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.
Workshop Manual
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive
Edition 08.2010
Service
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.
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
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.
Service
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.
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
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
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.
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
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
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.
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
Audi TT 2007 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 08.2010
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