
Note!
Room temperature must be at least 20°C when draining the steer‐
ing box.
– Turn the steering pinion in the direction indicated (arrow) far
as the end stop.
– Clamp steering box horizontally in a vice.
– Place drip tray under steering box.
– Saw off the steering box at the point indicated by -arrow A-.
– Hold the opened steering box over the drip tray and allow the
hydraulic fluid to drain. If necessary, turn the steering pinion
to the opposite stop.
6 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
5 Checking shock absorbers
5.1 Leaks at shock absorbers
Shock absorbers are often replaced because of externally visible
leakage. Inspections on the test rig and in the vehicle have shown
that in the majority of cases this replacement is not justified.
Slight loss of fluid (“sweating”) at the piston rod seal is not a rea‐
son for replacing a shock absorber. A shock absorber with slight
fluid leakage can be accepted as "OK" under the following con‐
ditions:
♦ Fluid seepage (as shown in the shaded part of the illustration)
is visible, but the fluid is dull and possibly dried by dust
♦ The fluid seepage extends only from the top shock absorber
seal (piston rod oil seal) down to the bottom spring plate
-arrow-.
Note!
Audi TT 1999 ➤
Slight fluid leakage is actually beneficial, as it lubricates the piston
rod oil seal and thus extends the life of the shock absorber. This
applies to shock absorbers on both the front and rear axles.
5.2 Noises from shock absorbers
Shock absorbers are often replaced because of noises (rumbling,
etc.) experienced by the customer. Inspections on the test rig and
in the vehicle have shown that in approx. 70% of these cases the
complaints and subsequent replacement are not justified.
In the case of complaints regarding rumbling or knocking noises
please proceed as follows:
– Carry out a road test with the customer - if possible on a dry,
uneven road - to establish when, where and how the noises
occur.
– To identify the fault please proceed on the basis of the fault
finding table “Noises at front and rear end of vehicle” ⇒ "Fault
finding. Running gear"
Note!
These noises are only very rarely caused by the shock absorbers.
5.3 Checking shock absorbers when re‐
moved
Defective shock absorbers can be identified by loud rumbling
noises when driving, caused by wheel hopping, especially on bad
roads. Heavy fluid leakage is an additional visual indication.
5. Checking shock absorbers 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
Note!
Shock absorbers are maintenance-free; shock absorber fluid can‐
not be topped up.
After removal, a shock absorber can be checked by hand as fol‐
lows:
– Compress shock absorber by hand.
♦ The piston rod should move smoothly over the entire stroke
with uniform resistance and without jolts.
– Release piston rod.
♦ If the shock absorber has sufficient gas pressure the piston
rod will return by itself to its original position.
Note!
♦
If this is not the case, the shock absorber does not necessarily
need to be renewed. Provided there has been no major loss
of fluid, it will still be as effective as a conventional shock ab‐
sorber.
♦
Even without gas pressure, the shock absorber will provide full
damping effect as long as there has been no major loss of fluid.
However, it may produce more noise.
5.4 Testing shock absorbers on shock test‐
er
The shock tester allows shock absorbers to be tested without re‐
moving them from the vehicle. The damping effect can be as‐
sessed on the basis of the pointer deflection or the print-out.
Special tools and workshop equipment required
♦ Boge shock tester
or
♦ Sachs shock tester -V.A.G 1975-
or
♦ Maha shock absorber tester -VAS 1990-
Note!
♦
Temperature +10°... +40° C
♦
Driver in vehicle.
♦
Tyre inflation pressure OK.
♦
Wheels of vehicle have been placed in a central and straight
position on the tyre contact plates.
♦
Front wheels in straight-ahead position.
♦
Handbrake not applied, brake pedal not depressed.
Test results
The condition of the shock absorbers can only be evaluated as
follows:
8 Rep. Gr.00 - Technical data
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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
♦ Satisfactory damping effect
or
♦ Unsatisfactory damping effect
Note!
♦
It is not possible to obtain more detailed readings specifying
the exact degree of impairment of damping effect.
♦
A forecast of the remaining service life is not permissible.
♦
Test results will be falsified if the suspension contacts the
bump stops when the readings are taken.
The following values apply only to tests conducted on the test
equipment listed above. If the given values are exceeded, this
shows that the effectiveness of the shock absorber has de‐
creased by more than 50%; in this case it should be renewed.
Front axle, TT Coupé with front-wheel drive:
♦ a = higher than 50: unsatisfactory damping effect
♦ a = lower than 50: satisfactory damping effect
Rear axle, TT Coupé with front-wheel drive:
♦ a = higher than 54: unsatisfactory damping effect
♦ a = lower than 54: satisfactory damping effect
Front axle, TT Coupé with four-wheel drive:
♦ a = higher than 49: unsatisfactory damping effect
♦ a = lower than 49: satisfactory damping effect
Rear axle, TT Coupé with four-wheel drive:
♦ a = higher than 50: unsatisfactory damping effect
♦ a = lower than 50: satisfactory damping effect
Audi TT 1999 ➤
Front axle, TT Roadster with front-wheel drive:
♦ a = higher than 50: unsatisfactory damping effect
♦ a = lower than 50: satisfactory damping effect
Rear axle, TT Roadster with front-wheel drive:
♦ a = higher than 54: unsatisfactory damping effect
♦ a = lower than 54: satisfactory damping effect
Front axle, TT Roadster with four-wheel drive:
♦ a = higher than 50: unsatisfactory damping effect
♦ a = lower than 50: satisfactory damping effect
Rear axle, TT Roadster with four-wheel drive:
♦ a = higher than 50: unsatisfactory damping effect
♦ a = lower than 50: satisfactory damping effect
5. Checking shock absorbers 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
40 – Front suspension
1 Subframe: exploded view
1.1 Repairing threads in longitudinal mem‐
ber
Under certain circumstances it is possible to repair the threads in
the captive nuts in the longitudinal member.
♦ Each thread can only be repaired once.
♦ If a second repair is needed, the captive nut must be renewed.
Caution
Always wear safety goggles when drilling.
♦ Have thread repair checked by foreman or supervisor.
♦ The thread insert must be of same length as the thread in the
body.
1.2 Exploded view of components
• Removing and installing cross piece for suspension strut
⇒ page 13
• Removing and installing diagonal strut for subframe
⇒ page 14
10 Rep. Gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
1 - Mounting bracket for sub‐
frame
The captive nut cannot be re‐
worked. If the nut is damaged,
the complete mounting bracket
must be renewed.
2 - Captive nut in body
❑ Thread in body can be
repaired using wire
thread insert according
to DIN 8140 (Helicoil).
Thread insert must be of
same length as thread in
body.
3 - Bush
❑ Two-piece version; note
installation position
⇒ page 13
❑ Removing and installing
⇒ page 29
4 - Hexagon bolt M 14 x 1.5 x
63
❑ Always renew
❑ Tighten to 100 Nm and
then turn 90° further.
❑ Thread in body can be
repaired using wire
thread insert according
to DIN 8140 (Helicoil).
Thread insert must be of
same length as thread in
body.
5 - Self-locking nut
❑ M 12 x 1.5
❑ Always renew if removed
6 - Rear wishbone bush
❑ Different versions available ⇒ ETKA
❑ Removing and installing ⇒ page 25
7 - Hexagon bolt M 12 x 1.5 x 70
❑ 70 Nm and turn 90° further
❑ Always renew if removed
8 - Self-locking nut
❑ Tightening torque: 75 Nm
❑ TT VR6 Roadster: 150 Nm
❑ M 12 x 1.5
❑ Always renew if removed
Audi TT 1999 ➤
9 - Swivel joint
❑ Checking ⇒ page 20
❑ Removing and installing ⇒ page 20
❑ Mark installation position; if wishbone is renewed, set to centre of elongated hole and check toe setting/
camber
❑ Wheel alignment ⇒ page 150
10 - Hexagon nut, 75 Nm
❑ M10
1. Subframe: exploded view 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
❑ Always renew if removed
11 - Wishbone
❑ Different versions available ⇒ ETKA
❑ The same version must be installed on both sides
❑ Removing and installing ⇒ page 20
12 - Hexagon bolt, 25 Nm
❑ M8 x 20
13 - Linkage for headlight range control
❑ Adjustment dimension for bracket with elongated hole ⇒ page 20
❑ Tighten nuts (M6) to 4 Nm.
❑ Headlight range control ⇒ page 17
14 - Front wishbone bush
❑ Different versions available ⇒ ETKA
❑ Removing and installing ⇒ page 24
15 - Hexagon bolt M 14 x 1.5 x 95
❑ 100 Nm and turn 90° further
❑ Always renew if removed
The captive nut cannot be reworked. If the nut is damaged, the complete mounting bracket must be renewed.
16 - Coupling rod
❑ Link between anti-roll bar and suspension strut
17 - Hexagon nut, 90 Nm
❑ M 12 x 1.5
❑ Always renew if removed
18 - Anti-roll bar
Removing and installing ⇒ page 14
19 - Hexagon bolt M 12 x 1.5 x 78
❑ 70 Nm and turn 90° further
❑ Always renew if removed
20 - Hexagon bolt, 25 Nm
❑ M8×45
21 - Hexagon bolt, 50 Nm
❑ M10×70
22 - Hexagon bolt, 50 Nm
❑ M10×30
23 - Pendulum support
24 - Subframe
❑ Removing and installing ⇒ page 27
❑ Installation position of cross piece ⇒ page 13
25 - Rubber bush
26 - Clamp
27 - Hexagon bolt, 25 Nm
❑ M8 x 20
12 Rep. Gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
Installation position of upper and lower halves of subframe bush
A - Upper half of bush without collar, ribs point towards body.
B - Lower half of bush, collar points towards bolt head
Installation position of subframe cross piece
Cross piece is not fitted on all vehicles.
F - Direction of travel
1 - Subframe
2 - Pop rivet nut, M10
- Insert using -V.A.G 1765 B- .
3 - Cross piece
- Fit with marking “L” or “links” to the left as seen facing in direction
of travel.
- Foam strip faces downwards -arrow-.
4 - Hexagon bolt, M10×45
- Use new bolts if detached.
- Use locking fluid D 000 600 A2 when installing.
- Tightening torque: 30 Nm and turn 90° further
Audi TT 1999 ➤
♦ Pop-rivet nut pliers -V.A.G 1765 B-
Cross piece for suspension strut
– Loosen nuts -3- (3x) and -2- (1x). Tightening torque: 20 Nm
– If necessary, re-adjust cross piece -1- by loosening nuts -4-
(2x). Tightening torque: 20 Nm
1. Subframe: exploded view 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
Diagonal strut for subframe
– Remove bolts -1- with lock washer -2- (8x). Tightening torque:
35 Nm.
– Take out diagonal strut -3-.
1.3 Removing and installing anti-roll bar
Removing
– Remove wheels.
– Remove noise insulation panel.
– Detach side noise insulation panels on left and right sides at
subframe.
– If fitted, detach headlight range control linkage at left wishbone
⇒ page 17 .
– Detach anti-roll bar from coupling rod. Tightening torque: 100
Nm. Use new nuts.
– Attach track rods to suspension struts using tensioning straps
-T10038- (apply straps next to inner rubber boots). This will
prevent the steering column from slipping off from the steering
box splines during the next step.
14 Rep. Gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
– For vehicles with 4WD and 165 kW engine (code: APX), de‐
tach the rubber mounting -arrow- at the front exhaust pipe.
Note the position of the rubber mounting for subsequent installa‐
tion.
– Remove bolts -1- for steering box.
Tightening torques:
Steering box to subframe. Use new bolts. 20 Nm + 90°
Audi TT 1999 ➤
– Position gearbox jack -V.A.G 1383 A- with universal mount
1359/2 and a hardwood support underneath the subframe.
– Remove diagonal strut (if fitted) ⇒ page 13 .
– Remove bolts for pendulum support -2-.
Tightening torques:
Pendulum support -2- 50 Nm
– Remove bolts -3- and -4- for subframe.
Tightening torques:
Subframe to body (use new bolts) 100 Nm + 90°
1. Subframe: exploded view 15
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
– Carefully lever subframe for steering box from main subframe
using a tyre lever or similar.
– If necessary, remove hexagon nut for retaining clip on anti-roll
bar clamp (left-side). Tightening torque: 22 Nm
– Carefully lower subframe.
Pay attention to side noise insulation panel and bracket for hy‐
draulic pipe on left side when lowering subframe.
– Remove bolt 27.
♦ Tightening torque: 25 Nm
– Disengage anti-roll bar clamp 26.
– Take out anti-roll bar 18 rearwards.
Installing
– Secure anti-roll bar -18- to subframe from the rear with bush
-25-, clamp -26- and bolt -27-.
16 Rep. Gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
♦ Tightening torque: 25 Nm. Installation position of anti-roll bar
bush ⇒ page 94
♦
– Remaining installation steps are carried out in reverse se‐
quence.
Installation position of anti-roll bar bush
1 - Anti-roll bar clamp
2 - Anti-roll bar bush
3 - Anti-roll bar
1.4 Vehicle level sender in vehicles with automatic headlight range control
Vehicles with gas discharge lamps have automatic headlight
range control as standard equipment.
1. Subframe: exploded view 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
The automatic headlight range control requires information re‐
garding compression and rebound travel at the front and rear
suspension in order to function correctly.
For this purpose the position of the lower left wishbone in relation
to the body is transferred to the vehicle level sender -G78- via a
coupling rod. This transmits electrical signals to the control unit
for the headlight range control.
On the rear axle, the signals are transmitted to the control unit by
the vehicle level sender -G76-.
These signals are required for calculating the current attitude of
the vehicle.
The automatic headlight range control reacts to changes in the
suspension height (attitude of the vehicle).
The attitude of the vehicle can vary in the following situations:
♦ Different loading conditions; vehicle empty, vehicle partly or
fully loaded
♦ Slow or fast driving
18 Rep. Gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
Caution
Headlight setting!
The basic headlight setting must always be checked when:
♦ The wishbone has been removed or renewed ⇒ Electrical
system; Repair group 01; Self-diagnosis of automatic head‐
light range control
♦ Assembly work has been carried out on the vehicle level send‐
er
♦ The vehicle level sender has been renewed
♦ The retaining clamp for the coupling rod on the wishbone has
been detached
Basic setting of headlights ⇒ Electrical system; Repair group 01;
Self-diagnosis of automatic headlight range control; Basic setting
1 - Bracket
2 - Hexagon nut, 8 Nm
3 - Vehicle level sender -G78-
❑ Is tested electrically via
self-diagnosis
❑ If malfunctions occur ⇒
Electrical system; Re‐
pair group 01; Self-diag‐
nosis of automatic
headlight range control
4 - Coupling rod from vehicle
level sender -G78-; tightening
torque at component -3-: 4 Nm
5 - Wishbone
6 - Hexagon bolt, 25 Nm
7 - Coupling rod
❑ Adjustment dimension
for bracket with elonga‐
ted hole ⇒ page 20
8 - Hexagon nut, 4 Nm
9 - Connector
10 - Longitudinal member
11 - Pop-rivet bolt
The pop-rivet bolt can be in‐
stalled with the pop rivet pliers
V.A.G 1765 B
Audi TT 1999 ➤
1. Subframe: exploded view 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
Adjustment dimension for headlight range control linkage at
bracket with elongated hole
Dimension a = 19 mm
Tighten nuts (M6) to 4 Nm.
1.5 Checking swivel joint
Checking axial play
– Pull wishbone firmly downwards and press back up again.
Checking radial play
– Press bottom of wheel firmly inwards and outwards.
Note!
♦
There must be no perceptible or visible “play” when carrying
out both tests.
♦
Observe the swivel joint while performing the tests.
♦
Take into account any existing wheel bearing play or “play” in
upper suspension strut mounting.
♦
Check rubber boot for damage, renew swivel joint if necessa‐
ry.
1.6 Removing and installing swivel joint
Special tools and workshop equipment required
♦ Ball joint puller -3287 A-
20 Rep. Gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
♦ Ball joint puller -Kukko 129/0-
♦ Torque wrench -V.A.G 1332- , measuring range 40...200 Nm
Removing
All vehicles
– Remove wheel.
– Mark positions of nuts.
– Remove bottom nuts from swivel joint.
Audi TT 1999 ➤
– Remove top nut from swivel joint.
Roadster TT VR6 only:
– Detach wishbone from swivel joint.
– Apply ball joint puller Kukko 129/0 as shown in the illustration
and press out swivel joint.
Note!
♦
Use the ball joint puller specified here and ensure it is seated
correctly, otherwise the sleeve in the wheel bearing housing
will be pulled out together with the swivel joint.
♦
Leave nut screwed on a few turns to protect swivel joint
threads.
All other vehicles:
1. Subframe: exploded view 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
– Apply ball joint puller as shown in the illustration and press out
swivel joint.
Note!
Leave nut screwed on a few turns to protect swivel joint threads.
Installing
Tightening torques:
Swivel joint to wishbone (use new nuts) 75 Nm
Swivel joint to wheel bearing housing on TT VR6
150 Nm
Roadster (use new nuts)
Swivel joint to wheel bearing housing on all other
75 Nm
vehicles (use new nuts)
– Secure swivel joint to wishbone (align nuts to markings).
Commercially available ring spanner inserts (18mm), e.g. Stahl‐
wille 732/10 or Hazet 6630c-18, can be used instead of V.A.G 1332/10- .
1 - Torx key -T40-
– Insert swivel joint in wheel bearing housing.
– Install new self-locking nut, and counterhold with Torx key -
T40- .
Note!
Ensure sealing boot is free of damage and not twisted.
– Check wheel alignment ⇒ page 150
1.7 Removing and installing wishbone
There are various different wishbone versions; refer to ⇒ ETKA
The same version must always be installed on both sides.
If an old version is already installed in the vehicle, both wishbones
must be renewed as a pair.
Removing
– Remove wheel.
22 Rep. Gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
– Remove noise insulation panel.
– If fitted, detach headlight range control linkage at left wishbone
⇒ page 17 .
– Mark positions of nuts.
– Remove bottom nuts from swivel joint.
– Remove hexagon bolts -1- and -2- and take out wishbone.
Note!
Bolt -1- is secured from above with a nut.
Audi TT 1999 ➤
When installing, note the following points in particular:
– Install wishbone in subframe and secure.
– Secure swivel joint to wishbone. (Align nuts to markings; se‐
cure new wishbone in central position).
The vehicle must be standing on its wheels when tightening the
bolt connections with bonded rubber bushes.
Otherwise, the bush would be subject to torsion loading and its
service life shortened.
– Check wheel alignment ⇒ page 150
1.8 Renewing wishbone bushes
There are various different wishbone versions; refer to ⇒ ETKA
The same version must always be installed on both sides.
Workshop press -V.A.G 1290 A- is used for pressing out.
1. Subframe: exploded view 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 07.2003
Note!
♦
Use assembly lubricating oil G 294 421 A1 when pressing in.
♦
Mixture ratio of lubricating oil to water: 1:9.
♦
This lubricating oil is acid-free and penetrates into the rubber
after a short time (by diffusion).
♦
It leaves a slightly sticky film, which ensures firm seating of the
bush.
♦
Most conventional greases/oils contain acid and cause a film
of lubricant to form.
♦
This may affect the rubber, or cause the entire bush to twist in
the wishbone instead of flexing when the suspension com‐
presses and rebounds.
The following instructions apply to vehicles in which the rear bush
as seen in the direction of travel (the larger of the two bushes) is
solid (i.e. without cavities).
On these vehicles the number 8N0 407 165 or 8N0 407 166 is
marked on the wishbone.
When installing, note the following points in particular:
– Press out bush.
Pressing in front wishbone bush
Note correct position of bush when installing.
24 Rep. Gr.40 - Front suspension
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