Steering (roadster) Audi TT 8J

GENERAL REPAIR INFORMATION

The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful steering gear repairs. Understandably, general safety guidelines apply when performing repairs.

A series of applicable general notes for individual repair procedures - otherwise listed several times at many points in the repair information - has been collected here. They apply for this repair information.

Steering Gear

1. Thoroughly clean connecting points and their surrounding areas before loosening.
2. When installing steering gear, make sure centering sleeves are correctly seated between console and steering gear.
3. Place removed parts on a clean surface and cover to prevent contamination. Use foils and paper. Only use lint-free cloths!
4. Only install clean components: Only unpack replacement parts immediately prior to installation.
5. Use exclusively lubricants and sealants marked with part numbers.
6. Carefully cover or seal open components, if repairs are not carried out immediately.
7. Two different steering gear versions were implemented in MY 2008. For information on the differences, refer to «GENERATION II AND III STEERING GEAR DIFFERENCES»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__generation-ii-and-iii-steering-gear) .

Gaskets and Seals

1. Always replace seals and gaskets.
2. After removing seals, inspect contact surface on housings and shafts for burrs and damage and repair if necessary.
3. Remove all residual sealant of fluid seals from sealing surfaces, no sealant residue must enter the steering gear housing when doing this.

Bolts and Nuts

Scheme 73

1. Loosen and tighten the bolts and nuts of covers and housings in a diagonal sequence.
2. Do not cant but loosen and tighten especially sensitive parts in diagonal manner in stages, e.g. servo motor with control module.
3. Torque specifications for unoiled bolts and nuts are given.
4. Always replace self-locking nuts and bolts.
5. Always replace the bolts and nuts, which are tightened with an additional tightening angle.

Electrical Components

Surely everyone has been shocked at one time or another when coming into contact with a metal object. The reason for this is the build-up of static electricity in the human body. This charge can lead to functional problems by touching the electrical components of steering gear.

Touch a grounded object - for example a water pipe or a vehicle hoist - before working on electrical components. Do not make direct contact on connector terminals.

Guided Fault Finding, OBD and Test Instruments

Scheme 74

1. Before performing repairs on electro-mechanical steering, the malfunction cause must be determined as exactly as possible using Vehicle Diagnostic, Testing and Information System VAS 5051B in operating modes "Guided Fault Finding", "Vehicle Self-Diagnosis" and "Test Instruments".

GENERATION II AND III STEERING GEAR DIFFERENCES

Generation II steering gear has been installed in the Audi TT from MY 07 since the start of production. This was replaced in model year 2008 with Generation III steering gear.

Vehicles equipped with Generation II steering gear can be converted to Generation III.

When converting from Generation II steering gear to Generation II, the electrical wire must also be replaced. Refer to 3 .

The steering gear can be identified when installed by the number of bolts.

Raise the vehicle.

Scheme 75

The illustration shows the Generation II steering gear.

The Generation II steering gear is secured to the subframe with four bolts -8-.

The Generation III steering gear is secured to the subframe with three bolts -8-. The clamp -9- with the bracket is also not used.

The generation III steering gear is only secured to the right of the subframe with one bolt -5-. The clamp -1-, rubber bushing -2- and bracket -3- are also not used. With Generation III steering gear, the right side of the steering gear housing is equipped with threads for the bolt instead of fasteners -1-, -2- and -3-.

Scheme 76

Note. The illustration shows the Generation II steering gear fasteners.

The Generation III steering gear is repaired and serviced the same way as the Generation II steering gear.

For additional information on Generation II and III steering gear, refer to STEERING GEAR ASSEMBLY OVERVIEW .

STEERING COLUMN, HANDLING AND TRANSPORTING

Correct Handling and Transport of Steering Column

Scheme 77

1. Transport steering column with two hands
2. Hold steering column at upper steering rod tube and in area of upper universal joint

Incorrect Handling of Steering Column

Scheme 78

Transporting at the following components leads to pre-damage to steering column

1. Clamping lever.
2. Weight compensation springs.
3. Deformation element.

Damage to universal joint bushings on lower steering column bushing due to

Scheme 79

1. Holding and carrying the steering column with a hand on the connecting shaft.
2. Bending joints more than 90°.

Scheme 80

1. Airbag Spiral Spring/Return Spring With Slip Ring -F138- Removing and installing, refer to «[For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation»(/audi/tt/8j-2006-2010/remont/accessories-equipment/#exterior-lights-switches-general-information-roadster) .
2. Steering Wheel with Airbag Removing and installing, refer to «STEERING WHEEL WITH AIRBAG»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__steering-wheel-with-airbag) . Various versions.
3. Bolt 50 Nm Always replace after removing it.
4. Harness Connector For Airbag Spiral Spring/Return Spring With Slip Ring -F138- Replacing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/airbag/#passenger-protection-airbags-seat-belts-roadster) .
5. Airbag Unit With Driver's Airbag Igniter -N95- and Driver's Airbag Igniter 2 -N250- WARNING: Follow safety precautions when working on airbag, refer to «General Safety Precautions»(/audi/tt/8j-2006-2010/remont/airbag/#passenger-protection-airbags-seat-belts-roadster__general-safety-precautions) . Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/airbag/#passenger-protection-airbags-seat-belts-roadster) .
6. Bolt Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/airbag/#passenger-protection-airbags-seat-belts-roadster) .
7. Sealing Cap Quantity: 2 For airbag unit bolt.

Scheme 81

1. Central Tube
2. Mounting Bracket Removing and installing, refer to «MOUNTING BRACKET WITH FREQUENCE DAMPER»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__mounting-bracket-with-frequence-damper) .
3. Bolt Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) .
4. Bolt Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) .
5. Steering Column Removing and installing, refer to «STEERING COLUMN»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__steering-column) .
6. Bolt 20 Nm Always replace after removing it.
7. Bolt 20 Nm
8. Bolt 20 Nm Always replace after removing it.
9. Support Installed on vehicles with knee airbags.
10. Support Installed on vehicles with knee airbags.
11. Bolt 20 Nm + 90° turn Always replace after removing it.
12. Brace Installed on the Roadster.
13. Strut Removing and installing, refer to «MOUNTING BRACKET WITH FREQUENCE DAMPER»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__mounting-bracket-with-frequence-damper) .
14. Bolt 9 Nm Clip the support -15- onto the steering column before installing.
15. Support Clip onto the steering column.
16. Bolt Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) .
17. Bolt Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) .
18. Bolt Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) .

STEERING GEAR ASSEMBLY OVERVIEW

1. Universal Joint
2. Bolt 20 Nm + 90° turn Always replace after removing it.
3. Electrical Wiring
4. Power Steering Gear Removing and installing, refer to «STEERING GEAR»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__steering-gear) . Various versions. When converting from Generation II steering gear to Generation II, the electrical wire -3- must also be replaced. With Power Steering Control Module -J500-. Can be tested in "Guided Fault Finding" using the Vehicle Diagnosis, Testing and Information System VAS 5051B.
5. Wheel Bearing Housing
6. Nut 20 Nm + 90° turn Always replace after removing it.
7. Subframe with Brackets
8. Bolt 50 Nm + 90° turn Always replace after removing it. Three bolts installed with the Generation III steering gear.
9. Clamp with Nuts Removing and installing, refer to «GENERATION II STEERING GEAR BONDED RUBBER BUSHING»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__generation-ii-steering-gear-bonded-rubber) . Always replace after removing it. Only installed with Generation II steering gear.
10. Shield
11. Bolt 6 Nm

FASTENER TIGHTENING SPECIFICATIONS

1. 1 Always replace after removal.

STEERING COLUMN, CHECKING FOR DAMAGE

Visual Check

Check whether parts of steering column indicate damage.

Functional Check

Check whether steering column can be turned without catching or difficulty of movement.

Check that the steering column can be adjusted with respect to height and reach.

STEERING WHEEL WITH AIRBAG

Removing

Set the wheels to the straight ahead position.

Position steering wheel as far back as possible. Use entire steering column adjustment range to do this.

Remove airbag unit. Refer to Removal and Installation .

Note. Removal and installation of steering wheel must take place in center position (wheels in straight-ahead position).

Remove screw -2-.

Scheme 82

Mark position of steering wheel/column with a felt-tip pen.

Remove steering wheel -3- from steering column.

Installing

Installation is the reverse of removal, with special attention to the following

Before positioning steering wheel, make sure wheels are in straight position.

When installing removed steering wheel: Make sure that markings on steering column/wheel align.

When installing a new steering wheel (without marking): Steering wheel must be position in center position (steering wheel spoke must be horizontal and wheels in straight-ahead position).

Install steering wheel.

Install airbag unit. Refer to Removal and Installation .

Perform road test.

If steering wheel is crooked, remove it again and rotate it on steering column splines.

STEERING COLUMN

Special tools and workshop equipment required

1. Vehicle Diagnosis, Testing and Information System VAS 5051B

Removing

The steering column is delivered only as a complete replacement part. Service is not possible.

The steering lock housing can be transferred. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Set the wheels to the straight ahead position.

Pull lever downward beneath steering column.

Bring steering column downward as far as possible and pull out.

Remove airbag unit. Refer to Removal and Installation .

Remove the airbag steering wheel. Refer to STEERING WHEEL WITH AIRBAG .

Remove the steering column switch trim. Refer to Removal and Installation .

Remove storage compartment on driver side. Refer to Removal and Installation .

Remove the driver side knee airbag if installed. Refer to Removal and Installation .

Remove the steering column switch. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Disconnect the harness connector -1-.

Scheme 83

Free up the cable guide -2-.

Remove the footwell vent underneath the steering column. Refer to Removal and Installation .

Disconnect ground wire -2- from steering column.

Scheme 84

Unclip the cable guide -3-.

Disconnect and free up all electrical connectors on steering column.

Remove the nuts -arrows- and the steering column universal joint cover -1-.

Scheme 85

Remove the bolt -1- and pull off universal joint -2- from steering gear.

Scheme 86

Remove the left and right knee airbag supports if installed. Refer to Removal and Installation .

Remove bolt -1-.

Scheme 87

First remove fuse panel bolts -arrow-, then bolts -1-.

Lower steering column slightly and carefully pull out upward.

Carefully remove steering column upward.

Installing

Installation is the reverse of removal, with special attention to the following

Refer to STEERING COLUMN, HANDLING AND TRANSPORTING .

Tightening specifications, refer to STEERING COLUMN AND MOUNTING BRACKET WITH FREQUENCY DAMPER ASSEMBLY OVERVIEW .

Engage steering column into assembly aid on mounting bracket.

Align steering column to mounting bracket and install.

Scheme 88

When doing this, pins -arrows A- of mounting bracket and holes -arrows B- of steering column must be positioned toward each other and inserted into one another.

Only in this way is the correct installation position of steering column to mounting bracket guaranteed.

Install the left and right knee airbag supports if installed. Refer to Removal and Installation .

Install the steering column switch. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Install the steering column switch trim. Refer to Removal and Installation .

Remove the footwell vent underneath the steering column. Refer to Removal and Installation .

Install the driver side knee airbag if installed. Refer to Removal and Installation .

Install the driver side storage compartment. Refer to Removal and Installation .

Installing steering wheel. Refer to STEERING WHEEL WITH AIRBAG .

Install the airbag in the steering wheel. Refer to Removal and Installation .

Calibrate Steering Angle Sensor -G85- with Vehicle Diagnosis, Testing and Information System VAS 5051B. Refer to WHEEL ALIGNMENT .

After the following assembly work, the Steering Angle Sensor -G85- must be calibrated.

1. When the steering angle sensor -G85- has been removed or replaced.
2. After removing or replacing steering column.
3. After removing or replacing steering column switch.
4. After removing or replacing steering lock housing.
5. If the steering wheel was offset.
6. After removing or replacing coil spring with slip ring (spiral spring).
7. After removing or replacing steering column electronics control module.

MOUNTING BRACKET WITH FREQUENCE DAMPER

Removing

Remove steering column. Refer to STEERING COLUMN .

Remove plenum chamber cover. Refer to Removal and Installation .

Remove bolt -arrow- in plenum chamber.

Scheme 89

Remove bolts -arrows-.

Scheme 90

Remove bolts -3-.

Mounting bracket with frequency damper can now be removed from body.

Installing

Installation is the reverse of removal, with special attention to the following

Tightening specifications, refer to STEERING COLUMN AND MOUNTING BRACKET WITH FREQUENCY DAMPER ASSEMBLY OVERVIEW .

Install steering column. Refer to STEERING COLUMN .

Installing plenum chamber cover. Refer to Removal and Installation .

STEERING GEAR

Special tools and workshop equipment required

1. Ball joint puller 3287 A
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332
4. Engine/transmission jack V.A.G 1383 A
5. Locating pins T10096
6. Vehicle diagnosis, testing and information System VAS 5051B

Removing

Note. The steering gear is removed together with the subframe, stabilizer bar and transverse links.

Set the wheels to the straight ahead position.

Disconnect the battery. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Remove the nuts -arrows- and the steering column universal joint cover.

Scheme 91

Remove the bolt -1- and remove the universal joint -2- from the steering gear.

Disconnect connector -2-, remove electrical wires -1- and -3-.

Scheme 92

Unclip wiring harness -4- from wiring shaft.

Remove the front wheels.

Remove lower noise insulation. Refer to Removal and Installation .

Remove noise insulation frame. Refer to Removal and Installation .

Loosen tie rod end nut, but do not remove yet.

Press tie rod end off of wheel bearing housing using 3287 A.

Scheme 93

Remove exhaust system bracket bolts -arrows-.

Scheme 94

Remove nut -1-.

Scheme 95

On vehicles with level control system sensor, remove nut -3- and disconnect connector -6-.

Scheme 96

Remove pendulum support from transmission, unscrew bolts -13- to do so.

Scheme 97

Disconnect Oil Level Thermal Sensor -G266- connector -1- and unclip electrical wire from bracket -2-.

Scheme 98

Mark location of nuts -arrows- on left and right sides of vehicle using a felt-tip pen.

Remove nuts -arrows- on left and right side of vehicle.

Remove transverse link from ball joint.

Subframe, locating, refer to SUBFRAME, SECURING .

Place V.A.G 1383 A with wood blocks -1- under subframe and apply slight counterpressure.

Scheme 99

Remove bolts -4- and -5-.

Lower subframe with attachments.

Note. When lowering, ensure the electrical wires have enough clearance.

Remove wiring guide from subframe.

Remove heat shields from steering gear.

Remove steering gear bolts -3- and -6-.

Remove steering gear from subframe.

Installing

Installation is the reverse of removal, with special attention to the following

Tightening specifications, refer to SUBFRAME, STABILIZER BAR, TRANSVERSE LINK, BALL JOINT, AND LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW .

Tightening specifications, refer to STEERING GEAR ASSEMBLY OVERVIEW .

The steering gear threaded sleeves must be seated in the subframe holes.

Clamp with nuts must be replaced after each removal.

Note. Coat seal on steering gear with lubricant, e.g. soft soap, before installing steering gear. After attaching steering gear to drive axle, make sure that seal on steering gear is positioned to mounting plate without kinks and opening to foot well is sealed correctly. Ingress of water and/or noises may be the result. Make sure sealing surfaces are clean.

Note. Make sure that the ball joint boot is not damaged or twisted.

Replace locking element after each removal.

Align nuts -arrows- according to markings made earlier and tighten.

Install noise insulation frame. Refer to Removal and Installation .

Install noise insulation. Refer to Removal and Installation .

Connect the battery. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Applies to Vehicles with Generation II Steering Gear

If a new steering gear was installed, the power steering control module -J500- must be programmed with the VAS 5051B and the characteristic lines must be downloaded in "Guided Fault Finding".

Applies to Vehicles with Generation III Steering Gear

If new steering box was installed, the power steering control module -J500- must be adapted with the VAS 5051B in "Guided Fault Finding".

Affects All Vehicles

Vehicle alignment required, see table. Refer to WHEN WHEEL ALIGNMENT IS NECESSARY .

On vehicles with electronically-controlled damping (Audi magnetic ride), reprogram control position using VAS 5051B.

On vehicles with automatic headlamp range control, perform headlamp basic setting. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Diagnosis and Testing .

If a vehicle alignment was performed, calibrate Steering Angle Sensor -G85- with VAS 5051B. Refer to WHEEL ALIGNMENT .

BOOT

Special tools and workshop equipment required

1. Locking pliers VAS 6199
2. Torque wrench V.A.G 1332
3. Hose clamp pliers V.A.G 1275
4. Vehicle Diagnosis, Testing and Information System VAS 5051B

Removing

Note. If bellows is faulty, moisture and dirt penetrates into steering gear. There must be a noticeable grease film present on steering rack in area of splines. If grease film is not present, steering gear must be replaced. Steering gear must also be replaced if there is corrosion or steering gear is damaged or worn out.

Turn steering wheel into straight ahead position.

Remove the wheel.

Clean outside of steering gear in area of bellows.

Note. While doing this, no dirt must enter the steering gear through the faulty bellows.

Mark position of nut -3- on tie rod.

Scheme 100

Loosen nut -3-, counterhold on tie rod end -2- while doing this.

Loosen spring clamp -1- using V.A.G 1275 from bellows and slide onto tie rod.

Remove clamp and pull off bellows from steering gear housing.

Now twist tie rod out of tie rod end.

Pull off bellows with spring clamp from tie rod.

Note. If corrosion, damage, wear-out or first signs of soiling on steering rack can be seen, complete steering gear must be replaced. If no grease film is visible on steering rack, steering gear must also be replaced completely.

Installing

Before installing, steering rack must be coated with grease G 052 192 A1 supplied in repair set.

For this purpose, turn steering to stop toward both sides in succession.

For clearer illustration, steering gear has been removed in the illustration.

Grease steering rack on toothed side -A- and on thrust piece side with grease G 052 192 A1.

Scheme 101

Turn steering wheel into straight ahead position.

Guide new clamp and bellows onto tie rod.

Install the tie rod up to the marking made during removal.

Tighten lock nut -3- to tightening specification, counterhold on tie rod end -2- while doing this.

Slide bellows -2- onto tie rod -1- as depicted in the illustration.

Scheme 102

Secure spring clamp on bellows using V.A.G 1275.

Slide bellows onto steering gear housing.

Tighten new clamp using VAS 6199 to the extent depicted in the illustration.

Scheme 103

Further installation is in the reverse sequence to removal.

Tightening specifications, refer to ELECTROMECHANICAL POWER STEERING GEAR

After the installation the vehicle must be measured.

Perform vehicle alignment. Refer to WHEEL ALIGNMENT .

Perform basic setting for Steering Angle Sensor -G85- via VAS 5051B in Guided Fault Finding.

Perform a basic setting and program the steering on vehicles with Generation II steering gear via VAS 5051B in Guided Fault Finding.

TIE ROD

Special tools and workshop equipment required

1. Ball joint puller 3287 A
2. Hose clamp pliers V.A.G 1275
3. Torque wrench V.A.G 1332
4. 38 mm open end wrench insert V.A.G 1923
5. Locking pliers VAS 6199
6. Vehicle Diagnosis, Testing and Information System VAS 5051B

Removing

Turn steering wheel into straight ahead position.

Clean outside of steering gear in area of bellows.

Loosen nut -3-, counterhold on tie rod end -2- while doing this.

Remove front wheel.

Loosen nut of track rod ball joint, but do not unscrew yet.

Note. To protect thread, screw nut on pin a few turns.

Press off track rod ball joint from wheel bearing housing using 3287 A and now unscrew nut.

Loosen spring clamp -1- using V.A.G 1275 from bellows and slide onto tie rod.

Remove clamp and pull off bellows from steering gear housing.

Remove the tie rod from steering gear using V.A.G 1923.

Scheme 104

Note. If corrosion, damage, wear-out or first signs of soiling on steering rack can be seen, complete steering gear must be replaced. If no grease film is visible on steering rack, steering gear must also be replaced completely.

Installing

Before installing, steering rack must be coated with grease G 052 192 A1 supplied in repair set.

For this purpose, turn steering to stop toward both sides in succession.

For clearer illustration, steering gear has been removed in the illustration.

Grease steering rack on toothed side -A- and on thrust piece side with grease G 052 192 A1.

Turn steering wheel into straight ahead position.

Twist tie rod far enough into tie rod end until dimension -a- is obtained.

Scheme 105

Dimension -a- = 390 +/- 1 mm

Guide new clamp and bellows onto tie rod.

Twist tie rod into steering gear and tighten to tightening specification.

Slide bellows -2- onto tie rod -1-, pay attention to correct position when doing this.

Slide bellows onto steering gear housing until it stops.

Tighten new clamp using VAS 6199 to the extent depicted in the illustration.

Further installation is in the reverse sequence to removal.

Tightening specifications, refer to ELECTROMECHANICAL POWER STEERING GEAR .

After the installation the vehicle must be measured.

Perform vehicle alignment, refer to WHEEL ALIGNMENT .

Perform basic setting for Steering Angle Sensor -G85- via VAS 5051B in "Guided Fault Finding".

Perform a basic setting and program the steering on vehicles with Generation II steering gear via VAS 5051B in "Guided Fault Finding".

GENERATION II STEERING GEAR BONDED RUBBER BUSHING

Removing

Remove lower noise insulation. Refer to Removal and Installation .

Remove the bolts -2- and -3- and press the shield -4- up slightly.

Scheme 106

Loosen the steering gear bolts -1- and -4- on the left side of the vehicle.

Scheme 107

Loosen the steering gear bolts -2- and -3- on the right side of the vehicle and remove them.

The illustration shows a removed subframe with steering gear.

Raise the steering gear -4- on the right side of the vehicle up slightly.

Remove the clamp -1- and rubber bushing -2- with the bracket -3- from the steering gear.

Installing

Installation is the reverse of removal, with special attention to the following

Torque specifications, refer to STEERING GEAR ASSEMBLY OVERVIEW .

SENSOR WIRE

Note. Currently it is not possible to perform this repair.

Special tools and workshop equipment required

1. Holding fixture VW 313
2. Thrust piece 3253/6 qty. 2
3. Torque wrench V.A.G 1331
4. Locking pliers VAS 6199
5. Transmission support T10108
6. Adapter T10304
7. Vehicle Diagnosis, Testing and Information System VAS 5051B
8. 2 bolts M10 x 60

Removing

Remove steering gear. Refer to STEERING GEAR .

Tension steering gear using 2 bolts M10 x 60 as depicted in the illustration.

Scheme 108

Clean steering gear in area of cover.

Remove clamp for bellows at left -1- and pull off bellows from steering gear housing.

Scheme 109

Turn steering into straight ahead position using T10304.

For this purpose, dimension -a- = 25.5 mm.

Remove gasket -1- from cover -2-.

Scheme 110

Mark installation position of cover -2- to steering gear housing -arrow-.

Remove cover -2-, unscrew bolts -3- to do this.

Prevent contact with electrical components -arrow- !

Scheme 111

Observe general repair notes for this. Refer to GENERAL REPAIR INFORMATION

Mark routing of sensor wire on steering gear housing.

Unclip sensor wire on steering gear housing.

Note. A locking mechanism -arrow- for steering pinion spiral spring is located on sensor wire in steering gear housing. When removing sensor wire, make sure that spiral spring is twisted only as far until connector can be removed (twist a maximum of 30°).

Now disconnect harness connector of sensor wire at steering pinion.

Scheme 112

To do so, press connector terminal out of spiral spring housing in -direction of arrow- using a screwdriver (3 mm blade width) as depicted in the illustration.

Pull locking mechanism in -direction of arrow- out of steering gear housing.

Scheme 113

Carefully pull sensor wire out of steering gear housing.

Disconnect harness connector of sensor wire at Power Steering Control Module -J500-.

Scheme 114

To do so, press button -A- in -direction of arrow- and then disconnect connector.

Installing

Carefully guide sensor wire into steering gear housing.

When doing this, insert connector terminal into housing of spiral spring, do not engage yet.

Connector terminal is coded and fits only in one direction.

Note. Twist spiral spring only as far until connector can be installed (maximum 30°).

Push locking mechanism into steering gear housing.

While doing this, make sure locking mechanism engages correctly in plastic ring of sensor unit -arrow-.

Scheme 115

Now engage connector in spiral spring housing.

Connect harness connector of sensor wire to Power Steering Control Module -J500-.

Connector must engage audibly.

Clip sensor wire in on steering gear housing.

Pay attention to wire routing.

Replace sealing ring on cover of steering pinion.

Fill intermediate area above shaft oil seal in cover -arrow- completely with grease G 052 192 A1 supplied.

Scheme 116

Place cover on as marked during removal (Refer to SENSOR WIRE ).

Install new bolts and tighten them to the specification.

Tightening specifications, refer to ELECTROMECHANICAL POWER STEERING GEAR .

Remove excess grease on cover of steering pinion and on steering pinion.

Further installation is in the reverse sequence to removal.

Install steering gear. Refer to STEERING GEAR .

Perform vehicle alignment. Refer to WHEEL ALIGNMENT .

Perform basic setting for Steering Angle Sensor -G85- via VAS 5051B in "Guided Fault Finding".

Then perform basic setting of steering system via VAS 5051B in "Guided Fault Finding".

HYDRAULIC THRUST PIECE, REMOVING, INSTALLING AND REPLACING

Note. Currently it is not possible to perform this repair.

Special tools and workshop equipment required

1. Holding fixture VW 313
2. Thrust piece 3253/6 qty. 2
3. Torque wrench V.A.G 1331
4. Locking pliers VAS 6199
5. Transmission support T10108
6. Adapter T10304
7. Friction meter VAS 6222
8. Adapter T10305
9. Vehicle Diagnosis, Testing and Information System VAS 5051B
10. Wet and dry vacuum cleaner for example V.A.G 1373
11. Cordless drill for example VAS 5036
12. 4 mm drill bit
13. 2 bolts M10 x 60

Removing

Remove steering gear. Refer to STEERING GEAR .

Clean steering gear in area of adjustment screw.

Tension steering gear using 2 bolts M10 x 60 as depicted in the illustration.

Determine starting torque of steering.

Scheme 117

First turn steering toward right in direction of travel until it stops.

Now turn steering uniformly toward left until it stops on friction meter, e.g. VAS 6222. Read off steering torque while doing this.

Specified value: 3 +/- 2 Nm

1 - Friction meter, e.g. VAS 6222

2 - 24 mm socket

Remove clamp for bellows at left -1- and pull off bellows from steering gear housing.

Turn steering into straight ahead position using T10304.

For this purpose, dimension -a- = 25.5 mm.

Rotate steering gear in mounting bracket so that thrust piece with adjustment screw points upward.

Now slide boot onto steering gear cover again.

Drill the 6 peenings out using a 4 mm drill bit until reaching dimension -a-.

Scheme 118

Dimension -a- = 3 mm

Vacuum up drill shavings completely from steering gear housing using V.A.G 1373.

Remove the adjustment screw.

Scheme 119

Remove sealing ring -arrow-.

Scheme 120

Pull steering rack in direction of thrust piece so that it disengages from steering rack.

Simultaneously pull out hydraulic thrust piece from steering gear housing using suitable pliers.

Scheme 121

Note. If corrosion, damage, wear-out or first signs of soiling on steering rack can be seen, complete steering gear must be replaced. If no grease film is visible on steering rack, steering gear must also be replaced completely.

Installing and Adjusting

Scheme 122

Coat new thrust piece -arrow A- (contact surface at steering gear), sealing ring and hole in steering gear housing -arrow B- with grease G 052 192 A1 supplied.

Install hydraulic thrust piece and sealing ring -arrow- by hand.

Tighten new adjustment screw to 40 Nm.

Peen the adjustment screw 6 times -arrows- using a punch.

Scheme 123

Punch points must be applied 2 graduation lines next to the drill out punch points.

Mark one graduation line of adjustment screw on the steering gear housing -1-.

Scheme 124

Remove the adjustment screw 5.5 graduation lines toward left -2-.

While doing this, a loosening torque of at least 15 Nm must be obtained.

If loosening torque is not obtained

Tighten adjustment screw to 40 Nm again.

Reinforce the 6 peenings using a punch.

Check applied marking of adjustment screw graduation line on steering gear housing, apply the marking again if necessary.

Remove the adjustment screw 5.5 graduation lines toward left.

A loosening torque of at least 15 Nm must be obtained.

Turn steering using T10304 from left stop to right stop.

Scheme 125

No hitching or jamming may occur while steering through. If there is, surface of steering rack is damaged and steering gear must be replaced.

Install left bellows onto steering gear housing with new clamp.

Determine starting torque of steering

First turn steering toward right in direction of travel until it stops.

Now turn steering uniformly toward left until it stops on friction meter, e.g. VAS 6222. Read off steering torque while doing this.

Specified value: 3 +/- 2 Nm

1 - Friction meter, e.g. VAS 6222

2 - 24 mm socket

If steering torque is exceeded

Loosen hydraulic thrust piece adjusting screws about one graduation line (turn adjustment screws toward left).

Then, check steering torque. Refer to Determine starting torque of steering .

If steering torque falls short

Install hydraulic thrust piece adjusting screws about one graduation line (turn adjustment screws toward right).

Then, check steering torque. Refer to Determine starting torque of steering .

Install steering gear. Refer to STEERING GEAR .

Perform vehicle alignment WHEEL ALIGNMENT .

Perform basic setting for Steering Angle Sensor -G85- via VAS 5051B in "Guided Fault Finding".

Then perform basic setting of steering system via VAS 5051B in "Guided Fault Finding".

THRUST PIECE, STEERING PINION SIDE, REMOVING, INSTALLING AND ADJUSTING

Note. Currently it is not possible to perform this repair.

Special tools and workshop equipment required

1. Holding fixture VW 313
2. Thrust piece 3253/6 qty. 2
3. Torque wrench V.A.G 1331
4. Locking pliers VAS 6199
5. Transmission support T10108
6. Adapter T10304
7. Universal dial gauge VW 387
8. 38 mm open end wrench insert V.A.G 1923
9. Adapter 3313
10. Friction meter VAS 6222
11. Vehicle Diagnosis, Testing and Information System VAS 5051B
12. Wet and dry vacuum cleaner for example V.A.G 1373
13. Cordless drill for example VAS 5036
14. Pliers for outer securing rings, for example HAZET-1847-2
15. 4 mm drill bit
16. Dial gauge
17. 2 bolts M10 x 80

Removing

Remove steering gear. Refer to STEERING GEAR .

Clean steering gear in area of adjustment screw for mechanical thrust piece.

Tension steering gear using 2 bolts M10 x 80 as depicted in the illustration.

Determine starting torque of steering.

First turn steering toward right in direction of travel until it stops.

Now turn steering uniformly toward left until it stops on friction meter, e.g. VAS 6222. Read off steering torque while doing this.

Specified value: 3 +/- 2 Nm

1 - Friction meter, e.g. VAS 6222

2 - 24 mm socket

Remove clamp for bellows at left -1- and pull off bellows from steering gear housing.

Turn steering into straight ahead position using T10304.

For this purpose, dimension -a- = 25.5 mm.

Slide bellows -1- without clamp back onto steering gear housing.

Rotate steering gear in mounting bracket so that thrust piece with adjustment screw points upward.

Drill the 6 peenings out using a 4 mm drill bit until reaching dimension -a-.

Scheme 126

Dimension -a- = 3 mm

Vacuum up drill shavings completely from steering gear housing using V.A.G 1373.

Remove the adjustment screw.

Remove spring and sealing ring -arrow-.

Scheme 127

Pull thrust piece out of steering gear housing using HAZET1847-2.

Scheme 128

Note. If corrosion, damage, wear-out or first signs of soiling on steering rack can be seen, complete steering gear must be replaced. If no grease film is visible on steering rack, steering gear must also be replaced completely.

Installing and Adjusting

Scheme 129

Coat new thrust piece (contact surface at steering gear), sealing ring and hole in steering gear housing with grease G 052 192 A1 supplied -arrows-.

Insert thrust piece by hand into steering gear housing.

Install new sealing ring -arrow- and new spring.

Tighten new adjustment screw to 40 Nm.

Peen the adjustment screw 6 times -arrows- using a punch.

Scheme 130

Punch points must be applied 2 graduation lines next to the drill out punch points.

Mark one graduation line of adjustment screw on the steering gear housing -1-.

Scheme 131

Remove the adjustment screw 6 graduation lines toward left -2-.

While doing this, a loosening torque of at least 15 Nm must be obtained.

If loosening torque is not obtained

Tighten adjustment screw to 40 Nm again.

Reinforce the 6 peenings using a punch.

Check applied marking of adjustment screw graduation line on steering gear housing, apply the marking again if necessary.

Remove the adjustment screw 6 graduation lines toward left.

A loosening torque of at least 15 Nm must be obtained.

Remove rubber plug from adjustment screw.

Attach a dial gauge with 0.001 graduations as depicted in the illustration.

Scheme 132

Tension dial gauge to 1 mm pre-load.

Rotate to tighten steering rack using V.A.G 1331 and V.A.G 1923 on tie rod to 40 Nm in one direction. When V.A.G 1331 disengages, set dial gauge to "0".

Now remove V.A.G 1331 from tie rod.

Read off value indicated on dial gauge.

Specified value: 0.005 to 0.05 mm

Turn steering using T10304 from left stop to right stop. Observe values indicating on dial gauge while doing this.

Specified value: 0.05 to 0.12 mm

Note. If specified values for steering rack play are not obtained, steering gear must be replaced completely!

Remove dial gauge and adapter, press rubber plug in adjustment screw.

Pull off left bellows from steering gear housing.

Turn steering from left stop to right stop, while doing this grease visible area of steering rack with grease G 052 192 A1 supplied.

Install left bellows onto steering gear housing with new clamp.

First turn steering toward right in direction of travel until it stops.

Now turn steering uniformly toward left until it stops on friction meter, e.g. VAS 6222. Read off steering torque while doing this.

Specified value: 3 +/- 2 Nm

1 - Friction meter, e.g. VAS 6222

2 - 24 mm socket

Loosen thrust piece adjusting screws on steering pinion side about one graduation line (turn adjustment screws toward left).

Then, check steering torque. Refer to DETERMINE STARTING TORQUE OF STEERING .

If steering torque falls short

Install thrust piece adjusting screws on steering pinion side about one graduation line (turn adjustment screws toward right).

Then, check steering torque. Refer to DETERMINE STARTING TORQUE OF STEERING .

Install steering gear. Refer to STEERING GEAR .

Perform vehicle alignment. Refer to WHEEL ALIGNMENT .

Perform basic setting for Steering Angle Sensor -G85- via VAS 5051B in "Guided Fault Finding".

Then perform basic setting of steering system via VAS 5051B in "Guided Fault Finding".

STEERING PINION WITH STEERING TORQUE SENSOR

Note. Currently it is not possible to perform this repair.

Special tools and workshop equipment required

1. Holding fixture VW 313
2. Thrust piece 3253/6 qty. 2
3. Torque wrench V.A.G 1331
4. Torque wrench V.A.G 1332
5. Transmission support T10108
6. Adapter T10304
7. Vehicle Diagnosis, Testing and Information System VAS 5051B
8. 2 bolts M10 x 60

Removing

Remove steering gear. Refer to STEERING GEAR .

Clean steering gear in area of steering pinion, screw plug and adjustment screw.

Tension steering gear using 2 bolts M10 x 80 as depicted in the illustration.

Remove thrust piece on steering pinion side. Refer to THRUST PIECE, STEERING PINION SIDE, REMOVING, INSTALLING AND ADJUSTING .

Turn steering gear with screw plug upward.

1. Tie rods must be assembled.

Remove the screw plug -arrow- and clean thread.

Scheme 133

Remove the hex nut -arrow- from steering pinion.

Scheme 134

Note. Steering rack moves up to stop when this is done.

Turn steering gear with steering pinion upward.

Remove sensor wire. Refer to SENSOR WIRE .

Note. Sensor wire must be replaced. It is supplied in replacement part set.

Mark position of steering pinion on steering gear housing.

Now pull steering pinion with steering torque sensor out of steering gear housing. Secure spiral spring against twisting using e.g. adhesive tape.

Scheme 135

Note. If corrosion, damage, wear-out or first signs of soiling on steering rack can be seen, complete steering gear must be replaced. If no grease film is visible on steering rack, steering gear must also be replaced completely.

Installing

Scheme 136

Coat bushing -arrow 1- and splines of steering pinion -arrow 2- with G 052 192 A1.

The new steering pinion with Steering Torque Sensor -G269- has an anti-twist element -arrow-. This may only be removed after locking to sensor wire.

Scheme 137

Only remove new steering pinion from packaging when it has been assembled.

Observe general repair notes for this. Refer to GENERAL REPAIR INFORMATION .

Insert steering pinion into steering gear housing.

Rotate steering pinion until spiral spring with sensor wire -arrow- can be locked. While doing this, the marking applied during removal must align with steering gear housing.

Note. Sensor wire must be replaced. It is supplied in replacement part set.

Pull anti-twist element off the spiral spring.

Tighten steering pinion with a new hex nut -arrow-.

Steering rack moves up to stop when this is done.

Fill hollow space of screw plug with grease G 052 192 A1.

Apply LOCTITE5910 sealant all around onto thread of screw plug -arrow- and install screw plug.

Install sensor wire. Refer to SENSOR WIRE .

Turn steering into straight ahead position using T10304.

For this purpose, dimension -a- = 25.5 mm.

Install and adjust thrust piece on steering pinion side. Refer to THRUST PIECE, STEERING PINION SIDE, REMOVING, INSTALLING AND ADJUSTING .

Tightening specifications, refer to ELECTROMECHANICAL POWER STEERING GEAR .

Install steering gear. Refer to STEERING GEAR .

Perform vehicle alignment. Refer to WHEEL ALIGNMENT .

Perform basic setting for Steering Angle Sensor -G85- via VAS 5051B in "Guided Fault Finding".

Then perform basic setting of steering system via VAS 5051B in "Guided Fault Finding".

ELECTROMECHANICAL POWER STEERING GEAR

Arrow- points in direction of travel

Scheme 138

1. Steering Gear Housing
2. Tie Rod 100 Nm If faulty, replace with tie rod end. Removing and installing, refer to «TIE ROD»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__tie-rod) .
3. Left Tie Rod End Check dust caps for damage and correct seating.
4. Nut 50 Nm Nut must be counterheld on tie rod end using a wrench when loosening and tightening.
5. Spring Clamp
6. Boot Removing and installing, refer to «BOOT»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__boot) . Check for damage. Must not be twisted after toe is adjusted.
7. Clamp Always replace after removing it. Install new clamp using Locking pliers VAS 6199.
8. Gasket Between steering gear and vehicle interior.
9. Bolt For mounting cap, refer to 10 to steering gear housing, refer to 1 . Quantity: 2.
10. Cover
11. Seal Always replace.
12. Steering Pinion with Steering Torque Sensor Removing and installing, refer to «STEERING PINION WITH STEERING TORQUE SENSOR»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__steering-pinion-with-steering-torque-sensor) . With Steering Torque Sensor -G269-.
13. Sensor Wire Removing and installing, refer to «SENSOR WIRE»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__sensor-wire) . Electrical connection between Steering Torque Sensor -G269- and Power Steering Control Module -J500-.
14. Right Tie Rod End Check dust caps for damage and correct seating.
15. Bolt For mounting servo motor to control module, refer to 20 on steering gear housing, refer to 1 .
16. Clamp with Nuts Always replace after removing it. Removing and installing, refer to «GENERATION II STEERING GEAR BONDED RUBBER BUSHING»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__generation-ii-steering-gear-bonded-rubber) . Not installed on vehicles with Generation III steering gear. The Generation III steering gear is secured to the housing with a bolt in this location.
17. Rubber Bushing Removing and installing, refer to «GENERATION II STEERING GEAR BONDED RUBBER BUSHING»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__generation-ii-steering-gear-bonded-rubber) . Not installed on vehicles with Generation III steering gear.
18. Bracket Removing and installing, refer to «GENERATION II STEERING GEAR BONDED RUBBER BUSHING»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__generation-ii-steering-gear-bonded-rubber) . Not installed on vehicles with Generation III steering gear.
19. Seal Always replace.
20. Servo Motor with Control Module With Power Steering Control Module -J500-. With Electromechanical Power Steering Motor -V187-. With Engine Speed (RPM) Sensor -G 577-. Can be tested in "Guided Fault Finding" using the Vehicle Diagnosis, Testing and Information System VAS 5051B.
21. Contact Foil Not an individual part, is installed on hydraulic thrust piece, refer to 22 . Coat with supplied grease G 052 192 A1 on contact side facing steering rack.
22. Hydraulic Thrust Piece Removing and installing, refer to «HYDRAULIC THRUST PIECE, REMOVING, INSTALLING AND REPLACING»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__hydraulic-thrust-piece-removing-installing-and) .
23. Seal Installed on hydraulic thrust piece, refer to 22 .
24. Seal Insert into steering gear housing between thrust piece and adjustment screw.
25. Adjustment Bolt For hydraulic thrust piece refer to 22 . Always replace.
26. Rubber Plug
27. Adjustment Bolt For mechanical thrust piece refer to 33 . Always replace.
28. Spring
29. Screw Plug Fill with grease G 052 192 A1 before installing. Coat thread with LOCTITE5910.
30. Nut Always replace after removing it.
31. Retaining Clip For mounting sensor wire refer to 13 to steering gear housing refer to 1 .
32. Seal Installed on mechanical thrust piece, refer to 33 .
33. Mechanical Thrust Piece Removing and installing, refer to «THRUST PIECE, STEERING PINION SIDE, REMOVING, INSTALLING AND ADJUSTING»(/audi/tt/8j-2006-2010/remont/manual-power-steering/#steering-roadster__thrust-piece-steering-pinion-side-removing) .
34. Contact Foil Not an individual part, is installed on mechanical thrust piece, refer to 33 . Coat with supplied grease G 052 192 A1 on contact side facing steering rack.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 139

Scheme 140

Scheme 141

1. Vehicle Diagnosis, Testing and Information System VAS 5051B
2. Wet and dry vacuum cleaner V.A.G 1373
3. Cordless drill VAS 5036
4. Pliers for outer securing rings, for example HAZET1847-2
5. Locating pins T10096
6. Hose clamp pliers V.A.G 1275
7. Adapter T10305

Scheme 142

Special tools and workshop equipment required

1. Ball joint puller 3287 A
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332
4. Engine/transmission jack V.A.G 1383 A

Scheme 143

Special tools and workshop equipment required

1. Holding fixture VW 313
2. Thrust piece 3253/6 qty. 2
3. Torque wrench V.A.G 1331
4. Locking pliers VAS 6199
5. Transmission support T10108
6. Adapter T10304
7. 2 bolts M10 x 60

Scheme 144

Special tools and workshop equipment required

1. Universal dial gauge VW 387
2. 38 mm open end wrench insert V.A.G 1923
3. Adapter 3313
4. Friction meter VAS 6222

See also:
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• Removal and Installation
• General Safety Precautions
• Description and Operation
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• Removal and Installation
• WHEEL ALIGNMENT
• Removal and Installation
• Removal and Installation
• SUBFRAME, SECURING
• SUBFRAME, STABILIZER BAR, TRANSVERSE LINK, BALL JOINT, AND LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW
• WHEN WHEEL ALIGNMENT IS NECESSARY
• GENERATION II AND III STEERING GEAR DIFFERENCES
• STEERING GEAR ASSEMBLY OVERVIEW
• STEERING WHEEL WITH AIRBAG
• MOUNTING BRACKET WITH FREQUENCE DAMPER
• STEERING COLUMN
• STEERING GEAR
• GENERATION II STEERING GEAR BONDED RUBBER BUSHING
• STEERING COLUMN, HANDLING AND TRANSPORTING
• STEERING COLUMN AND MOUNTING BRACKET WITH FREQUENCY DAMPER ASSEMBLY OVERVIEW
• ELECTROMECHANICAL POWER STEERING GEAR
• GENERAL REPAIR INFORMATION
• SENSOR WIRE
• Determine starting torque of steering
• THRUST PIECE, STEERING PINION SIDE, REMOVING, INSTALLING AND ADJUSTING
• TIE ROD
• BOOT
• STEERING PINION WITH STEERING TORQUE SENSOR
• HYDRAULIC THRUST PIECE, REMOVING, INSTALLING AND REPLACING