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.

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

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

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

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

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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Press in bush -arrow-.

Pressing out / pressing in rear wishbone bush

– Press in bush.

The following instructions apply to vehicles in which the rear bush as seen in the direction of travel (the larger of the two bushes) has kidney-shaped cavities (see illustration No. A40-0446-).

On these vehicles the number 8N0 407 157 or 8N0 407 158 is marked on the wishbone.

Workshop press -V.A.G 1290 A- is used for pressing out.

Pressing out front wishbone bush

– Cut off outer projecting rubber part of bush to create a flat sur‐

face.

– Support the wishbone with this contact surface on plate -

VW 402- .

Audi TT 1999 ➤

– Press out bush.

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.

Pressing in front wishbone bush

– Support the wishbone eye on a flat surface.

1. Subframe: exploded view 25

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Initially press in the bush as far as the stop.

– Then press in the bush further until the rubber bead on the

underside is completely visible -arrow-.

Installation position of rear bush in left wishbone

A - Part number

B - “Kidney-shaped” cavity; the larger of the two cavities faces forwards in direction of travel

C - Machined surface, press in bush flush with this surface.

F - Direction of travel

Note different shapes of kidney-shaped cavities - arrows -.

Installation position of rear bush in right wishbone

A - Part number

B - “Kidney-shaped” cavity; the larger of the two cavities faces forwards in direction of travel

C - Machined surface, press in bush flush with this surface.

F - Direction of travel

Note different shapes of kidney-shaped cavities -arrows-.

Pressing out / pressing in rear wishbone bush

26 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Use the special tools illustrated and press the bush out/in.

1.9 Removing and installing subframe

Special tools and workshop equipment required

♦ Gearbox jack -V.A.G 1383 A- with universal mount -

V.A.G 1359/2-

Audi TT 1999 ➤

♦ Torque wrench -V.A.G 1332- , measuring range 40...200 Nm

Removing

– Remove wheels.

– Remove noise insulation panel.

– Detach bracket for hydraulic pipe at subframe (left-side) if

necessary. Tightening torque: 3.5 Nm.

– If fitted, detach headlight range control linkage at left wishbone

⇒ page 17 .

1. Subframe: exploded view 27

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– 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.

– Remove nut for coupling rod from anti-roll bar.

– Remove Torx socket head bolt for noise insulation panel.

– Mark positions of nuts.

– Remove bottom nuts from swivel joint.

– Remove diagonal strut (if fitted) ⇒ page 13 .

– Remove bolts for steering box -1- and pendulum support -2-.

– For vehicles with 165 kW engine (code: APX), detach rubber

mounting at front exhaust pipe.

– Apply gearbox jack -V.A.G 1383 A- with universal mount

-1359/2- under subframe.

– Remove bolts -3- and -4- for subframe.

– If necessary, remove hexagon nut for retaining clip on anti-roll

bar clamp (left-side). Tightening torque: 22 Nm

28 Rep. Gr.40 - Front suspension

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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.

Pay attention to side noise insulation panel and bracket for hy‐ draulic pipe (left-side) when lowering subframe.

– Carefully lower subframe.

When installing, note the following points in particular:

Before inserting subframe bolts, position steering box on sub‐ frame and insert bolts for steering box.

Threaded sleeve -1- must be seated in hole in subframe.

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.

Audi TT 1999 ➤

– Install new self-locking nut, and counterhold with Torx key -

T40- .

Note!

Ensure sealing boot is free of damage and not twisted.

Tightening torques: Swivel joint to wishbone (use new nuts) 75 Nm Pendulum support to gearbox M10 x 70 50 Nm Pendulum support to gearbox M10 x 30 50 Nm Pendulum support to subframe 25 Nm Steering box to subframe (use new bolts) 20 Nm + 90° Coupling rod to anti-roll bar (use new nuts) 90 Nm Subframe to body (use new bolts) 100 Nm + 90°

After installation, check position of steering wheel by test-driving vehicle.

Wheel alignment must be checked and adjusted if steering wheel is not in central position.

1.10 Renewing subframe bushes

The bushes can be renewed after lowering the subframe.

1. Subframe: exploded view 29

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Special tools and workshop equipment required

♦ Gearbox jack -

V.A.G 1383 A-

♦ Splitter -Kukko 15-1 mit

Kukko17-1- ; items.1, 2 and 4 are not required.

♦ Base plate -VW 441-

♦ Thrust plate -VW 447 h-

♦ Torque wrench -

V.A.G 1332- , measuring range 40...200 Nm

– Remove noise insulation panel.

30 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Remove Torx socket head bolt for noise insulation panel -left

arrow-.

– For vehicles with 165 kW engine (code: APX), detach rubber

mounting at front exhaust pipe.

– Remove rear bolts -1-.

– Lower subframe by slackening the front bolts -2- until the

bushes are accessible.

Audi TT 1999 ➤

– Apply splitter tool Kukko 15-1 with Kukko 17-1, and pull out

upper half of bush.

– Insert thrust plate -VW 447 h- .

– Using gearbox jack and base plate -VW 441- , push subframe

upwards until lower half of bush drops out.

1. Subframe: exploded view 31

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Installation position of bush halves

A - Upper half of bush without collar, ribs point towards body.

B - Lower half of bush, collar points towards bolt head

Coat the rubber surfaces of the new bushes with assembly lubri‐ cant G 294 421 A1.

Note installation position of bushes ⇒ page 32 .

– Insert both bush halves.

– Press in new bushes using gearbox jack.

Tightening torques: Subframe to body (use new bolts) 100 Nm + 90°

After installation, check position of steering wheel by test-driving vehicle.

Wheel alignment must be checked and adjusted if steering wheel is not in central position.

32 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

2 Wheel bearing: exploded view

Load-bearing components or parts of the suspension must not be welded or straightened.

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.

The wheel bearings must not be subjected to load when the 12point nut / flange bolt has 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:

– Have a second mechanic press the brake pedal.

– Lift vehicle far enough to relieve load on front wheels.

– Loosen 12-point nut / 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.

– Tighten the outer joint to 190 Nm.

Audi TT 1999 ➤

2.1 Drive shaft / wheel hub splines

Vehicles with drive shaft secured by 12-point nut

♦ The drive shaft/wheel hub splines can either be “bonded” with

locking fluid, or on newer-version wheel hubs, (Part. No. 8N0 407 613 A or B), greased.

♦ In other words, the wheel hub version determines whether the

wheel hub is “bonded” or greased.

♦ Stocks of the old-version wheel hubs, Part No. 8N0 407 613,

(wheel hub stamped with 8N0 615) can still be used up for drive shafts that were“bonded”, but these must then still be “bonded” using locking fluid D 185 400 A2.

♦ Newer wheel hubs, Part No. 8N0 407 613 A or B, (wheel hub

stamped with 8N0 615A or B) must under no circumstances be “bonded”. These wheel hubs may be coated only with solid grease G 052 142 A2.

♦ It is permissible to have a “bonded” drive shaft/wheel hub on

one side of the vehicle and a greased drive shaft/wheel hub on the other side, because a “bonded” wheel hub may be re‐ placed with a greased one. However, a greased wheel hub must not be replaced with a “bonded” one. Procedure

⇒ page 34

The tightening torques for the 12-point nut are different:

♦ “Bonded” wheel hub: 265 Nm

♦ Greased wheel hub: 190 Nm + turn 90° further

♦ Always install a new 12-point nut

2. Wheel bearing: exploded view 33

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Procedure:

Condition of components on vehicle, as installed

Drive shaft is bonded to

wheel hub

Drive shaft and wheel hub

are greased

Drive shaft is bonded to

wheel hub

Drive shaft and wheel hub

are greased

Wheel hub being re‐

Procedure during assembly

newed?

not renewed ♦ Thoroughly clean adhesive residue from splines

of drive shaft and wheel hub.

♦ Apply locking fluid D 185 400 A2.

♦ Tighten 12-point nut to 265 Nm.

not renewed ♦ Apply solid grease G 052 142 A2.

♦ Tighten 12-point nut to 190 Nm + 90°.

renewed If 8N0 407 613 A or B is being installed:

♦ Thoroughly clean adhesive residue from splines

of drive shaft.

♦ Apply solid grease G 052 142 A2.

♦ Tighten 12-point nut to 190 Nm + 90°.

If 8N0 407 613 is being installed:

♦ Thoroughly clean adhesive residue from splines

of drive shaft.

♦ Apply locking fluid D 185 400 A2.

♦ Tighten 12-point nut to 265 Nm.

renewed Install 8N0 407 613 A or B only:

♦ Apply solid grease G 052 142 A2.

♦ Tighten 12-point nut to 190 Nm + 90°.

Vehicles with drive shaft secured by flange bolt

Loosening flange bolt

– Only loosen the flange bolt 90°, otherwise the wheel bearing

will be damaged.

– Lift vehicle far enough to relieve load on front wheels.

– Have a second mechanic press the brake pedal.

– Loosen flange bolt -2-.

– Remove wheels.

– Screw wheel bolts back in.

Installing flange bolt

34 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Always renew flange bolt -2-.

– Lightly grease splines on axle stub and contact surface of

wheel hub -1- / underside of bolt head -2- with solid grease G 052 142 A2.

Procedure when screwing in flange bolt

– Have a second mechanic press the brake pedal.

– Raise vehicle.

– Initial tightening torque: 240 Nm

– Fit wheels and lower vehicle onto its wheels. Observe the

notes ⇒ page 149 .

– Turn 90° further.

– Loosen flange bolt 90° only.

– Raise vehicle.

– Have a second mechanic press the brake pedal.

– Loosen flange bolt a further 90°.

– Tighten to 240 Nm.

– Lower vehicle onto its wheels.

– Turn 90° further.

Audi TT 1999 ➤

2. Wheel bearing: exploded view 35

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

2.2 Exploded view of components

1 - Suspension strut

❑ Different versions avail‐

able ⇒ ETKA

❑ The same version must

be installed on both sides

❑ Detaching suspension

strut from wheel bearing housing ⇒ page 37

❑ Exploded view

⇒ page 51

2 - Hexagon bolt

❑ Always renew if re‐

moved

3 - Hexagon socket head bolt, 8 Nm

4 - Speed sensor

❑ Before inserting sensor,

clean inner surface of fit‐ ting hole and coat with lubricating paste G 000

650.

5 - Self-locking nut

❑ Tightening torque: 45

Nm

❑ TT VR6 Roadster: 75

Nm

❑ Always renew if re‐

moved

6 - Track rod ball joint

7 - Hexagon bolt, 10 Nm

8 - 12-point nut (self-locking)

Refer to notes ⇒ page 33 and table ⇒ page 34

❑ Always renew if removed

9 - Cross-head screw, 4 Nm

10 - Brake disc (ventilated)

11 - Wheel hub with rotor for wheel speed sensor

Refer to notes ⇒ page 33 and table ⇒ page 34

❑ Rotor is welded to wheel hub ❑ Removing and installing with wheel bearing housing installed ⇒ page 38

12 - Splash plate

13 - Circlip

❑ Ensure proper seating

14 - Wheel bearing

❑ Removing and installing with wheel bearing housing installed ⇒ page 38

Before pressing in wheel bearing, coat entire inner surface of bore in wheel bearing housing with Molypaste

⇒ page 38

36 Rep. Gr.40 - Front suspension

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Audi TT 1999 ➤

Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

15 - Self-locking nut

❑ Tightening torque: 75 Nm ❑ TT VR6 Roadster: 150 Nm ❑ Always renew if removed

16 - 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

17 - Brake carrier

18 - Brake caliper

❑ Do not disconnect brake hose when working on front suspension ❑ Tie in position with wire or similar

19 - Guide pins, 25 Nm

20 - Protective cap

21 - Ribbed bolt, 125 Nm

❑ Clean ribbing on underside of bolt head ❑ Brake line must not be twisted or kinked

22 - Self-locking nut

❑ 60 Nm and turn 90° further ❑ Always renew if removed

23 - Wheel bearing housing

❑ Removing and installing ⇒ page 43

Before pressing in wheel bearing, coat entire inner surface of bore in wheel bearing housing with Molypaste

⇒ page 38

24 - Drive shaft

Refer to notes ⇒ page 33 and table ⇒ page 34

❑ Pressing drive shaft out of wheel hub; pressing in ⇒ page 57 , Drive shafts

Detaching suspension strut from wheel bearing housing

– Apply special tool -3424- as shown and force wheel bearing

housing apart.

2. Wheel bearing: exploded view 37

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Coat entire inner surface of bore in wheel bearing housing with Molypaste (AOS 115 000 01).

Note!

A grease sachet containing 3g of grease is included with the wheel bearing set.

2.3 Removing and installing front wheel bearing with wheel bearing housing in‐ stalled

Refer to notes ⇒ page 33 and table ⇒ page 34

38 Rep. Gr.40 - Front suspension

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Special tools and workshop equipment required

♦ Thrust plate -40-105-

♦ Press tool -3283-

♦ Puller -3423-

♦ Gearbox jack -

V.A.G 1383 A- with univer‐ sal mount -V.A.G 1359/2-

♦ Puller -2 - Kukko 18/0-

♦ Torque wrench -

V.A.G 1576- , measuring range: 75...400 Nm

Audi TT 1999 ➤

Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

♦ Foot pump with high pressure hose -V.A.G 1389 A/1-

If hand pump V.A.G 1389/1 is already available, this can be con‐ verted to a foot-operated pump.

To do this, use the conversion set -V.A.G 1389/3- .

2. Wheel bearing: exploded view 39

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

♦ Hydraulic wheel bearing tool -V.A.G 1459 B-

♦ Hollow piston cylinder HKZ-15 with thrust piece E-0-204-T

(hydraulic)

♦ Pull rod E-0-217+218

♦ Special nut E-8-214

♦ Thrust piece E-5

♦ Thrust piece E-10

♦ Thrust piece E-13-1

♦ Thrust sleeve E-65-1

♦ Thrust bolt E-15

♦ Supplementary set -V.A.G 1459 B/2-

♦ Support E-40

Preparing wheel bearing housing for pressing-out procedure

– Remove trim cap from light-alloy wheels (puller in vehicle tool

kit).

– Lift vehicle far enough to relieve load on front wheels.

– Loosen nut / bolt securing drive shaft.

– Remove wheels.

– Detach coupling rod from suspension strut on both sides of the

vehicle.

– Pull spring clip out from bracket and detach brake hose.

– Detach wire for speed sensor from suspension strut.

– Unbolt brake caliper from wheel bearing housing.

– Secure brake caliper to body with wire.

– Detach brake disc (disc is secured to hub with cross-head

bolt).

– Remove brake disc splash plate.

40 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Mark positions of nuts.

– Remove bottom nuts from swivel joint.

– Detach wishbone from swivel joint.

– Press out drive shaft.

♦ Ensure sufficient clearance when pressing out drive shaft.

– Remove drive shaft from wheel bearing housing and tie up.

Place gearbox jack -V.A.G 1383/A- with universal mount V.A.G 1359/2- underneath (to prevent risk of parts dropping out when pulling out wheel hub and wheel bearing).

Pulling out wheel hub

Audi TT 1999 ➤

– Insert thrust bolts -1- in wheel bearing housing.

– Attach support -2-, hollow piston cylinder -3- with pull rod and

special nut -4-.

– Hold appliance firmly and pull wheel hub out.

1 - Thrust bolt E-15

2 - Support E-40

3 - Hollow piston cylinder HKZ-15

4 - Special nut E-8-214 and pull rod

5 - High pressure hose with quick-release coupling

Pulling out wheel bearing

– Remove circlip.

– Set up thrust piece -1- with collar facing wheel bearing, thrust

sleeve -2- with four stepped internal diameters towards wheel bearing housing and hollow piston cylinder -3-with pull rod and special nut -4-.

– Pull out wheel bearing by actuating pump.

1 - Thrust piece E-5

2 - Thrust sleeve E-65-1

3 - Hollow piston cylinder HKZ-15

4 - Special nut E-8-214 and pull rod

2. Wheel bearing: exploded view 41

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Pulling inner bearing race off hub

– Insert special tool -3423- as shown.

– Screw cross-piece Kukko -18-0- into special tool -3423-.

– Mount special tool -40-105- on wheel hub and pull off inner

bearing race by turning spindle.

Pressing in wheel bearing

Coat entire inner surface of bore in wheel bearing housing with Molypaste (AOS 115 000 01).

Note!

A grease sachet containing 3g of grease is included with the wheel bearing set.

Pressing in wheel bearing

– Set up wheel bearing -1-, thrust piece -2- (fit with collar in

bearing) and hollow piston cylinder -3- with pull rod on wheel bearing housing.

– Fit thrust piece -4- (with wide collar towards wheel bearing

housing) and special nut -5- on inner side of wheel bearing housing.

– Press in wheel bearing by actuating pump.

– Insert circlip with long-nose pliers.

1 - Wheel bearing

2 - Thrust piece E-13-1

3 - Hollow piston cylinder HKZ-15

4 - Thrust piece E-10

5 - Special nut E-8-214 and pull rod

Pressing in wheel hub

42 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Fit wheel hub -1- and hollow piston cylinder -2- with pull rod

on wheel bearing.

– Fit special nut -4- and thrust piece -3- (with collar facing special

nut) on inboard side of wheel bearing housing.

– Press in wheel hub by actuating pump.

1 - Wheel hub

2 - Hollow piston cylinder HKZ-15

3 - Thrust piece E-5

4 - Special nut E-8-214 and pull rod

Pay attention to the following points on installation:

Refer to notes ⇒ page 33 and table ⇒ page 34

– Clean inner splines of wheel hub.

– Screw on new 12-point nut as far as possible.

– Secure brake caliper to wheel bearing housing. ⇒ Brake sys‐

tem; Repair group 46; Servicing front brakes

– Attach coupling rod to suspension strut with new nut.

– Lower vehicle, but make sure that wheels do not yet touch

ground.

Otherwise the wheel bearing could be subject to excessive load and damaged.

– Have a second mechanic press the brake pedal.

– Tighten 12-point nut.

2.4 Removing and installing wheel bearing housing

Audi TT 1999 ➤

Refer to notes ⇒ page 33 and table ⇒ page 34

2. Wheel bearing: exploded view 43

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Special tools and workshop equipment required

♦ Torque wrench -

V.A.G 1332- , measuring range 40...200 Nm

♦ Torque wrench -

V.A.G 1576- , measuring range 75...400 Nm

♦ Spreader tool -3424-

♦ Press tool -3283-

♦ Gearbox jack -

V.A.G 1383 A-

Removing

– Remove trim cap from light-alloy wheels (puller in vehicle tool

kit).

– Lift vehicle far enough to relieve load on front wheels.

– Loosen 12-point nut.

– Remove wheels.

44 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Detach coupling rod from suspension strut on both sides of the

vehicle.

– Pull spring clip out from bracket and detach brake hose.

– Detach wire for speed sensor from suspension strut.

– Unbolt brake caliper from wheel bearing housing.

– Secure brake caliper to body with wire.

– Detach brake disc (disc is secured to hub with cross-head

bolt).

– Remove brake disc splash plate.

Audi TT 1999 ➤

– Mark positions of nuts.

– Remove bottom nuts from swivel joint.

– Detach wishbone from swivel joint.

– If swivel joint also has to be removed, refer to ⇒ page 20 .

– Unscrew nut from track rod ball joint.

Note!

Leave nut screwed several turns onto track rod ball joint to protect thread.

– Detach track rod from steering arm with puller Kukko 129/0.

– Detach connector from ABS wheel speed sensor.

2. Wheel bearing: exploded view 45

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Press out drive shaft.

♦ Ensure sufficient clearance when pressing out drive shaft.

– Remove drive shaft from wheel bearing housing and tie up.

– Remove bolt and nut securing wheel bearing housing/sus‐

pension strut.

Note correct position of bolt -1- when installing (install from back to front in direction of travel).

– Insert special tool 3424 into slot -arrow-.

– Turn ratchet through 90° and detach from 3424.

– Pull wheel bearing housing downwards off shock absorber

tube.

When installing, note the following points in particular: notes

⇒ page 33 and table ⇒ page 34 .

Refer to notes ⇒ page 33 and table ⇒ page 34

– Clean inner splines of wheel hub.

– Screw on new 12-point nut as far as possible.

– Secure brake caliper to wheel bearing housing ⇒ Brake sys‐

tem; Repair group 46; Servicing front brakes

– Insert connector and wire for ABS wheel speed sensor in

brackets.

– Lower vehicle, but make sure that wheels do not yet touch

ground.

Otherwise the wheel bearing could be subject to excessive load and damaged.

– Have a second mechanic press the brake pedal.

– Tighten 12-point nut.

2.5 Removing and installing front wheel bearing with wheel bearing housing re‐ moved

Refer to notes ⇒ page 33 and table ⇒ page 34

46 Rep. Gr.40 - Front suspension

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Special tools and workshop equipment required

♦ Press tool -VW 408 A-

♦ Thrust plate -40-105-

♦ Ring spanner (46 mm)

-3252-

♦ Assembly tool -3253/1-

♦ Thrust plate -VW 401-

♦ Grip tool -3423-

Audi TT 1999 ➤

Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

2. Wheel bearing: exploded view 47

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

♦ Thrust plate -VW 447 i-

♦ Press tool -VW 412-

♦ Press tool -VW 432-

♦ Press tool -VW 442-

♦ Removal and installing tool

-VW 459/2-

♦ Press tool -VW 407-

♦ 2 – Puller -Kukko 18/0- (items 1, 3 and 4 are not required).

48 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Pressing wheel hub out of wheel bearing housing

Removing and installing circlip

– Make sure circlip is seated properly when installing.

– Use commercially available circlip pliers to take out circlip.

Audi TT 1999 ➤

Pressing wheel bearing out of wheel bearing housing

Pulling off inner bearing race

– Insert special tool -3423- as shown.

– Screw cross-piece Kukko -18-0- into special tool -3423-.

– Mount special tool -40-105- on wheel hub and pull off inner

bearing race by turning spindle.

2. Wheel bearing: exploded view 49

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Coat entire inner surface of bore in wheel bearing housing with Molypaste (AOS 115 000 01).

Note!

A grease sachet containing 3g of grease is included with the wheel bearing set.

Pressing wheel bearing into wheel bearing housing

Note!

Circlip must be fitted ⇒ page 49 after pressing in wheel bearing.

Pressing wheel hub into wheel bearing

Note!

When pressing in wheel hub, make sure special tool bears on inner bearing race.

50 Rep. Gr.40 - Front suspension

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

3 Suspension strut: exploded view

1 - Self-locking hexagon nut, 60 Nm

2 - Stop shell

3 - Body (suspension turret)

4 - Hexagon nut, 60 Nm

❑ Always renew

5 - Suspension strut mounting

❑ Coat with assembly lu‐

bricant G 294 421 A1.

6 - Deep groove ball thrust bearing

7 - Spring plate

8 - Coil spring

❑ Note colour code ❑ Surface of spring coil

must not be damaged

❑ Removing and installing

suspension strut

⇒ page 52

❑ Removing and installing

coil spring ⇒ page 52

❑ Note different spring/

shock absorber ver‐ sions; refer to vehicle data sticker

⇒ page 153

9 - Protective sleeve

10 - Bump stop

11 - Shock absorber

❑ Different versions avail‐

able ⇒ ETKA

❑ The same version must be installed on both sides ❑ Note different spring/shock absorber versions; refer to vehicle data sticker ⇒ page 153

12 - Coupling rod

❑ Link between anti-roll bar and suspension strut

13 - Self-locking nut

❑ 90 Nm ❑ Always renew if removed

14 - Hexagon bolt, 10 Nm

15 - Bracket

❑ For brake hose

16 - Spring clip

17 - Clamp

18 - Hexagon bolt

❑ Always renew if removed

3. Suspension strut: exploded view 51

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

19 - Self-locking nut

❑ 60 Nm and turn 90° further ❑ Always renew if removed

20 - Wheel bearing housing

❑ Detaching suspension strut from wheel bearing housing ⇒ page 52 ❑ Wheel bearing: overview ⇒ page 33

Detaching suspension strut from wheel bearing housing

– Apply special tool -3424- as shown and force wheel bearing

housing apart.

3.1 Removing and installing suspension strut/coil spring

Special tools and workshop equipment required

♦ Shock absorber set -

T10001-

♦ Suspension strut tensioner

-V.A.G 1752/1-

♦ Socket, 21 mm -3186-

♦ Spring retainer -

V.A.G 1752/4-

♦ Spreader tool -3424-

♦ Gearbox jack -

52 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

V.A.G 1383 A-

Removing and installing suspension strut

There are various different shock absorber versions; refer to ⇒ ETKA

The same version must always be installed on both sides.

If a different version is already installed in the vehicle, the shock absorbers must be renewed on both sides.

– Remove wheels.

– Detach coupling rod from suspension strut on both sides of the

vehicle.

– Pull spring clip out from bracket and detach brake hose.

– Detach wire for speed sensor from suspension strut.

– Remove noise insulation panel.

– Unbolt drive shaft from flange shaft on gearbox.

Initial tightening torque: 10 Nm

Tightening torque: 70 Nm

– Tie up drive shaft with wire.

Audi TT 1999 ➤

– Remove bolt and nut securing wheel bearing housing/sus‐

pension strut. Note installation position of bolt. -See illustra‐ tion-.

– Insert special tool 3424 into slot -arrow-.

– Turn ratchet through 90° and detach from 3424.

– Press brake disc towards suspension strut by hand.

Otherwise the shock absorber tube can become misaligned in the bore of the wheel bearing housing.

– Pull wheel bearing housing downwards off shock absorber

tube.

3. Suspension strut: exploded view 53

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Tie wheel bearing housing to subframe with wire -arrow-.

Remove hexagon nut for upper shock absorber mounting

1 - Commercially available ratchet handle

2 - -T10001/8-

3 - -T10001/11-

4 - -T10001/5-

When installing, note the following points in particular:

– Before inserting suspension strut, coat suspension strut

mounting -arrows- with assembly lubricant G 294 421 A1.

– Install suspension strut and secure to suspension turret. Tight‐

ening torque: 60 Nm

1 - Commercially available ratchet handle

2 - -T10001/8-

3 - -T10001/11-

4 - -T10001/5-

54 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Locate suspension strut on wheel bearing housing.

– Remove wire from wheel bearing housing.

– Using gearbox jack, carefully raise wheel bearing housing until

bolt securing suspension strut/wheel bearing housing can be inserted.

Note!

Do not press against the ball joint with the gearbox jack.

– At the same time, push brake disc by hand towards suspen‐

sion strut.

Otherwise the shock absorber tube can become misaligned in the bore of the wheel bearing housing.

– Take out spreader tool -3424-.

The shock absorber must be fully inserted in the wheel bearing housing (as far as the stop).

Further installation of suspension strut is performed in reverse order.

Tightening torques: Coupling rod to suspension strut (use new nuts) 90 Nm Wheel bearing housing to suspension strut (use

60 Nm + 90°

new nut and bolt)

Audi TT 1999 ➤

Removing and installing coil spring

Note different spring/shock absorber versions; refer to vehicle data sticker ⇒ page 153

– Compress coil spring with suspension strut tensioner -

V.A.G 1752/1-- until the upper spring plate is free.

– Unscrew hexagon nut from piston rod.

– Take off individual parts of suspension strut and coil spring

with suspension strut tensioner -V.A.G 1752/1-- .

1 - Commercially available ratchet handle

2 - -T10001/8-

3 - -T10001/11-

4 - -T10001/5-

5 - Suspension strut tensioner -V.A.G 1752/1-

6 - Spring retainer -V.A.G 1752/4-

Special tool -3186- can also be used an alternative for the tools shown above.

3. Suspension strut: exploded view 55

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Ensure that coil spring is seated correctly in adapter -

V.A.G 1752/- 4 -arrow-.

Installing

– Fit coil spring with suspension strut tensioner -V.A.G 1752/1--

onto bottom spring plate.

The end of the coil spring must make contact with the stop -arrow-.

Tightening torques: Hexagon nut for upper shock absorber mounting

60 Nm

(use new nut) Hexagon nut for upper spring plate 60 Nm

Further installation of suspension strut is performed in reverse order.

56 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

4 Drive shafts

4.1 Removing and installing drive shaft (ver‐ sion with bolted flange on inner joint)

Refer to ⇒ page 2 , ⇒ page 33 and table ⇒ page 34

Removing

– Remove trim cap from light-alloy wheels (puller in vehicle tool

kit).

– Only loosen the securing nut (or bolt) 90°, otherwise the wheel

bearing will be damaged.

– Lift vehicle far enough to relieve load on front wheels.

– Have a second mechanic press the brake pedal.

– Loosen securing nut (bolt) completely.

– Remove wheel.

– Unbolt drive shaft from flange shaft on gearbox.

– Mark positions of nuts.

– Remove bottom nuts from swivel joint.

– Detach wishbone from swivel joint.

Audi TT 1999 ➤

– Press out drive shaft. Position tool as shown in illustration.

Note!

Ensure sufficient clearance when pressing out drive shaft.

– Take out drive shaft.

Installation is performed in reverse sequence; note the following:

Refer to notes ⇒ page 33 and table ⇒ page 34

– Clean inner splines of wheel hub.

– Screw on new 12-point nut or flange bolt as far as possible.

– Lower vehicle, but make sure that wheels do not yet touch

ground.

Otherwise the wheel bearing could be subject to excessive load and damaged.

– Have a second mechanic press the brake pedal.

– Tighten 12-point nut or flange bolt.

4. Drive shafts 57

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

4.2 Removing and installing drive shaft (ver‐ sion with splines on inner joint)

Refer to ⇒ page 2 , ⇒ page 33 and table ⇒ page 34

Removing

– Remove trim cap from light-alloy wheels (puller in vehicle tool

kit).

– Only loosen the securing nut (or bolt) 90°, otherwise the wheel

bearing will be damaged.

– Lift vehicle far enough to relieve load on front wheels.

– Have a second mechanic press the brake pedal.

– Loosen securing nut (bolt) completely.

– Remove wheel.

– Mark positions of nuts.

– Remove bottom nuts from swivel joint.

– Detach wishbone from swivel joint.

– Press out drive shaft. Position tool as shown in illustration.

Note!

♦

Ensure sufficient clearance when pressing out drive shaft.

♦

Do not allow the drive shaft to hang down under its own weight, as this would bend the inner joint too far and damage it.

A second person is required for the next step

58 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Place aluminium wedge -T10161- between gearbox housing

and inner triple roller joint.

– Force drive shaft out of gearbox with a firm blow to aluminium

wedge -T10161- .

– Take out drive shaft.

Installation is performed in reverse sequence; note the following:

Refer to notes ⇒ page 33 and table ⇒ page 34

– Clean inner splines of wheel hub.

– Circlip for drive shaft must always be renewed if it has been

removed.

– Screw in new flange bolt as far as possible.

– Lower vehicle, but make sure that wheels do not yet touch

ground.

Otherwise the wheel bearing could be subject to excessive load and damaged.

– Have a second mechanic press the brake pedal.

– Tighten flange bolt.

Audi TT 1999 ➤

4. Drive shafts 59

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

4.3 Servicing drive shaft with constant velocity joint

Grease quantity and type

Constant velocity joints are packed with grease G 000 603:

Grease of which in:

Outer joint Total quantity Joint Boot

∅ mm [g] [g] [g]

98 120 80 40

Inner joint

∅ mm

108 120 70 50

Regrease joint when renewing boot.

60 Rep. Gr.40 - Front suspension

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1 - Outer constant velocity joint

❑ Renew only as com‐

plete unit

❑ Removing ⇒ page 62 ❑ Installing ⇒ page 63 ❑ Greasing ⇒ page 60 ❑ Checking ⇒ page 64

2 - Hexagon bolt

❑ Always renew if re‐

moved

Tightening torque ⇒ page 35

Observe instructions for re‐ moving and installing

⇒ page 34

3 - 12-point nut (self-locking)

Refer to notes ⇒ page 33 and table ⇒ page 34

Audi TT 1999 ➤

Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

4 - Outer constant velocity joint

❑ Renew only as com‐

plete unit

❑ Removing ⇒ page 62 ❑ Installing: drive onto

shaft with plastic ham‐ mer until compressed circlip seats

5 - Circlip

❑ Always renew ❑ Insert in groove on shaft

6 - Spacer ring (plastic)

❑ Installation position

⇒ page 64

7 - Convex washer

❑ Installation position ⇒ page 64

8 - Hose clip

❑ Always renew ❑ Tightening ⇒ page 63

9 - Boot for constant velocity joint

❑ Check for splits and chafing ❑ Material: Hytrel (polyelastomer)

10 - Hose clip

❑ Always renew ❑ Tightening ⇒ page 64

11 - Profile shaft

12 - Multi-point socket-head bolt

Initial tightening torque: 10 Nm

Tightening torque: 70 Nm

4. Drive shafts 61

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

13 - Lock plate

14 - Boot for inner constant velocity joint

❑ Material: Rubber ❑ With vent hole ❑ Check for splits and chafing ❑ Drive off CV joint with a drift ❑ Apply sealant D 454 300 A2 between joint and cover ⇒ page 64 .

15 - Inner constant velocity joint

❑ Renew only as complete unit ❑ Pressing off ⇒ page 62 ❑ Pressing on ⇒ page 63 ❑ Greasing ⇒ page 60 ❑ Checking ⇒ page 65

16 - Circlip

❑ Renew ❑ Remove and install with -VW 161- a

17 - Cover

❑ Always renew ❑ Drive off CV joint with a drift ❑ Apply sealant D 454 300 A2 between joint and cover ⇒ page 64 .

Removing outer constant velocity joint

– Drive joint off drive shaft with a firm blow from an aluminium

hammer.

Pressing off inner constant velocity joint

Note!

♦

First drive off boot with drift.

♦

Support ball hub.

62 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Pressing on inner constant velocity joint

– Press on joint as far as stop.

– Engage circlip.

Note!

Chamfer on internal diameter of ball hub (splines) must face con‐ tact shoulder on drive shaft.

Installing outer constant velocity joint with flange bolt

– Screw old bolt into CV joint as shown.

– Use plastic hammer to drive joint onto shaft until circlip en‐

gages.

Audi TT 1999 ➤

Venting joint boot

The CV joint boot is often squashed when it is installed on the joint body. This creates a partial vacuum inside the boot which draws in a fold -arrow- whilst driving. For this reason, vent the boot to equalise pressure after installation by briefly lifting the lip at the small-diameter end.

Tightening hose clips on outer joint

– Apply pliers V.A.G 1682 as shown. Ensure that the jaws of the

pliers seat in the ends of the hose clip -arrows B-.

– Tighten hose clip by turning spindle with torque wrench (take

care to keep pliers straight).

Note!

♦

Due to the hard material of the CV joint boot (as opposed to rubber), a stainless steel hose clip is required; this can only be tightened using pliers -V.A.G 1682- .

♦

Tightening torque: 25 Nm.

♦

Use torque wrench with 5...50 Nm range (e.g. -V.A.G 1331- ).

♦

Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.

♦

If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip with the specified tightening torque.

4. Drive shafts 63

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Tightening hose clip at small diameter of boot

Installation position of spacer ring and convex washer (wheel end)

1 - Convex washer

2 - Spacer ring (plastic)

Coating sealing surface of cover and cap with D 454 300 A2.

– Apply sealant on clean surface of cover and cap (hatched

area). Route continuous bead of sealant (2...3 mm ∅) around inside of holes -arrow-.

– Align cover and cap with bolt holes and drive or push onto joint.

– Wipe off surplus sealant.

4.4 Checking outer constant velocity joint

The joint should be dismantled to renew dirty grease or for check‐ ing the balls and ball tracks for wear and damage.

Removing

– Before dismantling, mark position of ball hub in relation to ball

cage and joint body with an electric scriber or oil stone (arrow).

– Swivel ball hub and ball cage.

– Take out balls one after the other.

64 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Turn cage until two cage openings -arrow- are level with joint

body.

– Lift out cage together with hub.

– Swivel one segment of the hub into one of the cage openings.

– Pivot hub out of cage.

The 6 balls in each joint belong to one tolerance group. Check stub axle, hub, cage and balls for pitting and signs of seizure. Excessive backlash in the joint will cause knocking or jolts under load change; in such cases the joint must be renewed. Polished areas and ball track marks are not a reason for changing the joint.

Installing

– Pack half the total quantity of grease into the joint body.

– Fit cage with hub into joint body.

Audi TT 1999 ➤

Note!

Cage must be inserted in correct position (i.e. sides facing in same direction as original position).

– Press in the balls one after the other from opposite sides, tak‐

ing care to re-establish the original position of the hub relative to the cage and the joint body.

– Fit new circlip in shaft.

– Distribute remaining grease in boot.

4.5 Checking inner constant velocity joint

The joint should be dismantled to renew dirty grease or for check‐ ing the balls and ball tracks for wear and damage.

– Swivel ball hub and ball cage.

– Push out joint in direction of arrow.

– Push balls out of cage.

Note!

Ball hub and joint are paired and must be marked before disman‐ tling. Ensure the balls run in the same tracks after assembly.

4. Drive shafts 65

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Align ball hub with cage as shown -arrows- and pivot hub out

of cage.

– Check joint, ball hub, ball cage and balls for pitting and signs

of seizure.

Note!

Excessive backlash in the joint will cause knocking or jolts under load change. In such cases the joint must be renewed. Polished areas and ball track marks are not a reason for changing the joint.

Installing

– Insert hub into cage via the two chamfers. No specific instal‐

lation position is required. Push balls into cage.

– Insert hub with cage and balls at a right angle to the joint.

Note!

When inserting, ensure that the wide spacing -a- on the joint body is aligned with the narrow spacing -b- on the hub after swivelling in.

– Swivel in ball hub; at the same time the hub must be swivelled

out of the cage -arrows- far enough to allow the balls to fit into the ball tracks.

66 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Swivel in the hub with balls by applying firm pressure on the

cage -arrow-.

Checking function of constant velocity joint:

The constant velocity joint is correctly assembled if the ball hub can be moved by hand backwards and forwards over its entire range of axial movement.

4.6 Servicing drive shaft with triple roller inner joint

Special tools and workshop equipment required

♦ Pliers -V.A.G 1682-

♦ Pliers -3340-

♦ Thrust plate -VW 402-

♦ Press tool -VW 411- I

♦ Press tool -VW 412-

♦ Tube -VW 416b-

Audi TT 1999 ➤

4. Drive shafts 67

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

♦ Support sleeve -VW 522-

♦ Torque wrench -V.A.G 1332- (measuring range: 5...50 Nm)

Grease quantity and type

68 Rep. Gr.40 - Front suspension

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Audi TT 1999 ➤

Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Outer joints are packed with grease G 000 603:

Inner triple roller joints are packed with grease G 000 605:

Grease of which in:

Outer joint Total quantity Joint Boot

∅ mm [g] [g] [g]

88 100 50 50 98 120 80 40

Triple roller in‐

ner joint

∅ mm

72 110 70 40

Regrease joint if required when renewing the boot.

4. Drive shafts 69

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

1 - Outer constant velocity joint

❑ Renew only as com‐

plete unit ❑ Removing ⇒ page 62 ❑ Installing ⇒ page 63 and

⇒ page 63

❑ Greasing ⇒ page 68 ❑ Checking ⇒ page 64

2 - Hexagon bolt

❑ Always renew if re‐

moved

Tightening torque ⇒ page 35

Observe instructions for re‐ moving and installing

⇒ page 34

3 - Outer constant velocity joint

❑ Renew only as com‐

plete unit ❑ Removing ⇒ page 62 ❑ Installing: drive onto

shaft with plastic ham‐

mer until compressed

circlip seats ❑ Greasing ⇒ page 68 ❑ Checking ⇒ page 64

4 - 12-point nut (self-locking)

5 - Profile shaft

6 - Boot for triple roller joint

7 - Hose clip

8 - Multi-point socket-head bolt

Initial tightening torque: 10 Nm

Tightening torque: 70 Nm

9 - Joint body

10 - Triple roller spider

Chamfer -arrow- faces towards drive shaft splines

❑ Rollers are not removable

11 - Circlip

❑ Renew ❑ Insert in groove on shaft

12 - O-ring

❑ Renew

13 - Cover

❑ Renew

14 - Hose clip

❑ Always renew ❑ Tightening ⇒ page 72

70 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

15 - Boot for constant velocity joint

❑ Check for splits and chafing ❑ Material: Hytrel (polyelastomer)

16 - Hose clip

❑ Always renew ❑ Tightening ⇒ page 72

17 - Convex washer

❑ Installation position ⇒ page 72

18 - Spacer ring (plastic)

❑ Installation position ⇒ page 72

19 - Circlip

❑ Always renew ❑ Insert in groove on shaft

Removing outer constant velocity joint

– Drive joint off drive shaft with a firm blow from an aluminium

hammer.

Audi TT 1999 ➤

Venting joint boot

The CV joint boot is often squashed when it is installed on the

joint body. This creates a partial vacuum inside the boot which

draws in a fold -arrow- whilst driving. For this reason, vent the boot

to equalise pressure after installation by briefly lifting the lip at the

small-diameter end.

4. Drive shafts 71

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

Tightening hose clips on outer joint

– Apply pliers V.A.G 1682 as shown. Ensure that the jaws of the

pliers seat in the ends of the hose clip -arrows B-.

– Tighten hose clip by turning spindle with torque wrench (take

care to keep pliers straight).

Note!

♦

Due to the hard material of the CV joint boot (as opposed to rubber), a stainless steel hose clip is required; this can only be tightened using pliers -V.A.G 1682- .

♦

Tightening torque: 25 Nm.

♦

Use torque wrench with 5...50 Nm range (e.g. -V.A.G 1331- ).

♦

Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.

♦

If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip with the specified tightening torque.

Tightening hose clip at small diameter of boot

Installation position of spacer ring and convex washer

1 - Convex washer

2 - Spacer ring (plastic)

Dismantling and assembling inner triple roller joint

Dismantling

– Bend open retaining tabs slightly and lever off cover.

72 Rep. Gr.40 - Front suspension

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

– Mark positions of parts 1 ... 3 in relation to each other before

dismantling.

The joint may be noisy if these parts are not marked and rein‐

stalled in their original positions.

Use a waterproof felt-tip pen for marking.

– Remove rubber ring -arrow- from groove.

1 - Joint body

2 - Triple roller spider

3 - Drive shaft

The rollers must not be pressed off the triple roller spider.

– Remove circlip.

Audi TT 1999 ➤

– Open hose clip.

– Cut open joint boot and remove from shaft.

The rollers on the triple roller spider must not be pressed off or

damaged.

– Insert drive shaft in press.

4. Drive shafts 73

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Hold drive shaft, then press triple roller spider off drive shaft.

– Pull joint body off shaft.

– Clean shaft and joint body.

Assembling

– Clamp drive shaft in vice using soft jaws.

– Push new boot onto shaft.

– Push joint body onto shaft.

Installing triple roller spider

Chamfer on spider faces towards shaft and is used as an assem‐ bly aid.

– Fit triple roller spider onto shaft as per markings and drive

home onto stop.

– Install new circlip; ensure correct seating.

– Grease joint ⇒ page 68 .

– Slide joint body over rollers and hold in position.

– Install joint boot.

– Fit hose clip.

74 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Insert seal -arrow- into groove.

– Position cover and bend down retaining tabs.

4.7 Servicing drive shaft with triple roller joint AAR 3300i (bolted flange / splines on inner joint)

Grease filling of joints

Grease G 600 003 Outer joint

Total quantity 120 g In joint 80 g In boot 40 g Grease G 600 605 Triple roller joint Total quantity 130 g In joint 80 g In boot 50 g

Note!

Audi TT 1999 ➤

Regrease joint when replacing boot.

4. Drive shafts 75

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

1 - Hexagon bolt with washer

❑ Always renew if re‐

moved

❑ Loosening and tighten‐

ing ⇒ page 34

2 - Hose clip

❑ Renew ❑ Tightening ⇒ page 78 ,

⇒ page 78 or ⇒ page 78

3 - Boot for constant velocity joint

❑ Check for splits and

chafing

4 - Hose clip

❑ Renew ❑ Tightening ⇒ page 78

⇒ page 78

5 - Profile shaft

6 - Hose clip

❑ Renew ❑ Tightening ⇒ page 78 ,

⇒ page 78 or ⇒ page 78

7 - Boot for triple roller joint

❑ Check for splits and

chafing

8 - Triple roller spider with roll‐ ers

❑ Chamfer -arrow- faces

towards drive shaft splines

9 - Circlip

❑ Renew ❑ Insert in groove on shaft

10 - Multi-point socket-head bolt

❑ Initial tightening torque: 10 Nm ❑ Tightening torque (M8): 40 Nm ❑ Tightening torque (M10): 70 Nm

11 - Joint body (version with splines)

❑ Before installing, grease splines on stub shaft with G 052 735

12 - Circlip

❑ Renew ❑ Insert in groove on shaft

13 - Joint body (version with bolted flange)

14 - Hose clip

❑ Renew ❑ Tightening ⇒ page 78 ⇒ page 78

15 - Convex washer

❑ Installation position ⇒ page 77

76 Rep. Gr.40 - Front suspension

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

16 - Spacer ring (plastic)

❑ Installation position ⇒ page 77

17 - Circlip

❑ Renew ❑ Insert in groove on shaft

18 - Outer constant velocity joint

❑ Renew only as complete unit ❑ Removing ⇒ page 77 ❑ Checking ⇒ page 64 ❑ Greasing: see table ⇒ page 75 ❑ Installing: ❑ Drive joint onto shaft with plastic hammer until circlip engages

Removing outer constant velocity joint

– Drive joint off drive shaft with a firm blow from an aluminium

hammer.

Audi TT 1999 ➤

Installation position of spacer ring and convex washer

1 - Convex washer

2 - Spacer ring (plastic)

Venting rubber boot

The CV joint boot is often squashed when it is installed on the joint body. This creates a partial vacuum inside the boot which draws in a fold -arrow- whilst driving.

Therefore please note the following:

– Before tightening the hose clips, vent the boot to equalise

pressure by briefly lifting the lip.

4. Drive shafts 77

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Tightening large hose clip for rubber boot

Tightening stainless-steel hose clips for Hytrel boots

– Apply pliers V.A.G 1682 as shown. Ensure that the jaws of the

pliers seat in the ends of the hose clip -arrows B-.

– Tighten hose clip by turning spindle -A- with torque wrench

(take care to keep pliers straight).

♦ Tightening torque: 20 Nm

Note!

♦

Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary.

♦

If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip when applying the specified tightening torque.

Tightening small hose clip for rubber boot

Dismantling and assembling triple roller joint AAR 3300i

78 Rep. Gr.40 - Front suspension

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Special tools and workshop equipment required

♦ Thrust plate -VW 401-

♦ Thrust plate -VW 402-

♦ Press tool -VW 408 A-

♦ Press tool -VW 411-

♦ Tube -VW 416 B-

♦ Thrust plate -VW 447 H-

Audi TT 1999 ➤

Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

♦ Assembly tool -T10065-

Dismantling

– Open hose clip on shaft and push back boot.

– Pull joint body off drive shaft.

4. Drive shafts 79

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

– Remove circlip (use commercial-type pliers -1- or -

VW 161 A- ).

– Insert drive shaft in press.

– Press triple roller spider off drive shaft.

– Pull joint boot off shaft.

– Clean shaft, joint body and groove for seal.

Assembling

– Push small hose clip for boot onto shaft.

– Push joint boot onto shaft.

– Push joint body onto shaft.

Fitting triple roller spider (tapered drive shaft version):

♦ Chamfer on spider faces towards shaft and is used as an as‐

sembly aid.

– Fit triple roller spider on shaft and press on as far as stop.

Fitting triple roller spider (cylindrical drive shaft version):

80 Rep. Gr.40 - Front suspension

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

– Fit triple roller spider on shaft and press on as far as stop.

Both drive shaft versions (continued):

– Make sure pressure does not exceed 3.0 t!

– If necessary, coat splines of drive shaft and triple roller spider

with polycarbamide grease G 052 142 A2.

– Install circlip (ensure proper seating).

– Slide joint body over rollers and hold in position.

– Press 70 g of drive shaft grease from repair kit into triple roller

joint.

– Press 60 g of drive shaft grease from repair kit into boot.

– Install joint boot.

– Install hose clip.

Checking outer constant velocity joint

The joint should be dismantled to renew dirty grease or for check‐ ing the balls and ball tracks for wear and damage.

Removing

Audi TT 1999 ➤

– Before dismantling, mark position of ball hub in relation to ball

cage and joint body with an electric scriber or oil stone

-arrow-.

– Swivel ball hub and ball cage and take out balls one after the

other.

– Turn cage until two cage openings -arrow- are level with joint

body.

– Lift out cage together with hub.

4. Drive shafts 81

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Swivel one segment of the hub into one of the cage openings.

– Pivot hub out of cage.

Note!

♦

The 6 balls in each joint belong to one tolerance group. Check stub axle, hub, cage and balls for pitting and signs of seizure.

♦

Excessive backlash in the joint will cause knocking or jolts un‐ der load change; in such cases the joint must be renewed.

♦

Polished areas and ball track marks are not a reason for changing the joint.

Installing

Installation is performed in reverse sequence; note the following:

– Pack half the total quantity of grease into the joint body.

– Fit cage with hub into joint body.

Note!

Cage must be inserted in correct position (i.e. sides facing in same direction as original position).

– Press in the balls one after the other from opposite sides, tak‐

ing care to re-establish the original position of the hub relative to the cage and the joint body.

– Fit new circlip in shaft.

– Distribute remaining grease in boot.

82 Rep. Gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

42 – Rear suspension

1 Servicing rear axle (front-wheel drive

vehicles)

1.1 Removing and installing rear axle

Special tools and workshop equipment required

♦ Gearbox jack -V.A.G 1383 A-

Audi TT 1999 ➤

♦ Brake charge and bleed equipment -V. A. G 1869-

Removing

– Unscrew fasteners -1- to -8- and remove guard plate for rear

axle.

– Remove wheels.

1. Servicing rear axle (front-wheel drive vehicles) 83

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Unclip brake cables -arrows-.

– Unfasten clamps -2- of brake hose retainer and detach brake

lines from axle beam. Seal lines with plugs.

– Slacken bolts -A- and attach brake caliper housing to body with

wire.

– Detach connector -1- from speed sensor.

– Unclip speed sensor wire from bracket.

Note!

Use gearbox jack -V.A.G 1383-- with attachment -1359/2- when removing and installing axle beam.

– Remove bolt -2- on left and right sides.

– Lower gearbox jack and take out coil spring.

– Support rear axle.

Using gearbox jack -V.A.G 1383 A- (for example)

84 Rep. Gr.42 - Rear suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Remove bolts -1- for mounting bracket on rear axle on both

sides and lower rear axle.

Installing

Greasing bonded rubber bush

– Before installing rear axle, grease kidney-shaped cavities of

bonded rubber bushes with assembly paste G 052 150 A2.

Installation is carried out in the reverse order.

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.

After installation, check position of steering wheel by test-driving vehicle.

Wheel alignment must be checked and adjusted if steering wheel is not in central position.

Tightening torques: Shock absorber to axle beam (use new bolts) 40 Nm + 90° Mounting bracket to rear axle (use new nuts and

80 Nm

bolts)

Audi TT 1999 ➤

Brake caliper to axle beam (hexagon socket

65 Nm

head bolt)

1.2 Rear axle beam: exploded view

Note!

♦

The axle beam and stub axles must not be straightened or welded.

♦

Always renew self-locking nuts.

1. Servicing rear axle (front-wheel drive vehicles) 85

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

1 - Wheel bolt, 120 Nm

2 - Cross-head screw

3 - Brake disc

4 - Protective cap

❑ Always renew if re‐

moved

Proper sealing can only be achieved by installing a new protective cap.

This is essential for optimum function and service life.

5 - 12-point nut (self-locking), 220 Nm

❑ Always renew if re‐

moved

6 - Wheel hub with wheel bear‐ ing

Wheel bearing and wheel hub are combined in one housing.

This wheel bearing/hub unit is maintenance-free and has zero play. There is no provision for adjustment or repair.

❑ Removing and installing

⇒ page 97

7 - Hexagon bolt, 50 Nm and turn 90° further

❑ Always renew if re‐

moved

8 - Splash plate

9 - Bracket for handbrake cable

10 - Handbrake cable

11 - Self-locking nut, 45 Nm and turn 90° further

❑ Always renew if removed

12 - Hexagon bolt, 30 Nm and turn 90° further

❑ Always renew if removed ❑ 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.

This repair may only be carried out on two nuts per side!

13 - Hexagon bolt, 45 Nm and turn 90° further

❑ Always renew if removed

14 - Mounting bracket for rear axle

❑ After installation, check total toe setting of rear axle and align if necessary. ❑ If possible do not loosen when removing rear axle

15 - Bracket for handbrake cable

16 - Bonded rubber bush

❑ Removing and installing ⇒ page 88 ❑ Lubricate kidney-shaped cavities with assembly paste G 052 150 A2

86 Rep. Gr.42 - Rear suspension

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

17 - Axle beam

❑ Keep contact surface and tapped holes for stub axle free from paint and dirt.

18 - Speed sensor

19 - Hexagon socket head bolt, 8 Nm

20 - Hexagon bolt, 20 Nm and turn + 45° further

21 - Damper weight

22 - Spring plate

Material: Zinc

❑ Check spring plate for damage

23 - Coil spring

❑ Note different coil spring versions; see vehicle data sticker ⇒ page 153

24 - Spring plate

25 - Hexagon bolt, 40 Nm + 90°

❑ Always renew if removed

26 - Hexagon bolt, 30 Nm and turn 90° further

❑ Always renew if removed ❑ 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.

This repair may only be carried out on one thread per side!

27 - Shock absorber

Checking function ⇒ page 93

❑ Different versions available ⇒ ETKA ❑ The same version must be installed on both sides

28 - Hexagon nut

❑ Always renew if removed ❑ Vehicle must be standing on its wheels when tightening nut

29 - Stub axle

❑ Must not be straightened ❑ Recutting the thread is not permitted

30 - Stone deflector

31 - Hexagon socket head bolt, 65 Nm

❑ Always renew if removed

32 - Brake caliper

Explanatory notes on weight codes (PR Nos.)

To facilitate matching of running gear components, the spring/ shock absorber combinations are classified according to weight codes (PR numbers).

The spring/shock absorber combination installed in the vehicle is indicated by the corresponding PR number on the vehicle data sticker.

1. Servicing rear axle (front-wheel drive vehicles) 87

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Vehicle data sticker (example)

– -A- is the PR No. for the front axle

– -B- is the PR No. for the rear axle

The vehicle data sticker can be found in the spare wheel recess and in the Service Schedule.

The PR numbers can be used to identify the correct spring/shock absorber combination in the Parts catalogue.

1.3 Removing and installing bonded rubber bush

Special tools and workshop equipment required

♦ Assembly tool -3301-

♦ Assembly tool -3346-

♦ Press tool -3416/1-

♦ Press tool -3416/2-

♦ Support tube -3416/3-

♦ Multi-purpose tool -

VW 771-

88 Rep. Gr.42 - Rear suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

Removing

– Unclip brake cable -arrows-.

– Unfasten clamps -2- from brake hose retainer.

– Remove hexagon bolt -1- securing bonded rubber bush.

Note!

Place a soft wooden block (approx. 10 cm x 10 cm) between axle beam and body in order to insert special tool.

– Insert special tool and knock guide bush out of axle beam.

Installing

Face of bonded rubber bush has a marking -1-.

Audi TT 1999 ➤

This must align with the edge -arrow- of the trailing arm -2-.

– Identify position of mark -1- on bonded rubber bush.

– Attach special tool to bonded rubber bush.

1. Servicing rear axle (front-wheel drive vehicles) 89

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Now bring bonded rubber bush with special tool into position

at rear axle.

– Ensure that mark aligns with edge of trailing arm.

– Pull in bonded rubber bush by turning spindle.

– Check position of bonded rubber bush after installing.

Greasing bonded rubber bush

– Before installing rear axle, grease kidney-shaped cavities of

bonded rubber bushes with assembly paste G 052 150 A2.

Further installation of rear axle is performed in reverse order.

Tightening torque: Mounting bracket to rear axle (use new nuts and

bolts)

80 Nm

1.4 Removing and installing shock absorb‐ er/spring

Special tools and workshop equipment required

♦ Gearbox jack -V.A.G 1383 A-

♦ Shock absorber set -T10001-

90 Rep. Gr.42 - Rear suspension

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

Removing spring

– Detach connector -1- from speed sensor.

– Unclip speed sensor wire from bracket.

– With vehicle standing on its wheels, remove bolts -1-. If nec‐

essary, lift vehicle until bolts are accessible.

– Raise vehicle to working height, thus relieving load on coil

spring.

– Take out spring.

Installing spring

– Check whether lower spring plate (zinc) is damaged.

– Renew if necessary.

– Install spring together with upper spring plate.

Note installation position.

Audi TT 1999 ➤

End of spring -arrow- must lie against stop on spring plate.

1. Servicing rear axle (front-wheel drive vehicles) 91

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

– Use gearbox jack -V.A.G 1359/2-- to press rear axle upwards.

– Bolt shock absorber to body. Tightening torque: 30 Nm + 90°.

Use new bolts!

Removing shock absorber

– With vehicle standing on its wheels, remove bolts -1-. If nec‐

essary, lift vehicle until bolts are accessible.

– Raise vehicle to working height, thus relieving load on coil

spring.

– Remove hexagon bolt -2- securing shock absorber to axle.

For ease of illustration the procedure is shown with the wheel re‐ moved.

– Take out shock absorber.

Installation is carried out in the reverse order.

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.

Tightening torques: Shock absorber to rear axle (use new nuts/

40 Nm + 90° bolts). Load the rear of the vehicle with the weight of one person when tightening.

Shock absorber to body (use new bolts) 30 Nm + 90°

92 Rep. Gr.42 - Rear suspension

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

1.5 Shock absorbers: exploded view (front-wheel drive vehicles)

1 - Gas-filled shock absorber

❑ Different versions avail‐

able ⇒ ETKA

❑ The same version must

be installed on both sides

Checking function

Compress shock absorber by hand. It should be possible to press in the piston rod smoothly and with uniform force over the full travel.

The piston rod will return to its initial position if there is sufficient gas pressure in the shock absorber.

If the piston rod does not return to its initial position by itself, the shock absorber may still be serviceable, provided there is no loss of fluid.

1. Servicing rear axle (front-wheel drive vehicles) 93

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Audi TT 1999 ➤ Running gear, front-wheel drive and four-wheel drive - Edition 07.2003

2 - Protective cap

3 - Protective tube

4 - Bump stop

5 - Shock absorber mounting

6 - Self-locking hexagon nut, 25 Nm

❑ Always renew if re‐

moved

❑ Removing ⇒ page 94

7 - Cover

Removing hexagon nut from shock absorber

1 - Commercially available ratchet handle

2 - Socket -T10001/9-

3 - -T10001/11-

4 - Socket -T10001/1-

Special tool 3079 can also be used.

94 Rep. Gr.42 - Rear suspension

Audi TT 15 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Technical data

1.1 Running gear

1.2 Steering

2 General notes:

3 Securing subframe to body

3.1 Repairing damaged threads

4.1 Releasing gas in front gas-filled shock absorbers

4.2 Releasing gas in rear gas-filled shock absorbers

4.3 Draining power steering box

5 Checking shock absorbers

5.1 Leaks at shock absorbers

5.2 Noises from shock absorbers

40 – Front suspension

1 Subframe: exploded view

1.2 Exploded view of components

1.3 Removing and installing anti-roll bar

1.4 Vehicle level sender in vehicles with automatic headlight range control

1.5 Checking swivel joint

1.6 Removing and installing swivel joint

1.7 Removing and installing wishbone

1.8 Renewing wishbone bushes

1.9 Removing and installing subframe

1.10 Renewing subframe bushes

2 Wheel bearing: exploded view

2.1 Drive shaft / wheel hub splines

2.2 Exploded view of components

2.4 Removing and installing wheel bearing housing

3 Suspension strut: exploded view

3.1 Removing and installing suspension strut/coil spring

4 Drive shafts

4.3 Servicing drive shaft with constant velocity joint

4.4 Checking outer constant velocity joint

4.5 Checking inner constant velocity joint

4.6 Servicing drive shaft with triple roller inner joint

4.7 Servicing drive shaft with triple roller joint AAR 3300i (bolted flange / splines on inner joint)

42 – Rear suspension

1.1 Removing and installing rear axle

1. Servicing rear axle (front-wheel drive vehicles) 83

1.2 Rear axle beam: exploded view

1.3 Removing and installing bonded rubber bush

1.5 Shock absorbers: exploded view (front-wheel drive vehicles)