Audi TT 57 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 2007 ➤
Running gear, front-wheel drive and four-wheel drive
Edition 08.2010
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT00120
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 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Proper disposal of fluid-filled components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Releasing gas in gas-filled shock absorbers (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Releasing gas in gas-filled shock absorbers (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Releasing gas in Audi magnetic ride shock absorbers (front) . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Releasing gas in Audi magnetic ride shock absorbers (rear) . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Checking shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Leaks at shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Checking shock absorbers when removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Checking shock absorbers on shock tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Repairing threads in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Lifting suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Exploded views of front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender . . . . . . . . . . . . . . . . . . 14
2.1 Exploded view of subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender . . . . 15
2.2 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Servicing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Locating subframe in position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Removing and installing wishbone and mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7 Renewing bonded rubber bush in wishbone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8 Renewing mounting bracket for wishbone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.10 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.11 Removing and installing front left vehicle level sender G78 and front right vehicle level sender
G289 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Wheel bearing housing, wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Exploded view of wheel bearing housing and wheel bearing unit . . . . . . . . . . . . . . . . . . . . 39
3.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Audi magnetic ride (AMR) - electronic damping control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Overview of Audi magnetic ride (AMR) - electronic damping control . . . . . . . . . . . . . . . . . . 45
4.2 Removing and installing electronically controlled damping control unit J250 . . . . . . . . . . 46
4.3 Procedure for re-adapting reference position with vehicle diagnostic, testing and information
system VAS 5051B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 Suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1 Exploded view of suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 Servicing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 General notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 Loosening and tightening hexagon bolt securing drive shaft to wheel hub . . . . . . . . . . . . 56
6.3 Loosening and tightening twelve-point bolt securing drive shaft to wheel hub . . . . . . . . . . 56
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 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
6.4 Removing and installing drive shaft (version with bolted flange on inner joint) . . . . . . . . . . 58
6.5 Removing and installing drive shaft with sliding CV joint (version with splines on inner
joint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.6 Removing and installing drive shaft with triple roller joint AAR 3300i (with splines for stub
shaft on gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.7 Removing and installing drive shaft with triple roller joint AAR 3300i (with splines for insertion
in gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.8 Servicing drive shaft (sliding inner CV joint with 100 mm dia.) . . . . . . . . . . . . . . . . . . . . . . 74
6.9 Servicing drive shaft (sliding inner CV joint with 108 mm dia.) . . . . . . . . . . . . . . . . . . . . . . 82
6.10 Servicing drive shaft (sliding inner CV joint with splines, 100 mm dia.) . . . . . . . . . . . . . . . . 88
6.11 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.12 Checking inner sliding CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.13 Servicing drive shaft with triple roller joint AAR 2600i . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.14 Dismantling and assembling drive shaft with triple roller joint AAR 2600i . . . . . . . . . . . . . . 100
6.15 Servicing drive shaft with triple roller joint AAR 3300i (with splines for insertion in gearbox)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.16 Servicing drive shaft with triple roller joint AAR 3300i (with splines for stub shaft on
gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1 General notes on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 General notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.3 Repairing damaged threads in longitudinal member (subframe to body) . . . . . . . . . . . . . . 117
1.4 Lifting suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.5 Overview of rear axle (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Overview of rear axle (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2 Subframe, diagonal strut, lower transverse link, upper transverse link, track rod, vehicle level
sender (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.1 Exploded view of subframe, diagonal strut, lower transverse link, upper transverse link, track
rod, vehicle level sender (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.2 Removing and installing subframe with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.3 Removing and installing diagonal struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.5 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.7 Removing and installing rear left vehicle level sender G76 and rear right vehicle level sender
G77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3 Wheel bearing housing, wheel bearing unit, trailing arm with mounting bracket, stone
deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.1 Exploded view of wheel bearing housing, wheel bearing unit, trailing arm with mounting
bracket, stone deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 142
3.4 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.5 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 147
3.6 Servicing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.7 Removing and installing stone deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4 Shock absorbers, coil springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.1 Exploded view of shock absorbers, coil springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.2 Removing and installing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.3 Servicing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.4 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.1 Exploded view of anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
6 Subframe, lower transverse link, upper transverse link, track rod, vehicle level sender (four-
wheel drive) - Coupé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.1 Exploded view of subframe, lower transverse link, upper transverse link, track rod, vehicle
level sender (four-wheel drive) - Coupé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.2 Removing and installing subframe with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.3 Removing and installing subframe bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6.5 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.7 Removing and installing rear left vehicle level sender G76 and rear right vehicle level sender
G77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7 Subframe, diagonal struts, cross member, lower transverse link, upper transverse link, track
rod, vehicle level sender (four-wheel drive) - Roadster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7.1 Exploded view of subframe, diagonal struts, cross member, lower transverse link, upper
transverse link, track rod, vehicle level sender (four-wheel drive) - Roadster . . . . . . . . . . 181
7.2 Removing and installing diagonal struts - Roadster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.3 Removing and installing cross member - Roadster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8 Wheel bearing housing, wheel bearing unit, trailing arm with mounting bracket . . . . . . . . 185
8.1 Exploded view of wheel bearing housing, wheel bearing unit, trailing arm with mounting
bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.3 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 191
8.4 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8.5 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 195
8.6 Servicing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
9 Shock absorbers, coil springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
9.1 Exploded view of shock absorbers, coil springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
9.2 Removing and installing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.3 Servicing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9.4 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
10 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
10.1 Exploded view of anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
10.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11 Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
11.1 General notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
11.2 Loosening and tightening hexagon bolt securing drive shaft to wheel hub . . . . . . . . . . . . 210
11.3 Loosening and tightening twelve-point bolt securing drive shaft to wheel hub . . . . . . . . . . 211
11.4 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
11.5 Servicing drive shaft with outer constant velocity joint, 90 mm diameter . . . . . . . . . . . . . . 214
11.6 Servicing drive shaft with outer constant velocity joint, 82 mm diameter . . . . . . . . . . . . . . 222
11.7 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
11.8 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2 Tyre monitor display (TMD+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.1 General notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.2 Removing and installing tyre pressure monitoring control unit 2 J793 . . . . . . . . . . . . . . . . 233
3 Tyre pressure monitoring system (TPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.2 Tyre pressure monitoring system - exploded view of components . . . . . . . . . . . . . . . . . . 236
3.3 Operation of tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.4 Removing and installing tyre pressure monitor control unit J502 . . . . . . . . . . . . . . . . . . . . 238
3.5 Exploded view of tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3.6 Removing and installing tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3.7 Changing a tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Contents iii
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
4 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.2 Wheel alignment must be checked: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.3 Explanatory notes on weight codes used in production (PR numbers) . . . . . . . . . . . . . . . . 244
4.4 Test requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.5 Wheel alignment specifications, front-wheel drive and four-wheel drive (Coupé/Roadster)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.6 Measurement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.7 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.8 Adjusting camber at rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.9 Adjusting toe setting at rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.10 Adjusting toe setting at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.1 Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.3 Bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.5 Guided Fault Finding, Vehicle Self-Diagnosis and Test Instruments . . . . . . . . . . . . . . . . . . 252
2 Steering wheel with airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.1 Steering wheel with airbag - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.2 Removing and installing steering wheel with airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3 Steering column, mounting bracket with strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3.1 Steering column and mounting bracket with strut (LHD vehicles) - exploded view . . . . . . 255
3.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3.4 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3.5 Removing and installing mounting bracket with strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3.6 Steering column and mounting bracket with strut (RHD vehicles) - exploded view . . . . . . 262
4 Electro-mechanical steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4.1 Differences between steering boxes (generations 2 and 3) . . . . . . . . . . . . . . . . . . . . . . . . 264
4.2 Electro-mechanical steering box (LHD vehicles) - exploded view . . . . . . . . . . . . . . . . . . . . 266
4.3 Removing and installing electro-mechanical steering box . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4.4 Exploded view - servicing electro-mechanical steering box . . . . . . . . . . . . . . . . . . . . . . . . 272
4.5 Removing and installing rubber boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.7 Removing and installing bonded rubber bush for generation 2 steering box . . . . . . . . . . . . 281
4.8 Renewing sensor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
4.9 Renewing and adjusting hydraulic thrust piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.10 Renewing and adjusting thrust piece at steering pinion end . . . . . . . . . . . . . . . . . . . . . . . . 291
4.11 Removing and installing steering pinion with steering moment sender G269 . . . . . . . . . . 298
4.12 Electro-mechanical steering box (RHD vehicles) - exploded view . . . . . . . . . . . . . . . . . . . . 302
iv Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
00 – Technical data
1 Technical data
⇒ „1.1 Running gear“, page 1
⇒ „1.2 Steering“, page 1
⇒ „1.3 Wheels, tyres“, page 1
1.1 Running gear
Audi TT 2007 ➤
Front axle
Rear axle
Wheelbase mm 2467
Track width (front/rear)
1) Front/rear track width only applicable to tyre size 225/55/R16 on 7.5Jx16 ET45
rims (ET= rim offset)
1)
mm 1572 / 1558
Four-link suspension with separate spring/shock absorber layout
Front-wheel drive and four-wheel drive
MacPherson struts with bottom wishbones
Subframe
Anti-roll bar
Tubular anti-roll bar
1.2 Steering
Steering
box
Maximum steering angle at in‐
side wheel
Turning circle diameter approx. 10.9 m
Electro-mechanically assisted, maintenance-free rack-and-pinion steering
Front-wheel drive and four-wheel drive
36° 48'
1.3 Wheels, tyres
For general information on wheel/tyre combinations, winter tyres,
snow chains and recommended tyre makes, refer to ⇒ Wheel/
Tyre Guide .
1. Technical data 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
2 Proper disposal of fluid-filled compo‐
nents
⇒ „2.1 Releasing gas in gas-filled shock absorbers (front)“,
page 2
⇒ „2.2 Releasing gas in gas-filled shock absorbers (rear)“,
page 3
⇒ „2.3 Releasing gas in Audi magnetic ride shock absorbers
(front)“, page 3
⇒ „2.4 Releasing gas in Audi magnetic ride shock absorbers
(rear)“, page 4
2.1 Releasing gas in gas-filled shock ab‐
sorbers (front)
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.
WARNING
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 fully 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
fluid comes out.
2 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
2.2 Releasing gas in gas-filled shock ab‐
sorbers (rear)
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.
WARNING
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 fully 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
fluid comes out.
Audi TT 2007 ➤
2.3 Releasing gas in Audi magnetic ride shock absorbers (front)
– Clamp magnetic ride shock absorber vertically in a vice.
WARNING
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.
– Drill a second 6 mm ∅ hole -arrow B- through outer tube 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
fluid comes out.
2. Proper disposal of fluid-filled components 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
2.4 Releasing gas in Audi magnetic ride shock absorbers (rear)
– Clamp magnetic ride shock absorber vertically in vice with pis‐
ton rod facing downwards.
WARNING
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.
– Drill a second 6 mm ∅ hole -arrow B- through outer tube 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
fluid comes out.
4 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
3 Checking shock absorbers
⇒ „3.1 Leaks at shock absorbers“, page 5
⇒ „3.2 Checking shock absorbers when removed“, page 5
⇒ „3.3 Checking shock absorbers on shock tester“, page 6
3.1 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 seal) down to the bottom spring plate
-arrow-.
Audi TT 2007 ➤
3.2 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.
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.
3. Checking shock absorbers 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
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.
3.3 Checking shock absorbers on shock tester
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.
♦
Vehicle stationary.
♦
Correct tyre inflation pressure.
♦
Wheels of vehicle in a central and straight position on the tyre
contact plates.
♦
Front wheels in straight-ahead position.
♦
Handbrake not applied, brake pedal not depressed.
♦
Ignition on.
♦
Test mode active on vehicles with Audi magnetic ride (AMR)
- electronic damping control.
Activating test mode for Audi magnetic ride (AMR) - electronic
damping control
– Press shock absorber damping adjustment button -E387-
⇒ page 45 in centre console and hold for over 5 seconds.
Diode in shock absorber damping adjustment button -E387flashes during test mode.
– The test mode is deactivated when shock absorber damping
adjustment button -E387- ⇒ page 45 is pressed again, when
the ignition is switched off, or when the vehicle is driven at a
speed of at least 10 km/h.
Test results
The condition of the shock absorbers can only be evaluated as
follows:
♦ Satisfactory damping effect
or
♦ Unsatisfactory damping effect
6 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
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 stated values are exceeded, the
shock absorber action has deteriorated to such an extent that re‐
placement is recommended.
Example:
Maximum value = 70
♦ a = higher than 70: unsatisfactory damping effect
♦ a = lower than 70: satisfactory damping effect
Maximum values „a“ in mm
Audi TT 2007 ➤
Note
♦
If the reading is higher than the maximum value „a“ listed in
the table, the damping effect is unsatisfactory ⇒ renew the
shock absorber.
♦
If the reading is lower than the maximum value „a“ listed in the
table, the damping effect is satisfactory ⇒ the shock absorber
does not have to be renewed.
Front axle Damping effect
Inadequate Adequate
Standard running gear (1BA)
a = Greater than 60 a = Less than 60
Sports running gear (1BV) a = Greater than 60 a = Less than 60
Sports running gear (1BD) a = Greater than 60 a = Less than 60
Rear axle Damping effect
Inadequate Adequate
Standard running gear
(1BA)
a = Greater than60a = Less than
60
Sports running gear (1BV) a = Greater than60a = Less than
60
Sports running gear (1BD) a = Greater than60a = Greater
than 60
Vehicles with Audi magnetic ride (AMR) - electronic damping
control
Note
These values apply only when the test mode is activated
⇒ page 6 (in test mode, a diode flashes in the shock absorber
damping adjustment button -E387- ⇒ page 45 ).
3. Checking shock absorbers 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
Front axle Damping effect
Inadequate Adequate
Sports running gear (1BL)
a = Greater than 50 a = Less than 50
Sports running gear (1BQ) a = Greater than 50 a = Less than 50
Rear axle Damping effect
Inadequate Adequate
Sports running gear (1BL)
a = Greater than50a = Less than
50
Sports running gear (1BQ) a = Greater than50a = Less than
50
8 Rep. gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
40 – Front suspension
1 General notes
⇒ „1.1 General information“, page 9
⇒ „1.2 Contact corrosion“, page 10
⇒ „1.3 Repairing threads in longitudinal member“, page 10
⇒ „1.4 Lifting suspension to unladen position“, page 11
⇒ „1.5 Exploded views of front axle“, page 13
1.1 General information
All contact surfaces must be cleaned when installing wax-coated
components. The contact surfaces must be free of wax and
grease.
Tightening torques refer to unoiled bolts and nuts.
Always renew self-locking bolts/nuts.
Always renew bolts and nuts which are tightened by turning
through a specified angle.
Load-bearing components and other suspension parts must not
be welded or straightened.
Do not subject coil springs to hammer blows or weld splashes and
do not make any new colour markings.
Do not perform welding or cutting operations (using power grind‐
ers) near the coil springs or suspension struts. Cover up coil
springs or suspension struts if necessary.
Make sketches or take photographs when unfastening or remov‐
ing and installing hydraulic or pneumatic pipes or electrical wires.
This ensures re-installation at the original location.
Any cable ties, brackets or fasteners removed during repair work
must be re-attached at their original standard locations.
Before fitting the outer joint in the wheel hub, apply a thin coat of
assembly paste to the splines on the outer joint ⇒ Electronic parts
catalogue .
When working on the vehicle, do not allow the drive shafts to hang
down under their own weight and never let the joints bend to such
an extent that they contact the end stop.
Do not attempt to move the vehicle without the drive shafts fitted;
this would 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 120 Nm (twelve-point bolt) or 200 Nm
(hexagon bolt).
Bonded rubber bushes can only be turned to a limited extent. The
suspension must therefore always be in the unladen position or
the reference position when the suspension link attachments are
tightened.
♦ Lifting suspension to unladen position (vehicles with coil
springs)
⇒ „1.4 Lifting suspension to unladen position“, page 11
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,
Audi TT 2007 ➤
1. General notes 9
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Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
bolts and nuts must then be fully tightened by turning them
through the specified angle.
WARNING
All bolts and nuts must be fully tightened according to specifi‐
cations before the vehicle is driven on public roads.
1.2 Contact corrosion
Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers ...) are used.
For this reason, all the fasteners on the vehicle have a special
surface coating.
In addition, rubber parts, plastic parts and adhesives are made of
non-conductive material.
Always install new parts as listed in the Parts catalogue if you are
not sure whether used parts can be refitted.
Note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage resulting from contact corrosion is not covered under
the warranty.
1.3 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.
WARNING
Always wear safety goggles when drilling.
♦ Have all thread repairs checked by foreman or supervisor.
♦ The thread insert must be of the same length as the thread in
the body.
♦ Repair any damage to underseal ⇒ Body Repairs; Rep. gr.
00 ; Corrosion protection measures
10 Rep. gr.40 - Front suspension
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Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
1.4 Lifting suspension to unladen position
Special tools and workshop
equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Tensioning strap -T10038-
♦ Support -T10149-
Audi TT 2007 ➤
Note
All bolts on running gear components with bonded rubber bushes
must always be tightened with the suspension in the unladen po‐
sition (vehicle unladen).
Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension components
with bonded rubber bushes must be brought into a position cor‐
responding to the normal position of the unladen vehicle while
driving (unladen position).
Otherwise, the bush would be subject to torsion loading and its
service life would be shortened.
This position can be simulated on the lifting platform by raising
the appropriate part of the suspension with the engine and gear‐
box jack -V.A.G 1383 A- and support -T10149- .
1. General notes 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
– Before commencing work, use measuring tape or similar to
measure dimension -a- from wheel centre to lower edge of
wheel housing.
This measurement must be taken with the suspension in the un‐
laden position (vehicle unladen).
– Make a note of the measured value. This will be needed when
tightening the bolts and/or nuts on the suspension.
Before raising wheel unit, secure vehicle to arms of lifting platform
using tensioning straps -T10038- .
If vehicle is not secured, there is a risk of it slipping off the lifting
platform.
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support -T10149- to wheel hub using wheel bolt.
– Raise wheel bearing housing with engine and gearbox jack -
V.A.G 1383 A- until distance -a- is obtained.
The bolts/nuts on the relevant suspension mountings must not be
tightened until the distance -a- between the wheel centre and the
lower edge of the wheel housing is the same as the distance
measured before commencing work.
WARNING
♦ Do not lift or lower the vehicle while the engine/gearbox
jack is under the vehicle.
♦ Do not leave engine and gearbox jack -V.A.G 1383 A- un‐
der vehicle for longer than necessary.
– Tighten relevant bolts/nuts.
– Lower wheel bearing housing.
– Pull out engine/gearbox jack from under vehicle.
– Remove support -T10149- .
12 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 08.2010
1.5 Exploded views of front axle
I -
⇒ „2 Subframe, anti-roll bar,
wishbone, swivel joint, vehicle
level sender“, page 14
II -
⇒ „3 Wheel bearing housing,
wheel bearing unit“,
page 39
III -
⇒ „4 Audi magnetic ride (AMR)
- electronic damping control“,
page 45
IV -
⇒ „5 Suspension strut“,
page 48
V -
⇒ „6 Drive shafts“, page 55
Audi TT 2007 ➤
1. General notes 13
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 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
2 Subframe, anti-roll bar, wishbone,
swivel joint, vehicle level sender
⇒ „2.1 Exploded view of subframe, anti-roll bar, wishbone, swivel
joint, vehicle level sender“, page 15
⇒ „2.2 Removing and installing subframe“, page 17
⇒ „2.3 Servicing subframe“, page 22
⇒ „2.4 Locating subframe in position“, page 25
⇒ „2.5 Removing and installing anti-roll bar“, page 26
⇒ „2.6 Removing and installing wishbone and mounting bracket“,
page 27
⇒ „2.7 Renewing bonded rubber bush in wishbone“, page 31
⇒ „2.8 Renewing mounting bracket for wishbone“, page 34
⇒ „2.9 Removing and installing swivel joint“, page 35
⇒ „2.10 Checking swivel joint“, page 37
⇒ „2.11 Removing and installing front left vehicle level sender G78
and front right vehicle level sender G289 “, page 37
14 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 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
2.1 Exploded view of subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender
1 - Nut
❑ 65 Nm
❑ When tightening, coun‐
terhold multi-point sock‐
et of joint pin
❑ Always renew if re‐
moved
2 - Anti-roll bar
❑ Removing and installing
⇒ page 26
❑ Different versions possi‐
ble. For correct version
refer to ⇒ Electronic
parts catalogue „ETKA“
3 - Coupling rod
❑ Link between anti-roll
bar and suspension
strut
4 - Nut
❑ 65 Nm
❑ When tightening, coun‐
terhold multi-point sock‐
et of joint pin
❑ Always renew if re‐
moved
5 - Mounting bracket
❑ Locating in position
⇒ page 26
❑ With bonded rubber
bush
❑ Renewing mounting
bracket for wishbone
⇒ page 34
6 - Bolt
❑ 50 Nm + 90°
❑ Always renew if removed
7 - Bolt
❑ 70 Nm + 90°
❑ Always renew if removed
8 - Bolt
❑ 9 Nm
9 - Front left vehicle level sender -G78- and front right vehicle level sender -G289-
❑ Removing and installing ⇒ page 37
10 - Wishbone
❑ Removing and installing wishbone and mounting bracket ⇒ page 27
❑ Renewing bonded rubber bush for wishbone ⇒ page 31
❑ Renewing mounting bracket for wishbone ⇒ page 34
11 - Retaining plate
❑ Always renew if removed
2. Subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender 15
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
12 - Nut
❑ 20 Nm + 90°
❑ Always renew if removed
13 - Swivel joint
❑ Removing and installing ⇒ page 35
❑ Checking ⇒ page 37
14 - Nut
❑ 40 Nm + 45°
❑ Always renew if removed
15 - Nut
❑ 9 Nm
16 - Bolt
❑ 70 Nm + 90°
❑ Different country-specific versions are possible; for correct version, refer to ⇒ Electronic parts catalogue
„ETKA“
❑ Note different thread lengths
❑ Positioned with indentation on bolt head at rear underbody attachment point
❑ Always renew if removed
17 - Bolt
❑ 70 Nm + 90°
❑ Different country-specific versions are possible; for correct version, refer to ⇒ Electronic parts catalogue
„ETKA“
❑ Always renew if removed
18 - Bolt
❑ 50 Nm + 90°
❑ Attachment for steering box
❑ Always renew if removed
19 - Bolt
❑ 20 Nm + 90°
❑ Attachment for anti-roll bar
❑ Always renew if removed
20 - Bolt
❑ 70 Nm + 180°
❑ Always renew if removed
❑ Suspension must be in unladen position when tightening ⇒ page 11
21 - Bolt
❑ 100 Nm + 90°
❑ Do not tighten until pendulum support is bolted to gearbox
❑ Always renew if removed
22 - Bonded rubber bush (bottom) for pendulum support
❑ Removing and installing ⇒ page 22
23 - Pendulum support
❑ Bolt to gearbox first, then to subframe
❑ Different versions are possible; for correct version, refer to ⇒ Electronic parts catalogue „ETKA“
24 - Bolt
❑ Tightening torque for vehicles with manual gearbox ⇒ Rep. gr. 34
❑ Tightening torque for vehicles with automatic gearbox ⇒ Rep. gr. 37
16 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 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
25 - Bolt
❑ Tightening torque for vehicles with manual gearbox ⇒ Rep. gr. 34
❑ Tightening torque for vehicles with automatic gearbox ⇒ Rep. gr. 37
26 - Subframe
❑ Removing and installing ⇒ page 17
❑ Servicing subframe ⇒ page 22
❑ Locating subframe in position ⇒ page 25
❑ Different versions possible. For correct version refer to ⇒ Electronic parts catalogue „ETKA“
27 - Bonded rubber bush (top) for pendulum support
❑ Removing and installing ⇒ page 22
2.2 Removing and installing subframe
Special tools and workshop equipment required
♦ Locating pins -T10096-
♦ Engine and gearbox jack -V.A.G 1383 A-
♦ Torque wrench -V.A.G 1331-
2. Subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender 17
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 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
♦ Torque wrench -V.A.G 1332-
Removing
Note
The subframe is removed together with the anti-roll bar and wish‐
bones.
– Remove wheels.
– Detach noise insulation (bottom) ⇒ Rep. gr. 66 .
– Remove frame for noise insulation ⇒ Rep. gr. 50 .
– Remove bolts -arrows- for exhaust bracket.
– Remove nut -1-.
18 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 08.2010
– On vehicles with vehicle level sender, unplug connector and
unscrew nut from linkage at wishbone.
– Unscrew bolts -13- and remove pendulum support from gear‐
box.
Audi TT 2007 ➤
– Unplug connector -1- for oil level and oil temperature sender
-G266- and unclip wiring from bracket -2-.
– Mark positions of nuts -arrows- with felt pen on both sides of
vehicle.
– Remove nuts -arrows- on both sides of vehicle.
– Pull wishbone out of swivel joint.
– Locate subframe in position ⇒ page 25 .
2. Subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
– Remove bolts -3- and -6- for steering box.
– Position engine and gearbox jack -V.A.G 1383 A- with suitable
wooden block -1- under subframe and press subframe up‐
wards lightly.
– Remove bolts -4- and -5-.
– Lower subframe with attached components approx. 30 mm
and pry threaded sleeves for steering box out of holes in sub‐
frame.
– Secure steering box to body.
20 Rep. gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
– Detach cable guide from subframe -arrow-.
– Lower subframe with attached components.
Installing
Installation is performed in reverse sequence; note the following:
Tightening torques
⇒ „2.1 Exploded view of subframe, anti-roll bar, wishbone, swivel
joint, vehicle level sender“, page 15
Tightening torques
⇒ „4 Electro-mechanical steering box“, page 264
Threaded sleeves of steering box must be located in subframe
holes.
– Always renew retaining plate if removed
⇒ Item 11 (page 15) .
– Align position of nuts -arrows- according to markings made on
removal and tighten nuts.
– Install frame for noise insulation ⇒ Rep. gr. 50 .
– Install noise insulation ⇒ Rep. gr. 66 .
– On vehicles with electronic damping control (Audi magnetic
ride), re-adapt reference position ⇒ Vehicle diagnostic, testing
and information system VAS 5051.
– On vehicles with automatic headlight range control, carry out
basic adjustment of headlights ⇒ Rep. gr. 94 .
– Check and adjust wheel alignment as required, see chart
⇒ page 243 .
Audi TT 2007 ➤
2. Subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
2.3 Servicing subframe
Special tools and workshop
equipment required
♦ Removal tool -3372-
♦ Thrust plate -VW 401-
♦ Press tool -VW 407-
♦ Press tool -VW 432-
♦ Assembly tool -T10214-
♦ Assembly tool -T10267-
♦ Tube from assembly tool -T10244/3-
– Remove subframe ⇒ page 17 .
– Detach pendulum support from subframe.
22 Rep. gr.40 - Front suspension
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
Pressing out bonded rubber bush
– Attach assembly tool -T10267- -4- to subframe. Secure re‐
taining pins of tool with locking pins.
1 - Press tool -VW 407-
2 - Thrust piece -3372/1-
3 - Thrust plate -VW 401-
4 - Assembly tool -T10267-
5 - Tube -T10244/3-
– Press out both bonded rubber bushes together as shown.
Note
♦
The flattened side of press tool -3372/1- must face the attach‐
ment -A- on assembly tool -T10267- , otherwise the attach‐
ment can be damaged.
♦
The tube -T10244/3- has two different internal diameters. The
subframe must be positioned on the larger diameter of the tube
-T10244/3- .
Audi TT 2007 ➤
Pressing in bonded rubber bush
– Bolt together both bonded rubber bushes with the genuine bolt
(the two recesses -arrows- must be exactly above each other).
– Insert the assembled bonded rubber bushes into the larger
diameter of tube -T10214/2- (with bolt head pointing down‐
wards).
1 - Press tool -VW 432-
2 - Press tool -T10214/3- without bolts.
3 - Bonded rubber bush
4 - Tube -T10214/2-
5 - Tube -T10214/1-
6 - Thrust plate -VW 401-
2. Subframe, anti-roll bar, wishbone, swivel joint, vehicle level sender 23
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
– Press in bonded rubber bushes -1- until dimension -a- is ob‐
tained.
Dimension -a- = 2 - 3 mm.
– Align tube -T10214/2- containing pressed-in bonded rubber
bushes on subframe. The corners of the inner core of the bush
-1- should lie parallel with the edge of assembly tool -T10267-
-2-.
The distance -a- must be identical on both sides to ensure parallel
alignment.
– Place subframe onto smaller internal diameter of tube -
T10244/3- .
– Press in bushes as far as stop (until a force of 20 kN is at‐
tained).
1 - Press tool -VW 407-
2 - Thrust piece -T10214/3-
3 - Tube -T10214/2-
4 - Assembly tool -T10267-
5 - Tube -T10244/3-
– Detach assembly tool -T10267- from subframe and check
pressed-in bonded rubber bushes for proper seating.
• The outer diameter -1- of the two bonded rubber bushes may
project up to 2 mm above the edge in the vicinity of the aper‐
ture for the pendulum support.
• The recesses of the bonded rubber bushes must be positioned
in the centre of the aperture in the subframe.
• There may be a gap -arrow- between the bonded rubber bush‐
es.
– Install subframe ⇒ page 17 .
24 Rep. gr.40 - Front suspension
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