Front Suspension (coupe) Audi TT 8J

GENERAL REPAIR INFORMATION

When installing waxed components, contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.

Torque specifications for unoiled bolts and nuts are given.

Always replace self-locking nuts and bolts.

Always replace the bolts and nuts, which are tightened with an additional tightening angle.

Welding or straightening operations are not permitted on load-bearing or wheel-controlling components.

Always avoid the following actions with coil springs: Striking with a hammer, welding beads, applying color identification later.

Do not perform any welding or grinding (separating work) in coil spring or suspension strut area! Cover coil spring or suspension struts if necessary.

When loosening, removing or installing hydraulic, pneumatic or electrical line, always make a sketch or take a picture. Doing so records the original installation locations.

If the cable ties, brackets or mounting elements were removed during the repair procedure, they must be installed at their original location.

Lightly coat the splines on the outer joint with assembly paste before installing the outer joint into the wheel hub.

Never allow the drive axle just to hang loose under the vehicle or to bend them at the joints.

Vehicles without a drive axle must not be moved, otherwise the wheel bearing will be damaged. If vehicle must be moved, observe the following

Install an outer joint in place of the drive axle.

Tighten the outer joint to 120 Nm (twelve-point bolt) or 200 Nm (hex bolt).

Bonded rubber bushings can only be turned to a limited extent. Only tighten threaded connections at control arms if vehicle is in curb weight position or control position.

1. Wheel bearing, lifting to curb weight position on vehicles with coil springs, refer to «WHEEL BEARING, LIFTING TO CURB WEIGHT POSITION»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__wheel-bearing-lifting-to-curb-weight) .

Note. If the vehicle must still be aligned, every bolt and nut that must be loosened for adjustment is only tightened to torque specification. Tighten the bolts and nuts to the specified additional tightening angle after the alignment/adjustment is complete.

CONTACT CORROSION

Contact corrosion can occur when incorrect fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only fastening elements with a special surface coating are installed.

In addition, rubber or plastic parts and adhesive are made of non-conductive materials.

If there are doubts as to whether parts should be reinstalled, install new parts according to the parts information.

Note. We recommend only using original replacement parts, they have been tested and are compatible with aluminum. We recommend using Audi accessories. Damage due to contract corrosion is not covered under warranty!

LONGITUDINAL MEMBER THREADS, REPAIRING

It is possible to service the threads of the weld nuts in the longitudinal member depending on certain conditions.

1. Servicing work may only be performed once per thread.
2. If servicing is necessary after this, the nuts must be replaced.

1. Have the thread repair checked by the responsible foreman or next person in charge.
2. Thread insert must be same length as thread in body.
3. Repair any damage to the underbody protection.

WHEEL BEARINGS MUST NOT BE BURDENED WHEN DRIVE AXLE CONNECTION IS LOOSE.

If the bearings are loaded by the vehicle's own weight the wheel bearing will be damaged. This reduces the service life of the wheel bearings.

Vehicles without a drive axle must not be moved, otherwise the wheel bearing will be damaged. If vehicle must be moved, observe the following

Install an outer joint in place of the drive axle.

Tighten the outer joint to 120 Nm (twelve-point bolt) or 200 Nm (hex bolt).

Loosening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Tightening the threaded connection between the drive axle and flange shaft

1. First diagonally tighten all six bolts to 10 Nm. Then diagonally tighten them again to the tightening specification.

Lightly coat the splines on the outer joint with assembly paste before installing the outer joint into the wheel hub.

Never allow the drive axle just to hang loose under the vehicle or to bend them at the joints.

Always replace self-locking nuts and bolts.

Always replace the bolts and nuts, which are tightened with an additional tightening angle.

WHEEL BEARING, LIFTING TO CURB WEIGHT POSITION

Special tools and workshop equipment required

1. Engine/transmission jack V.A.G 1383 A
2. Tensioning strap T10038
3. Wheel hub support T10149

Note. All bolts at suspension parts with bonded rubber bushings must always be tightened in curb weight position (unloaded condition).

Bonded rubber bushings can only be turned to a limited extent.

Parts with bonded rubber bushings must therefore be brought into a position that corresponds to the position in driving mode before being tightened (curb weight position).

Otherwise, the bonded rubber bushing will be stressed resulting in a shortened service life.

By raising appropriate suspension using V.A.G 1383 A and T10149, this position can be simulated on the hoist.

Before starting work, take measurement -a-, e.g. with tape measure, from center of wheel to lower edge of wheelhouse.

Scheme 1

Note. Measurement must be performed in curb weight position (unloaded condition).

Note measured value. It will be required for tightening bolts/nuts.

Turn wheel hub far enough until one of the holes for wheel bolts is on top.

Install T10149 with wheel bolt on wheel hub.

Using V.A.G 1383 A, lift wheel bearing housing until dimension -a- is reached.

Scheme 2

Note. Tightening of the respective bolts/nuts must then only occur after dimension -a-, which was measured before installation between the wheel hub center and the lower edge of wheel housing, has been attained

Tighten respective bolts/nuts.

Lower wheel bearing housing.

Move V.A.G 1383 A away from under vehicle.

Remove T10149.

Scheme 3

1. I - Refer to «SUBFRAME, STABILIZER BAR, TRANSVERSE LINK, BALL JOINT, AND LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
2. II - Refer to «WHEEL BEARING HOUSING AND WHEEL BEARING UNIT ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
3. III - Refer to «AUDI MAGNETIC RIDE (AMR) - ELECTRONICALLY-CONTROLLED DAMPING ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe)
4. IV - Refer to «SUSPENSION STRUT ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
5. V - Refer to «DRIVE AXLE WITH 100 MM DIAMETER BOLTED INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) , «DRIVE AXLE WITH 108 MM DIAMETER INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) , «DRIVE AXLE WITH 100 MM DIAMETER INSERTED INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) , «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) , «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, INSTALLED IN TRANSMISSION»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) or «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, MOUNTED ON TRANSMISSION STUB SHAFT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .

Scheme 4

1. Nut 65 Nm Counterhold at socket head of joint bolt when tightening. Always replace after removing it.
2. Stabilizer Bar Removing and installing, refer to «STABILIZER BAR»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__stabilizer-bar) . Different versions. Allocation.
3. Coupling Rod Linking stabilizer to suspension strut.
4. Nut 65 Nm Counterhold at socket head of joint bolt when tightening. Always replace after removing it.
5. Mounting Bracket Locating, refer to «SUBFRAME, SECURING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__subframe-securing) . With bonded rubber bushing Transverse link mounting bracket, replacing, refer to «TRANSVERSE LINK MOUNTING BRACKET»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__transverse-link-mounting-bracket) .
6. Bolt 50 Nm + 90° turn Always replace after removing it.
7. Bolt 70 Nm + 90° turn Always replace after removing it.
8. Bolt 9 Nm
9. Left Front Level Control System Sensor -G78- and Right Front Level Control Sensor -G289- Removing and installing, refer to «LEVEL CONTROL SYSTEM SENSOR»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__level-control-system-sensor) .
10. Transverse Link Transverse link with mounting bracket, removing and installing, refer to «TRANSVERSE LINK WITH MOUNTING BRACKET»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__transverse-link-with-mounting-bracket) . Transverse link bonded rubber bushing, replacing, refer to «TRANSVERSE LINK BONDED RUBBER BUSHING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__transverse-link-bonded-rubber-bushing) . Transverse link mounting bracket, replacing, refer to «TRANSVERSE LINK MOUNTING BRACKET»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__transverse-link-mounting-bracket) .
11. Locking Element Always replace after removing it.
12. Nut 20 Nm + 90° turn Always replace after removing it.
13. Ball Joint Removing and installing, refer to «BALL JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__ball-joint) . Checking, refer to «BALL JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__ball-joint-checking) .
14. Nut 40 Nm + 45° turn Always replace after removing it.
15. Nut 9 Nm
16. Bolt 70 Nm + 90° turn There are different versions depending on the country. Allocation. Note the different bolt lengths. Positioned with the indentation on the bolt head at the rear bolting point on the underbody. Always replace after removing it.
17. Bolt 70 Nm + 90° turn There are different versions depending on the country. Allocation. Always replace after removing it.
18. Bolt 50 Nm + 90° turn Threaded connection on steering gear. Always replace after removing it.
19. Bolt 20 Nm + 90° turn Threaded connection on stabilizer bar. Always replace after removing it.
20. Bolt 70 Nm + 180° turn Always replace after removing it. Tighten only in curb weight position. Refer to «WHEEL BEARING, LIFTING TO CURB WEIGHT POSITION»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__wheel-bearing-lifting-to-curb-weight) .
21. Bolt 100 Nm + 90° turn Only tighten when pendulum support is bolted to transmission. Always replace after removing it.
22. Lower Bonded Rubber Bushing for Pendulum Support Ejecting and pressing in, refer to «SUBFRAME BONDED RUBBER BUSHINGS»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__subframe-bonded-rubber-bushings) .
23. Pendulum Support Bolt first to transmission, then to subframe. Different versions. Allocation.
24. Bolt Manual transmission tightening specifications, refer to «DESCRIPTION AND OPERATION»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe) and refer to «SPECIFICATIONS»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe) . Automatic transmission tightening specifications, refer to «DESCRIPTION AND OPERATION»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe) and refer to «SPECIFICATIONS»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe) .
25. Bolt Manual transmission tightening specifications, refer to «DESCRIPTION AND OPERATION»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe) and refer to «SPECIFICATIONS»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe) . Automatic transmission tightening specifications, refer to «DESCRIPTION AND OPERATION»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe) and refer to «SPECIFICATIONS»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe) .
26. Subframe Removing and installing, refer to «SUBFRAME»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__subframe) . Subframe, servicing, refer to «SUBFRAME BONDED RUBBER BUSHINGS»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__subframe-bonded-rubber-bushings) . Subframe, securing, refer to «SUBFRAME, SECURING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__subframe-securing) . Different versions. Allocation.
27. Upper Bonded Rubber Bushing for Pendulum Support Ejecting and pressing in, refer to «SUBFRAME BONDED RUBBER BUSHINGS»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__subframe-bonded-rubber-bushings) .

SUBFRAME, SECURING

Special tools and workshop equipment required

1. Locating pins T10096
2. Torque wrench V.A.G 1331

Installing T10096

Scheme 5

To secure subframe with transverse links, T10096 must be bolted to items -1-, -8-, -9- and -16-, one after the other.

Replace bolts with T10096 and tighten to 20 Nm.

Securing Mounting Bracket

Scheme 6

Scheme 7

Position of front axle is now secured.

Removing T10096

Installation is performed in the reverse order of removal. Make sure that the T10096 are replaced one after the other with new bolts.

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

Scheme 8

1. Suspension Strut
2. Tie Rod End
3. Bolt 70 Nm + 90° turn Always replace after removing it. Bolt point must face in direction of travel.
4. Bolt 8 Nm
5. Left Front ABS Wheel Speed Sensor -G47- /Right Front ABS Wheel Speed Sensor -G45- Before inserting sensor, clean inner surface of fitting hole and coat with grease G 000 650.
6. Cover Plate
7. Nut 20 Nm + 90° turn Always replace after removing it.
8. Bolt 10 Nm
9. Brake Disc
10. Bolt Hex bolt: 200 Nm + 180° turn. Refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) . Twelve point bolt: 70 Nm + 90° turn. Refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) . Always replace after removing it. Different versions. Allocation. Before installing, clean the threads in the constant velocity joint with a tap.
11. Bolt 4 Nm
12. Wheel Hub with Wheel Bearing Removing and installing, refer to «WHEEL BEARING UNIT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__wheel-bearing-unit) . Sensor ring for ABS is installed in wheel hub. Various versions. Allocation.
13. Wheel Bearing Housing Removing and installing, refer to «WHEEL BEARING HOUSING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__wheel-bearing-housing) . Allocation.
14. Bolt 70 Nm + 90° turn Always replace after removing it.
15. Drive Axle
16. Nut Always replace after removing it.

Scheme 9

1. Shock Absorber with Right Front Dampening Adjustment Valve -N337- Suspension strut, removal and installation, refer to «SUSPENSION STRUT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__suspension-strut) . Suspension strut, servicing, refer to «SUSPENSION STRUT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
2. Right Front Level Control Sensor -G289- Removing and installing, refer to «LEVEL CONTROL SYSTEM SENSOR»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__level-control-system-sensor) .
3. Electronic Damping Control Module -J250- Removing and installing, refer to «ELECTRONIC DAMPING CONTROL MODULE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__electronic-damping-control-module) If the module is replaced, the control position must be reprogrammed. Component location: Installed under the passenger's seat.
4. Damping Adjustment Button -E387- Component location: Installed in the center console switch strip.
5. Shock Absorber with Right Rear Dampening Adjustment Valve -N339- Shock absorber, vehicles with FWD, removing and installing, refer to «SHOCK ABSORBER»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe__shock-absorber) . Shock absorber, vehicles with FWD, servicing, refer to «SHOCK ABSORBER, FWD»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe__shock-absorber-fwd) . Shock absorber, vehicles with AWD, removing and installing, refer to «SHOCK ABSORBER»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe) . Shock absorber, vehicles with AWD, servicing, refer to «SHOCK ABSORBER, AWD»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe__shock-absorber-awd) .
6. Right Rear Level Control System Sensor -G77- Removing and installing, refer to «LEVEL CONTROL SYSTEM SENSORS»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe) .
7. Shock Absorber with Left Rear Dampening Adjustment Valve -N338- Shock absorber, vehicles with FWD, removing and installing, refer to «SHOCK ABSORBER»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe__shock-absorber) . Shock absorber, vehicles with FWD, servicing, refer to «SHOCK ABSORBER, FWD»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe__shock-absorber-fwd) . Shock absorber, vehicles with AWD, removing and installing, refer to «SHOCK ABSORBER»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe) . Shock absorber, vehicles with AWD, servicing, refer to «SHOCK ABSORBER, AWD»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe__shock-absorber-awd) .
8. Left Rear Level Control System Sensor -G76- Removing and installing, refer to «LEVEL CONTROL SYSTEM SENSORS»(/audi/tt/8j-2006-2010/remont/suspension-rear/#rear-suspension-coupe) .
9. Dampening Adjustment Indicator Lamp -K189- The instrument cluster indicator light comes on if there is a malfunction.
10. Shock absorber with Left Front Dampening Adjustment Valve -N336- Suspension strut, removal and installation, refer to «SUSPENSION STRUT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__suspension-strut) . Suspension strut, servicing, refer to «SUSPENSION STRUT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
11. Left Front Level Control System Sensor -G78- Removing and installing, refer to «LEVEL CONTROL SYSTEM SENSOR»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__level-control-system-sensor) .

Scheme 10

1. Shock Absorber Suspension strut, removal and installation, refer to «SUSPENSION STRUT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__suspension-strut) . individually replaceable Allocation. On vehicles with electronically-controlled damping (Audi magnetic ride), the control position must be reprogrammed using the Vehicle Diagnosis, Testing and Information System VAS 5051B each time a shock absorber is replaced.
2. Buffer Stop Not installed on vehicles with electronically controlled damping (Audi magnetic ride).
3. Protective Sleeve
4. Coil Spring Removing and installing, refer to «SUSPENSION STRUT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Note color code. Allocation. Spring allocation via PR No. These numbers can be found on vehicle data plate. Surface of spring coil may not be damaged.
5. Axial Groove Ball Bearing
6. Suspension Strut Bearing Note installation direction.
7. Nut 60 Nm Always replace after removing it.
8. Suspension Strut Dome
9. Bolt 15 Nm + 90° turn Always replace after removing it.

HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING

Special tools and workshop equipment required

1. Angle wrench V.A.G 1756

Loosening

Scheme 11

With vehicle still standing on its wheels, loosen bolt a maximum of 90°, otherwise wheel bearing will be pre-damaged.

Raise vehicle enough that wheels hang freely.

Operate brake (second mechanic required).

Remove bolt -2-.

Tightening

Replace bolt -2-.

Note. Before installing, clean the threads in the constant velocity joint with a tap. Wheels must not yet touch the ground to tighten the drive axle, wheel bearing may otherwise be damaged.

Operate brake (second mechanic required).

Tighten bolt to 200 Nm.

Lower the vehicle onto its wheels.

Tighten bolt an additional 180°.

12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING

Special tools and workshop equipment required

1. Socket XZN 24T10361
2. Angle wrench V.A.G 1756

The wheel bearing must not be under a load while the drive axle threaded connection on the wheel side is loose.

If the bearings are loaded by the vehicle's own weight the wheel bearing will be damaged. This reduces the service life of the wheel bearings. Therefore, observe the following

Vehicles without a drive axle must not be moved, otherwise the wheel bearing will be damaged. If vehicle must be moved, observe the following

Install an outer joint in place of the drive axle.

Tighten outer joint to 120 Nm.

Loosening

Scheme 12

With vehicle still resting on wheels, loosen 12-point bolt with T10361 maximum 90°, otherwise, wheel bearing will be damaged.

Raise vehicle enough that wheels hang freely.

Operate brake (second mechanic required).

Remove 12-point bolt -arrow-.

Note. Before installing, clean the threads in the constant velocity joint with a tap.

Fastening

Replace 12-point bolt.

Note. Wheels must not yet touch the ground to tighten the drive axle, wheel bearing may otherwise be damaged.

Operate brake (second mechanic required).

Tighten 12-point bolt to 70 Nm.

Lower the vehicle onto its wheels.

Tighten 12-point bolt an additional 90°.

FASTENER TIGHTENING SPECIFICATIONS

BALL JOINT, CHECKING

Axial Play, Checking

Scheme 13

Pull transverse link down and press up again.

Radial Clearance, Checking

Scheme 14

Press wheel firmly in and out at bottom.

Note. Observe lower ball joint while performing checks. There should not be any noticeable or visible "play" in either of the two checks. Make allowance for any wheel bearing play or "play" in strut mounting at top. Check rubber boot for damage, replace lower ball joint, if necessary.

CONTROL POSITION ENTRY, REPROGRAMMING WITH VEHICLE DIAGNOSIS, TESTING AND INFORMATION SYSTEM

Special tools and workshop equipment required

1. Vehicle Diagnostic, Testing and Information System VAS 5051B with corresponding diagnostic cable.

Connect VAS 5051B with corresponding diagnostic cable to vehicle.

Switch VAS 5051B on.

VAS 5051B is ready to operate when it displays operating modes in button fields.

Switch on ignition.

Note. If control modules or electric/electronic components were replaced, component adaptation should be carried out in "Guided Functions".

Touch Guided Functions and the screen.

Then

"Chassis (Repair group 01; 40 - 49)"

"14 - Wheel damping electronics"

Select the corresponding program in "Guided Functions".

14 - Code control module (repair group 40)

or

14 - Replace control module (repair group 40)

or

14 - Reprogram control position (repair group 40)

Now follow the instructions on the screen.

OUTER CV JOINT, CHECKING

It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or damage.

Removing

Scheme 15

Before disassembling mark ball hub position in relation to the ball cage and housing with an electric scriber or oil stone -arrow-.

Tilt ball hub and ball cage and remove balls one after another.

Turn cage until two cage windows -arrow- rest on joint body.

Scheme 16

Lift out cage with hub.

Swing a hub segment in a cage window.

Scheme 17

Fold hub out from cage.

Note. 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.

Installing

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

Press quantity of grease specified in table into joint body.

1. 90 mm diameter outer joint, grease quantities, refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__filling-joints-with-grease) .
2. 98 mm diameter outer joint, grease quantities, refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__filling-joints-with-grease) .

Insert cage with hub into joint body.

Note. Cage must be installed laterally correct.

Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be established again.

Install new circlip in shaft.

Distribute remaining grease in the joint boot.

INNER CV JOINT, CHECKING

It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or damage.

Note. Ball hub and joint piece are paired. Before removing, mark in relation to each other using a waterproof felt-tip pen.

Removing

Swing ball hub and ball cage.

Scheme 18

Press out ball joint housing in -direction of arrow-.

Press balls out of cage.

Flip out ball hub from ball cage via running path of ball -arrows-.

Scheme 19

Check joint piece, ball hub, ball cage and balls for small broken off depressions (pitting build-up) and chafing.

Note. Excessive circumferential backlash in joint makes itself noticed via tip-in shock. Joint must be replaced in such cases. Flattening and running marks of balls are no reason to replace joint.

Installing

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

Insert ball hub into ball cage via two chamfers. The installation position is at random. Press balls into cage.

Scheme 20

Insert hub with cage and balls upright into joint piece.

Note. When inserting, make sure that in each case the wide gap -a- at joint piece contacts narrow gap -b- at hub after swinging in. Chamfer on inner diameter of ball hub (splines) must face large diameter of joint piece. Use the felt-tip pen markings made during removal to help with installation.

Swing in ball hub, to do so swing out hub far enough from cage -arrows- so that the balls have the distance of the running paths.

Scheme 21

Swing in hub with balls by pressing forcefully onto cage -arrow-.

Scheme 22

CV Joint, Checking for Function

CV joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length.

SUBFRAME

Special tools and workshop equipment required

1. Locating pins T10096
2. Engine/transmission jack V.A.G 1383 A
3. Torque wrench V.A.G 1331
4. Torque wrench V.A.G 1332
5. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

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

Remove wheels.

Remove lower noise insulation. Refer to Removal and Installation .

Remove noise insulation frame. Refer to Removal and Installation .

Remove exhaust system bracket bolts -arrows-.

Scheme 23

Remove nut -1-.

Scheme 24

On vehicles with a level control system sensor, disconnect the connector and remove the nut from the linkage on the transverse link.

Scheme 25

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

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

Scheme 26

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 .

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

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

Scheme 27

Remove bolts -4- and -5-.

Lower subframe with attachments approximately 30 mm and pry steering gear threaded sleeves out of holes in subframe.

Secure steering gear on body.

Remove cable guide from subframe -arrow-.

Scheme 28

Lower subframe with attachments.

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.

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 .

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] Description and Operation .

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

SUBFRAME BONDED RUBBER BUSHINGS

Special tools and workshop equipment required

1. Installation device 3372
2. Thrust plate VW 401
3. Punch VW 407
4. Thrust piece VW 432
5. Assembly tool T10214
6. Assembly tool T10267
7. Tube from assembly tool T10244/3

Remove subframe. Refer to SUBFRAME .

Remove pendulum support from subframe.

Pressing Out the Bonded Rubber Bushing

Scheme 29

Install T10267 -4- on subframe. Secure safety bolts using securing pins.

1. Punch VW 407
2. Thrust piece 3372/1
3. VW 401
4. T10267
5. Tube T10244/3

Press out both bonded rubber bushings at the same time as depicted in the illustration.

Note. Flat side of 3372/1 must face insert -A- on T10267, otherwise insert may be damaged. T10244/3 has a larger and a smaller inner diameter. Subframe must contact larger inner diameter of T10244/3.

Pressing In the Bonded Rubber Bushing

Scheme 30

Bolt both bonded rubber bushings with original bolt, cutouts -arrows- must align when doing this.

Insert bolted bonded rubber bushings, with bolt head downward, into large diameter of tube T10214/2.

Scheme 31

1. VW 432
2. Thrust piece T10214/3 without bolts
3. Bonded rubber mount
4. T10214/2
5. Tube T10214/1
6. VW 401

Press bonded rubber bushing -1- in until dimension -a- has been obtained.

Scheme 32

Dimension -a- = 2 - 3 mm.

Align T10214/2 on subframe with pressed in bonded rubber bushings. Edges of bonded rubber bushing inner core -1- must run on imaginary line parallel to edge of T10267 -2-.

Scheme 33

Distance -a- must be identical at left and right to guarantee parallelism.

Subframe makes contact on smaller inner diameter of T10244/3.

Press in bearing on stop and until a pressing force of 20 kN has been obtained.

Scheme 34

1. VW 407
2. T10214/3
3. T10214/2
4. T10267
5. T10244/3

Remove T10267 from subframe and check seating of the pressed in bonded rubber bushing.

Scheme 35

1. The outer diameter -1- of both bonded rubber bushings must project up to 2 mm beyond edge in area of opening for pendulum support.
2. Cutouts of bonded rubber bushings must lie at center in opening of subframe.
3. Gap -arrow- between bonded rubber bushings is permissible.

Install subframe. Refer to SUBFRAME .

STABILIZER BAR

Special tools and workshop equipment required

1. Locating pins T10096
2. Engine/transmission jack V.A.G 1383 A
3. Torque wrench V.A.G 1331
4. Torque wrench V.A.G 1332

Removing

Remove subframe. Refer to SUBFRAME .

Remove stabilizer bar from subframe -11 and 14-.

Remove the stabilizer bar.

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 .

Install subframe. Refer to SUBFRAME .

Replace locking element after each removal.

TRANSVERSE LINK WITH MOUNTING BRACKET

Special tools and workshop equipment required

1. Locating pins T10096
2. Torque wrench V.A.G 1332
3. Torque wrench V.A.G 1331
4. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Remove the wheel.

Remove lower noise insulation. Refer to Removal and Installation .

On vehicles with a level control system sensor, remove the nut from the linkage on the transverse link.

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Pull wheel bearing housing with ball joint out of transverse link.

Replace bolt -1- for left side, -8- for right side using T10096 and tighten locating pins to 20 Nm.

Remove bolts -1-.

Remove left side bolt -15- or right side bolt -10-.

Note. On vehicles where bolt -15- or -10- is not to be removed, subframe must be removed. Refer to 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 .

Install left side bolt -15- or right side bolt -10- and tighten by hand.

Replace locking element after each removal.

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

Note. Bonded rubber bushings can only be turned to a limited extent. Only tighten suspension screws when vehicle is in curb weight or control position. Wheel bearing, lifting to curb weight position on vehicles with coil springs, refer to WHEEL BEARING, LIFTING TO CURB WEIGHT POSITION .

Tighten left side bolt -15- or right side bolt -10- in curb weight position. Refer to WHEEL BEARING, LIFTING TO CURB WEIGHT POSITION .

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] Removal and Installation .

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

TRANSVERSE LINK BONDED RUBBER BUSHING

Special tools and workshop equipment required

1. Assembly tool T10219
2. Thrust plate VW 402
3. Punch VW 411

Pressing Out the Bonded Rubber Mount

Scheme 36

Press out bonded rubber bushings as depicted in the illustration.

1. VW 411
2. Tube T10219/1
3. VW 402

Pressing In the Bonded Rubber Bushing

Scheme 37

Bonded rubber bushing installed position: the notches -arrows- are symmetrical to the transverse link axle.

The "knobs" -1 and 2- face forward as illustrated.

Scheme 38

1. Bonded rubber bushing must be installed at an angle to prevent damaging it when pressing in. The bonded rubber bushing will straighten itself out while it is being installed.

Coat the outside of the bonded rubber bushing with installation lubricant (thinned with water in ration 1:20).

Place bonded rubber bushing on at an angle (in direction of transverse link), when doing this the lip -arrow- must slip into hole as shown in the illustration.

1. Drift T10219/2
2. Tube T10219/1
3. VW 402

Press in bonded rubber bushings as far until core -1- and transverse link hole -2- are at the same height.

Scheme 39

Press bearing in transverse link back slightly.

Scheme 40

1. Tube T10219/1
2. VW 402

Dimensions -a- and -b- must be identical.

Scheme 41

TRANSVERSE LINK MOUNTING BRACKET

Special tools and workshop equipment required

1. Punch VW 411
2. Thrust plate VW 401
3. Thrust plate VW 402
4. Sleeve VW 426
5. Punch VW 412
6. Assembly tool T10219

Mounting Bracket, Pressing Off Transverse Link

Note. Hold transverse link firmly while pressing off.

1. VW 401
2. VW 411
3. VW 402

Press mounting bracket with bonded rubber bushing off transverse link.

Mounting Bracket, Pressing Onto Transverse Link

Scheme 42

Coat the hex on the transverse link with installation lubricant (thinned down with water to a ratio of 1:20).

Carefully press bearing onto transverse link as far as stop.

1. VW 412
2. VW 426
3. Mounting bracket with bonded rubber bushing.
4. Transverse link
5. Tube T10219/1 from T10219
6. VW 401

BALL JOINT

Special tools and workshop equipment required

1. Ball joint puller 3287 A
2. Angle wrench V.A.G 1756
3. Ring Spanner Insert V.A.G 1332/10
4. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Remove the wheel.

On vehicles with a level control system sensor, remove the nut from the linkage on the transverse link.

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Disengage the transverse link from the ball joint.

Position 3287 A on ball joint as shown in the illustration.

Scheme 43

Press ball joint out of wheel bearing housing.

Installing

Scheme 44

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 .

Install new self-locking nut, and counter-hold using Internal Torx Bit T40 -item 1-.

Note. Standard ring spanner inserts (AF 18 mm) can also be used instead of the V.A.G 1332/10.

Replace locking element after each removal.

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

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 .

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

LEVEL CONTROL SYSTEM SENSOR

General Information

Vehicles with electronically-controlled damping (Audi magnetic ride) and/or gas discharge lamps have an automatic headlamp range control system as standard equipment. Refer to AUTOMATIC HEADLAMP VERTICAL AIM CONTROL OVERVIEW .

In order to function, the electronically-controlled damping (Audi magnetic ride) and automatic headlamp range control require information about the compression or rebound travel at the front and rear suspension.

For this, the position of the left/right track transverse link in relation to the body is transferred via a coupling rod to Left Front Level Control System Sensor -G78- and Right Front Level Control Sensor -G289-. These transmit electrical signals to the Electronic Damping Control Module -J250- and/or Left/Right High-intensity Gas Discharge Lamp Control Module -J343/344-.

Left/right high-intensity gas discharge lamp control module, servicing, refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

At the rear suspension, these signals are transmitted from the Left Rear Level Control System Sensor -G76- and Right Rear Level Control System Sensor -G77- to the electronic damping control module and/or the left/right high-intensity gas discharge lamp control module.

These signals are required for determining vehicle level.

The automatic headlamp range control reacts independently to changes in vehicle level.

The vehicle level can change in the following situations

1. Trailer Mode
2. Different load conditions; vehicle empty, vehicle partially or fully loaded

Vehicle level sensor is available as replacement part only complete with coupling rod and upper and lower retaining plates.

Note. Program the control position on vehicles with electronically-controlled damping (Audi magnetic ride) and check the headlamp adjustment if

Scheme 45

1. Assembly work was performed on level control system sensor.
2. The transverse link was removed and installed.
3. The threaded connections -2- or -5- were loosened.

Removing

Disconnect the connector.

Remove nut -5-.

Remove bolt -2-.

Remove level control system sensor -3-.

Installing

Installation is performed in the reverse order of removal. Observe the following when doing so

The hooks on the coupling rod must be guided onto the transverse link.

Sensor lever must point outward.

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

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

Perform headlamp basic setting. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Diagnosis and Testing .

WHEEL BEARING HOUSING

Special tools and workshop equipment required

1. Ball joint puller 3287A
2. Torque wrench V.A.G 1332
3. Engine/transmission jack V.A.G 1383 A
4. Angle wrench V.A.G 1756
5. Spreader 3424
6. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Loosen the drive axle threaded connection on the wheel side.

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Remove the wheel.

Remove the brake caliper and secure it to the body using wire. Refer to Removal and Installation .

Remove brake line and electrical line bracket from wheel bearing housing.

Remove the ABS speed sensor. Refer to Removal and Installation .

Remove disc brake.

Remove cover plate from wheel bearing housing.

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

Scheme 46

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

On vehicles with a level control system sensor, remove the nut from the linkage on the transverse link.

On vehicles with electronically-controlled damping (Audi magnetic ride), disconnect connector -2-.

Note. Remove the connector -2- with both hands. Use one hand to open the retainer and use the other hand to press it off. Do not use tools.

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Guide transverse link out of wheel bearing housing with ball joint.

Remove wheel bearing housing from drive axle splines.

Note. The drive axle must not hang down, otherwise the inner joint will be damaged by overflexing. Secure drive axle to body using wire.

Separate wheel bearing housing/suspension strut threaded connection -arrow-.

Scheme 47

Insert 3424 into slot of wheel bearing housing.

Scheme 48

Using a ratchet and the 3424, open the wheel bearing housing slot.

Pull wheel bearing housing with ball joint down from shock absorber tube and remove.

Installing

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

Tightening specifications, refer to WHEEL BEARING HOUSING AND WHEEL BEARING UNIT ASSEMBLY OVERVIEW .

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

Replace locking element after each removal.

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

Tighten drive axle to wheel hub threaded connection.

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

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 .

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

WHEEL BEARING UNIT

Special tools and workshop equipment required

1. Angle wrench V.A.G 1756
2. Torque wrench V.A.G 1332
3. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Remove drive axle. Refer to DRIVE AXLE, BOLTED INNER JOINT , DRIVE AXLE WITH CV JOINT, INSERTED INNER JOINT , DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, MOUNTED ON TRANSMISSION STUB SHAFT or DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, INSTALLED IN TRANSMISSION .

Remove the brake caliper and secure it to the body using wire. Refer to Removal and Installation .

Remove the ABS speed sensor. Refer to Removal and Installation .

Remove disc brake.

Remove bolts -arrows-.

Scheme 49

Remove wheel bearing unit from wheel bearing housing.

The wheel bearing -1- must always face up.

Scheme 50

Always set the wheel bearing unit down on the wheel hub -2-.

Installing

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

Tightening specifications, refer to WHEEL BEARING HOUSING AND WHEEL BEARING UNIT ASSEMBLY OVERVIEW .

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

Replace locking element after each removal.

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

Tighten drive axle to wheel hub threaded connection.

Hex bolt, refer to HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING .

12-point bolt, refer to 12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING .

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 .

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

ELECTRONIC DAMPING CONTROL MODULE

Special tools and workshop equipment required

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

Removing

Scheme 51

Note. The electronic damping control module -J250- is installed under the right front seat.

Remove the right front seat. Refer to Seat Frames .

Cut carpet at markings as shown using a standard carpet knife.

Fold carpet up and unclip control module -2- -arrows-.

Scheme 52

Disconnect electrical connector -1- and remove control module -2-.

Installing

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

If the Electronic Damping Control Module -J250- is replaced, the control position must be reprogrammed.

Insert control module access carpet frame Interior Trim

Reprogram control position using VAS 5051B

SUSPENSION STRUT

Special tools and workshop equipment required

1. Angle wrench V.A.G 1756
2. Torque wrench V.A.G 1332
3. Ball joint puller 3287 A
4. Spreader 3424
5. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Loosen the drive axle threaded connection on the wheel side.

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Remove the wheel.

Remove the brake caliper and secure it to the body using wire. Refer to Removal and Installation .

Remove brake line and electrical line bracket from wheel bearing housing.

Remove the ABS speed sensor. Refer to Removal and Installation .

Remove coupling rod upper hex nut -arrow- from suspension strut.

Scheme 53

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

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

On vehicles with a level control system sensor, remove the nut from the linkage on the transverse link.

On vehicles with electronically-controlled damping (Audi magnetic ride), disconnect connector -2-.

Note. Remove the connector -2- with both hands. Use one hand to open the retainer and use the other hand to press it off. Do not use tools.

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Guide transverse link out of ball joint and remove wheel bearing housing from drive axle splines.

Note. The drive axle must not hang down, otherwise the inner joint will be damaged by overflexing. Secure drive axle to body using wire.

Remove plenum chamber cover. Refer to Removal and Installation .

Remove upper shock absorber mount hex bolts -arrows-.

Scheme 54

Remove suspension strut.

Disconnect suspension strut to wheel bearing housing connection.

Insert 3424 into slot of wheel bearing housing.

Scheme 55

Using a ratchet and the 3424, open the wheel bearing housing slot.

Remove suspension strut -1- from wheel bearing housing -2-.

Installing

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

Tightening specifications, refer to WHEEL BEARING HOUSING AND WHEEL BEARING UNIT ASSEMBLY OVERVIEW .

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

Insert suspension strut, one of the two markings -arrows- must point in direction of travel when doing this.

Scheme 56

Replace locking element after each removal.

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

Tighten drive axle to wheel hub threaded connection.

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Installing plenum chamber cover. Refer to Removal and Installation .

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 .

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

DRIVE AXLE, BOLTED INNER JOINT

Removing

Remove noise insulation. Refer to Removal and Installation .

Loosen wheel side drive axle threaded connection.

Loosening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Remove the wheel.

Remove drive axle from transmission flange, see -arrows-.

Scheme 57

On vehicles with a level control system sensor, remove the nut from the linkage on the transverse link.

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Guide transverse link out of wheel bearing housing with ball joint.

Tip suspension strut outward while pressing drive shaft out of wheel bearing unit with a brass drive (possibly tapping lightly)

Remove drive axle.

Installing

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

Lightly coat the splines on the outer joint with assembly paste before installing the outer joint into the wheel hub.

Tightening specifications, refer to WHEEL BEARING HOUSING AND WHEEL BEARING UNIT ASSEMBLY OVERVIEW .

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

Tightening specifications, refer to DRIVE AXLE WITH 100 MM DIAMETER BOLTED INNER CV JOINT .

Tightening specifications, refer to DRIVE AXLE WITH 108 MM DIAMETER INNER CV JOINT .

Replace locking element after each removal.

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

Tighten drive axle to wheel hub threaded connection.

Tightening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

On vehicles with electronically-controlled damping (Audi magnetic ride), reprogram the control position using Vehicle Diagnostic, Testing and Information System VAS 5051B.

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

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

DRIVE AXLE WITH CV JOINT, INSERTED INNER JOINT

Special tools and workshop equipment required

1. Slide hammer - complete set VW 771
2. Tensioning strap T10038
3. Puller T10382
4. Torque wrench V.A.G 1332
5. Angle wrench V.A.G 1756
6. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Loosen wheel side drive shaft threaded connection.

Loosening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Remove the wheel.

Remove noise insulation. Refer to Removal and Installation .

Remove the wheel housing liner lower section when removing the drive axle. Refer to Removal and Installation .

Remove the level control system sensor, if applicable. Refer to LEVEL CONTROL SYSTEM SENSOR .

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Guide transverse link out of wheel bearing housing with ball joint.

Remove the coupling rod from the stabilizer bar on both sides.

Slide outer joint out of wheel hub by hand.

Secure the drive axle to keep it from falling down.

Note. In order to remove the drive axle from the transmission using the T10382, the suspension strut and all its components must be pulled to the back. Be careful not to damage any parts, for example, brake hose, ABS line.

Scheme 58

Pull the suspension strut and its components using the T10038 as far as possible to the back, for example on the workshop hoist arm, until the T10382 can be installed parallel to the drive axle.

Install the T10382.

Scheme 59

For the CV joint -1-, the opening -arrow- in the removing plate T10382/1 must face the spindles T10382/2.

Place the T10382/1 behind the CV joint -1-.

Scheme 60

The opening -arrow- in the T10382/1 must face the CV joint -1-.

Attach the T10382/2 and the traverseT10382/3 to the T10382/1.

Scheme 61

Attach the VW 771 to the T10382/3.

Remove the drive axle with a few hits on the VW 771.

Scheme 62

Note. Make sure there is enough clearance to the heat shield when removing the right drive axle. Adjust the position of the T10382 if necessary.

Remove the drive axle from the vehicle.

Installing

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

Tightening specifications, refer to WHEEL BEARING HOUSING AND WHEEL BEARING UNIT ASSEMBLY OVERVIEW .

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

All Wheel Drive

Tap on the front side of the stub shaft using a plastic mallet.

Applies to All

Lightly coat the splines on the outer joint with assembly paste before installing the outer joint into the wheel hub

Remove any paint residue and/or corrosion in threads/splines of outer joint.

Install a new seal -1- and locking ring -2- into the groove on the stub shaft on the transmission.

Scheme 63

Apply approximately 2 g of grease around the splines on the transmission.

Bring outer and inner splines of the transmission and CV joint into engagement.

Grab drive axle by hand and push it into the CV joint up to the stop.

Now push the CV joint with one >>jerk<< onto the transmission stub shaft.

Note. If it is difficult to install the drive axle even though the splines are positioned correctly, then slide it in the slip joint. Do not use a hammer or a knocking tool under any circumstances!

Make sure the CV joint is securely fitted by pulling the CV joint against the circlip resistance.

Remove the T10038.

Insert outer joint as far as possible into the splines in the wheel hub.

Replace locking element after each removal.

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

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

Install the lower noise insulation. Refer to Removal and Installation .

Install the wheel housing liner lower section when installing the drive axle. Refer to Removal and Installation .

Install the level control system sensor, if applicable. Refer to LEVEL CONTROL SYSTEM SENSOR .

Tighten drive axle to wheel hub threaded connection.

Tightening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

On vehicles with electronically-controlled damping (Audi magnetic ride), reprogram the 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 .

Axle alignment is required, see Table. Refer to WHEN WHEEL ALIGNMENT IS NECESSARY .

DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, INSTALLED IN TRANSMISSION

Special tools and workshop equipment required

1. Torque wrench V.A.G 1332
2. Wedge T10161
3. Tensioning strap T10038
4. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Loosen wheel side drive axle threaded connection.

Loosening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Remove the wheel.

Remove noise insulation. Refer to Removal and Installation .

Remove the wheel housing liner lower section when removing the drive axle. Refer to Removal and Installation .

Remove the level control system sensor, if applicable. Refer to LEVEL CONTROL SYSTEM SENSOR .

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Guide transverse link out of wheel bearing housing with ball joint.

Remove the coupling rod from the stabilizer bar on both sides.

Slide outer joint out of wheel hub by hand.

Secure the drive axle to keep it from falling down.

Note. In order to remove the drive axle from the transmission using the T10382, the suspension strut and all its components must be pulled to the back. Be careful not to damage any parts, for example, brake hose, ABS line.

Pull the suspension strut and its components using the T10038 as far as possible to the back, for example on the workshop hoist arm, until the T10382 can be installed parallel to the drive axle.

Attach T10161 between transmission housing and triple roller joint.

Scheme 64

Press inner joint out of transmission via a hammer blow on the T10161.

Remove drive axle.

Installing

Insert new securing ring into groove of joint piece pin.

Bring outer and inner splines of joint piece and transmission into engagement.

Grab drive axle by hand and push it into the joint up to the stop.

Now slide joint piece into transmission with a >>tug<<.

Slide path in joint piece can be used for this >>tug<<. When doing this, do not pull the drive axle too far out of the joint.

Note. Do not use a hammer or a knocking tool under any circumstances!

Check drive axle for secure fitting in transmission by pulling joint piece against resistance of the securing ring.

Remove the T10038.

Lightly coat the splines on the outer joint with assembly paste before installing the outer joint into the wheel hub.

Remove any paint residue and/or corrosion in threads/splines of outer joint.

Insert outer joint as far as possible into wheel hub splines.

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

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

Install the lower noise insulation. Refer to Removal and Installation .

Install the wheel housing liner lower section when installing the drive axle. Refer to Removal and Installation .

Install the level control system sensor, if applicable. Refer to LEVEL CONTROL SYSTEM SENSOR .

Tighten drive axle to wheel hub threaded connection.

Tightening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

On vehicles with electronically-controlled damping (Audi magnetic ride), reprogram the 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 .

Axle alignment is required, see Table. Refer to WHEN WHEEL ALIGNMENT IS NECESSARY .

DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, MOUNTED ON TRANSMISSION STUB SHAFT

Special tools and workshop equipment required

1. Slide hammer - complete set VW 771
2. Tensioning strap T10038
3. Puller T10382
4. Torque wrench V.A.G 1332
5. Angle wrench V.A.G 1756
6. Vehicle Diagnostic, Testing and Information System VAS 5051B

Removing

Loosen wheel side drive axle threaded connection.

Loosening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

Remove the wheel.

Remove the lower noise insulation. Refer to Removal and Installation .

Remove the wheel housing liner lower section when removing the drive axle. Refer to Removal and Installation .

Remove the level control system sensor, if applicable. Refer to LEVEL CONTROL SYSTEM SENSOR .

Mark location of nuts -arrows- with felt-tip pen.

Mark location of nuts -arrows- with felt-tip pen.

Remove nuts -arrows-.

Guide transverse link out of wheel bearing housing with ball joint.

Remove the coupling rod from the stabilizer bar on both sides.

Slide outer joint out of wheel hub by hand.

Secure the drive axle to keep it from falling down.

Install the T10382

Scheme 65

For the CV joint -1-, the surface -arrow- in the removing plate T10382/1 must face the spindles T10382/2.

Attach the T10382 to the VW 771.

Note. In order to remove the drive axle from the transmission using the T10382, the suspension strut and all its components must be pulled to the back. Be careful not to damage any parts, for example, brake hose, ABS line.

Pull the suspension strut and its components using the T10038 as far as possible to the back, for example on the workshop hoist arm, until the T10382 can be installed parallel to the drive axle.

Install the T10382 and remove the drive axle.

Note. Make sure there is enough clearance to the heat shield when removing the right drive axle. Adjust the position of the T10382 if necessary.

Remove the drive axle from the vehicle.

Installing

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

Tightening specifications, refer to WHEEL BEARING HOUSING AND WHEEL BEARING UNIT ASSEMBLY OVERVIEW .

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

Tap on the front side of the stub shaft using a plastic mallet.

Lightly coat the splines on the outer joint with assembly paste before installing the outer joint into the wheel hub.

Remove any paint residue and/or corrosion in threads/splines of outer joint.

Install a new seal -1- and locking ring -2- into the groove on the stub shaft on the transmission.

Apply approximately 2 g of grease around the splines on the transmission.

Bring outer and inner splines of the transmission and CV joint into engagement.

Grab drive axle by hand and push it into the CV joint up to the stop.

Now push the CV joint with one >>jerk<< onto the transmission stub shaft. Slide path in joint piece can be used for this >>tug<<. When doing this, do not pull the drive axle too far out of the joint.

Note. Do not use a hammer or a knocking tool under any circumstances!

Make sure the ball joint is securely fitted by pulling the ball joint against the circlip resistance.

Remove the T10038

Insert outer joint as far as possible into wheel hub splines.

Replace locking element after each removal.

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

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

Install the lower noise insulation. Refer to Removal and Installation .

Install the wheel housing liner lower section when installing the drive axle. Refer to Removal and Installation .

Install the level control system sensor, if applicable. Refer to LEVEL CONTROL SYSTEM SENSOR .

Tighten drive axle to wheel hub threaded connection.

Tightening the connection between the drive axle and wheel hub

1. Hex bolt, refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) .
2. 12-point bolt, refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) .

On vehicles with electronically-controlled damping (Audi magnetic ride), reprogram the 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 .

Axle alignment is required, see Table. Refer to WHEN WHEEL ALIGNMENT IS NECESSARY .

Special tools and workshop equipment required

1. Torque wrench V.A.G 1332
2. Spring compressor V.A.G 1752/1
3. Spring holder V.A.G 1752/4
4. Shock absorber set T10001
5. Ratchet (commercially available)

Coil Spring, Removing

Remove suspension strut but do not disconnect from wheel bearing housing. Refer to SUSPENSION STRUT .

Pretension coil spring using V.A.G 1752/1 until upper axial groove ball bearing is free.

Remove hex nut from piston rod.

Remove individual components of suspension strut and coil spring with V.A.G 1752/1.

Scheme 66

1. V.A.G 1752/1
2. V.A.G 1332
3. Ring spanner insert AF 21T10001/8
4. Ratchet T10001/11
5. Ring spanner insert AF 21T10001/5
6. V.A.G 1752/4

Make sure the coil spring is properly seated in the V.A.G 1752/4 see -arrow-.

Scheme 67

Coil Spring, Installing

Scheme 68

Place coil spring with V.A.G 1752/1 on lower spring plate.

End of spring coil must rest against stop -arrow-.

Tighten new hex nut on piston rod. Refer to SUSPENSION STRUT ASSEMBLY OVERVIEW .

Relieve the tension on the V.A.G 1752/1 and remove from the coil spring.

Install suspension strut. Refer to SUSPENSION STRUT .

FILLING JOINTS WITH GREASE

Note. Grease joint again when replacing protective joint boot.

Scheme 69

1. Outer Constant Velocity Joint Replace only as complete unit. Checking, refer to «OUTER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__outer-cv-joint-checking) . Removing, refer to «DRIVE AXLE WITH 100 MM DIAMETER INSERTED INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Grease table, refer to «DRIVE AXLE WITH 100 MM DIAMETER INSERTED INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Installing, refer to «DRIVE AXLE WITH 100 MM DIAMETER INSERTED INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
2. Bolt Hex bolt: 200 Nm + 180° turn. Refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) . Twelve point bolt: 70 Nm + 90° turn. Refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) . Different versions. Allocation. Always replace after removing it. Before installing, clean the threads in the constant velocity joint with a tap.
3. Profile Shaft
4. Clamp Replace. Tensioning, refer to «STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__stainless-steel-clamps-for-hytrel-protective) .
5. CV Boot for Outer CV Joint Without ventilation bore. Check for tears and scuffing.
6. Clamp Replace. Tensioning, refer to «STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__stainless-steel-clamps-for-hytrel-protective) .
7. Dished Washer Installed position, refer to «INSTALLED LOCATION OF SPRING WASHER AND THRUST WASHER ON OUTER JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
8. Spacer Ring (Plastic) Installed position, refer to «INSTALLED LOCATION OF SPRING WASHER AND THRUST WASHER ON OUTER JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
9. Securing Ring Replace. Insert in shaft groove.
10. Protective Boot for Inner Constant Velocity Joint Without ventilation bore. Check for tears and scuffing. Drive off CV joint using drift. Coat the sealing surface of the CV joint with sealant -- before installing.
11. Clamp Replace. Tensioning, refer to «STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__stainless-steel-clamps-for-hytrel-protective) .
12. Backing Plate
13. Bolt Pre-tightening specification: 10 Nm and diagonally Tightening specification M8: 40 Nm and diagonally Tightening specification M10: 70 Nm and diagonally Always replace after removing it.
14. Securing Ring Replace. Removing and installing using VW 161 A, refer to «REMOVING SECURING RING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
15. Gasket NOTE: Bonding surface on CV joint must be free of grease and oil!
16. Inner Constant Velocity Joint Replace only as complete unit. Checking, refer to «INNER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__inner-cv-joint-checking) Pressing off, refer to «Pressing Off Inner Constant Velocity Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . grease --> table, page «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Pressing on, refer to «DRIVE AXLE WITH 100 MM DIAMETER BOLTED INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
17. Dished Washer Installed position, refer to «INSTALLED LOCATION OF SPRING WASHER ON INNER JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .

Disassembling and Assembling

Special tools and workshop equipment required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 408 A
4. Punch VW 411
5. Sleeve VW 416 B
6. Thrust pad VW 447 H
7. Circlip pliers VW 161 A
8. Torque wrench V.A.G 1331
9. Torque wrench V.A.G 1332
10. CV joint boot clamp tool V.A.G 1682
11. Assembly tool T10065

Scheme 70

Drive constant velocity joint off drive shaft by hitting forcefully with a light alloy hammer.

Scheme 71

1. Dished Washer
2. Thrust Washer

Scheme 72

Before installing CV joint or triple roller star, splines -A- must be lightly coated with grease used in joint.

Install old drive shaft bolt in joint as shown in the illustration.

Scheme 73

Drive joint onto shaft with plastic hammer until circlip engages.

Inner CV Joint, Disassembling And Assembling

Scheme 74

Scheme 75

Scheme 76

Constant Velocity Joint, Assembling

Scheme 77

PRESSING ON INNER CV JOINT

Before installing CV joint or triple roller star, splines -A- must be lightly coated with grease used in joint.

Scheme 78

Note. Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

Install circlip

Apply sealant -- -hatched surface- to clean surface on inner side of protective joint boot cap. Sealant bead: unbroken, 2 to 3 mm diameter Skirt area around inner holes -arrow-.

Scheme 79

Use sealant --.

Slide joint protective boot onto drive shaft.

Drive axle, protective joint boot and cap contact surfaces must be free of grease.

Make sure you do not damage the sealant bead.

Using bolts -arrows-, align protective boot and cap with bolt holes.

Scheme 80

It must be aligned exactly because it cannot be aligned after driving on.

Drive off protective boot with cap using plastic hammer.

Clear away leaking sealing immediately.

Scheme 81

Position V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -arrows B- of hose clamp.

Tighten hose clamp by turning spindle -A- using a torque wrench (do not tilt clamping pliers).

1. Tightening specifications: 20 Nm

Note. Be sure thread of spindle in clamping pliers moves freely. Grease with MOS 2 grease, if necessary. If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

Scheme 82

Note. Grease joint again when replacing protective joint boot.

Scheme 83

1. Bolt Hex bolt: 200 Nm + 180° turn. Refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) . Twelve point bolt: 70 Nm + 90° turn. Refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) . Different versions. Allocation. Always replace after removing it. Before installing, clean the threads in the constant velocity joint with a tap.
2. Outer Constant Velocity Joint Replace only as complete unit. Checking, refer to «OUTER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__outer-cv-joint-checking) . Removing, refer to «DISASSEMBLING OUTER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Grease table, refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Installing, refer to «OUTER CV JOINT, INSTALLING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
3. Securing Ring Replace. Insert in shaft groove.
4. Spacer Ring (Plastic) Installed position, refer to «LOCATION OF SPACER RING AND SPRING WASHER ON OUTER JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__location-of-spacer-ring-and-spring) .
5. Dished Washer Installed position, refer to «LOCATION OF SPACER RING AND SPRING WASHER ON OUTER JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__location-of-spacer-ring-and-spring) .
6. Clamp Replace. Tensioning, refer to «Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
7. CV Boot for Outer Constant Velocity (CV) Joint Without ventilation bore. Check for tears and scuffing.
8. Clamp Replace. Tensioning, refer to «Stainless Steel Clamps for Hytrel Protective Joint Boots, Tensioning»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
9. Profile Shaft
10. Clamp Replace. Tensioning, refer to «LARGE CLAMPS FOR RUBBER PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
11. Protective Boot for Inner Constant Velocity Joint Check for tears and scuffing
12. Bolt Pre-tightening specification: 10 Nm and diagonally. Tightening specification M8: 40 Nm and diagonally. Tightening specification M10: 70 Nm and diagonally. Always replace after removing it.
13. Backing Plate
14. Clamp Replace. Tensioning, refer to «LARGE CLAMPS FOR RUBBER PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
15. Inner Constant Velocity Joint Replace only as complete unit. Checking, refer to «INNER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__inner-cv-joint-checking) . Pressing off, refer to «Pressing Off Inner Constant Velocity Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Grease table, refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Pressing on, refer to «DRIVE AXLE WITH 108 MM DIAMETER INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
16. Securing Ring Replace. Removing and installing using VW 161 A. Refer to «CIRCLIP, REMOVING AND INSTALLING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
17. Cover Replace. Drive off CV joint using drift. Apply sealant -- between the joint and the cover. Refer to «COAT THE SEALING SURFACE ON THE COVER WITH SEALANT -- AND THEN INSTALL IT.»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .

Disassembling and Assembling

DISASSEMBLING OUTER CV JOINT

Drive constant velocity joint off drive shaft by hitting forcefully with a light alloy hammer.

LOCATION OF SPACER RING AND SPRING WASHER ON OUTER JOINT

1 - Dished washer

2 - Spacer ring (plastic)

OUTER CV JOINT, INSTALLING

Before installing CV joint or triple roller star, splines -A- must be lightly coated with grease used in joint.

Install old drive shaft bolt in joint as shown in the illustration.

Drive joint onto shaft with plastic hammer until circlip engages.

Inner CV joint, Disassembling and Assembling

Scheme 84

Drive cover down with copper or brass drift.

Scheme 85

Drive out CV joint boot with a drift.

Support ball hub when pressing off.

Before installing CV joint or triple roller star, splines -A- must be lightly coated with grease used in joint.

Scheme 86

Press on joint until stop.

Install circlip.

Note. Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive axle.

APPLY SEALANT -HATCHED AREA- TO CLEAN COVER SURFACE

1. Sealant bead: Unbroken, 2 to 3 mm diameter Guide past inner hole area -arrow-.

Align new cover with bolts -arrows- to bolt holes.

Scheme 87

It must be aligned exactly because it cannot be aligned after driving on.

Drive cover on with a plastic hammer.

Wipe off any sealant -- leaking out.

Scheme 88

The CV boot is frequently pressed in when placed on the CV joint body. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven -arrow-.

Therefore, observe the following

Before clamping the clamping sleeves, balance pressure by raising protective joint boot.

STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING

Position CV joint boot clamp tool V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -arrows B- of hose clamp.

Tighten hose clamp by turning spindle -A- using a torque wrench (do not tilt clamping pliers).

1. Tightening specifications: 20 Nm

Note. Be sure thread of spindle in clamping pliers moves freely. Grease with MOS 2 grease, if necessary. If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

Scheme 89

1. Bolt Twelve point bolt: 70 Nm + 90° turn. Refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) . Hex bolt: 200 Nm + 180° turn. Refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) . Different versions. Allocation. Always replace after removing it. Before installing, clean the threads in the constant velocity joint with a tap.
2. Outer Constant Velocity Joint Replace only as complete unit. Removing, refer to «OUTER CV JOINT, REMOVING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) Divide the grease between the ball paths. Refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) Installing: Drive onto shaft until impact using plastic hammer. Checking, refer to «OUTER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__outer-cv-joint-checking) .
3. Securing Ring Always replace after removing it. Insert in shaft groove.
4. Clamp Always replace after removing it. Tensioning, refer to «MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED.»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__mount-and-tension-stainless-steel-clamp) .
5. Protective Boot Check for tears and scuffing Material: Hytrel (Polyelastomer)
6. Clamp Always replace after removing it. Tensioning, refer to «MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED.»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__mount-and-tension-stainless-steel-clamp) .
7. Drive Axle
8. Clamp Always replace after removing it. Tensioning, refer to «MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED.»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__mount-and-tension-stainless-steel-clamp) .
9. CV Joint Protective Boot Material: Hytrel (Polyelastomer). Check for tears and scuffing.
10. Securing Ring Always replace after removing it. Insert in shaft groove.
11. Clamp Always replace after removing it. Tensioning, refer to «MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED.»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__mount-and-tension-stainless-steel-clamp) .
12. CV Joint Replace only as complete unit Removing, refer to «REMOVING THE INNER CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Divide the grease between the ball paths. Refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Installing: Drive onto shaft until impact using plastic hammer.
13. Protective Cap Removing, refer to «OUTER CV JOINT, REMOVING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Installing, refer to «MOUNTING THE CAP ONTO THE CV JOINT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .

Scheme 90

Secure the drive axle with protective covers in a vise clamp.

Open both clamping sleeves and remove protective joint boot from outer joint.

Strike a copper or brass drift -A- on CV joint inner race with a hammer.

Remove joint and protective joint boot.

Installing the Outer Joint

Scheme 91

Note. Joints and protective joint boots must be free of grease.

Replace the circlip -1-.

Slide on the small clamp with the protective boot and position the protective boot on the drive axle.

Position CV boot in outer groove -arrow B-.

Inner groove -arrow A- must remain visible "identification groove" (for correct installation of CV boot).

Add approximately 70% of the grease to the inner joint. See the table. Refer to FILLING JOINTS WITH GREASE .

Before installing joint piece, splines -A- must be lightly coated with grease used in joint.

Slide on CV joint up to sealing ring.

Scheme 92

Align sealing ring at center with opening upward -see arrows-.

Screw old drive axle bolt into joint as shown in the illustration.

Scheme 93

Drive joint onto drive axle with plastic hammer until circlip engages.

Add the rest of the grease into the joint on the boot side.

Slide the protective boot onto the joint.

Bleed protective joint boot.

Make sure the protective boot is seated on the joint correctly.

Protective joint boot must fit in groove and on joint contour.

Tension clamps on outer joint. Refer to MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED. .

Scheme 94

Secure the drive axle with protective covers in a vise clamp.

Fold back boot.

Remove the CV joint from the drive axle using a drift -A-.

Drive must be applied exactly on star of CV joint.

Installing the Inner CV Joint

Drive onto shaft with plastic hammer until securing ring engages.

MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED.

Attach CV joint boot clamp tool V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -arrows B- of hose clamp.

Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).

Note. A stainless steel clamp must be used due to the hardness of the CV boot material (compared to rubber). This clamp can only be tensioned using the V.A.G 1682. Tightening specifications: 25 Nm. Use torque wrench -C- with adjustment range 5...50 Nm (e.g. torque wrench V.A.G 1331). Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2 grease if necessary. If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Scheme 95

1. Three arm extractor, for example Kukko 45-2
2. Thrust pad VW 447 H

Scheme 96

1. Thrust piece T10243

Mount the cap far enough onto the joint until the ridge -arrow A- fits into the groove -arrow B-.

Note. Grease joint again when replacing protective joint boot.

Scheme 97

1. Bolt Hex bolt: 200 Nm + 180° turn. Refer to «HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__hex-bolt-between-drive-axle-and) . Twelve point bolt: 70 Nm + 90° turn. Refer to «12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__12-point-bolt-between-drive-axle-and) . Different versions. Allocation. Always replace after removing it. Before installing, clean the threads in the constant velocity joint with a tap.
2. Clamp Replace. Tensioning, refer to «LARGE CLAMPS FOR RUBBER PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
3. CV Boot Check for tears and scuffing.
4. Clamp Replace. Tensioning, refer to «LARGE CLAMPS FOR RUBBER PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
5. Profile Shaft
6. Clamp Replace Tensioning, refer to «LARGE CLAMPS FOR RUBBER PROTECTIVE JOINT BOOTS, TENSIONING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
7. Protective Joint Boot for Triple Roller Joint Check for tears and scuffing.
8. Triple Roller Star with Rollers Chamfer -arrow- faces splines of drive axle. When installing triple roller star on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.
9. Securing Ring Replace.
10. Bolt Pre-tightening specification: 10 Nm and diagonally. Tightening specification M8: 40 Nm and diagonally. Tightening specification M10: 70 Nm and diagonally. Always replace after removing it.
11. Bolted Joint
12. Clamp Replace. Tensioning, refer to «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I, DISASSEMBLY AND ASSEMBLY»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__drive-axle-with-triple-roller-joint) .
13. Dished Washer Installed position, refer to «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I, DISASSEMBLY AND ASSEMBLY»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__drive-axle-with-triple-roller-joint) .
14. Spacer Ring (Plastic) Installed position, refer to «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I, DISASSEMBLY AND ASSEMBLY»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__drive-axle-with-triple-roller-joint) .
15. Securing Ring Replace. Insert in shaft groove.
16. Outer Constant Velocity Joint Replace only as complete unit. Removing, refer to «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I, DISASSEMBLY AND ASSEMBLY»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__drive-axle-with-triple-roller-joint) . Installing, refer to «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I, DISASSEMBLY AND ASSEMBLY»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__drive-axle-with-triple-roller-joint) . Checking, refer to «OUTER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__outer-cv-joint-checking) . Grease table, refer to «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I, DISASSEMBLY AND ASSEMBLY»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__drive-axle-with-triple-roller-joint) . When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.

REMOVING OUTER CONSTANT VELOCITY JOINT

Drive constant velocity joint off drive shaft by hitting forcefully with a light alloy hammer.

LOCATION OF SPACER RING AND PLATE SPRING

1 - Dished washer

2 - Spacer ring (plastic)

Before installing CV joint or triple roller star, splines -A- must be lightly coated with grease used in joint.

Install old drive shaft bolt in joint as shown in the illustration.

Drive joint onto shaft with plastic hammer until circlip engages.

The CV boot is frequently pressed in when placed on the CV joint body. This creates a vacuum in the CV boot, which pulls a fold inward when the car is driven -arrow-.

Therefore, observe the following

Before clamping the clamping sleeves, balance pressure by raising protective joint boot.

Scheme 98

Position CV joint boot clamp tool V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -arrows B- of hose clamp.

Tighten hose clamp by turning spindle -A- using a torque wrench (do not tilt clamping pliers).

1. Tightening specifications: 20 Nm

Note. Be sure thread of spindle in clamping pliers moves freely. Grease with MOS 2 grease, if necessary. If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

Scheme 99

DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2600I, DISASSEMBLY AND ASSEMBLY

Special tools and workshop equipment required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 408 A
4. Punch VW 411
5. Sleeve VW 416 B
6. Thrust pad VW 447 H
7. Assembly tool T10065

Disassembling

Scheme 100

Open clamp at shaft and slide back CV boot.

Pull off joint piece from drive axle.

Remove securing ring.

1 - VW 161 A

Insert drive axle in vise.

Press triple roller star off drive axle.

Scheme 101

Pull off CV boot from shaft.

Clean shaft, joint and groove for oil seal.

Assembling

Slide small clamp for joint protective boot onto shaft.

Slide CV boot onto shaft.

Slide joint piece onto shaft.

Triple Roller Star, Conical Drive Axle, Installing

1. The chamfer on star faces toward shaft, this is used as an assembly aid.

Before installing CV joint or triple roller star, splines -A- must be lightly coated with grease used in joint.

Connect triple roller star on shaft and press on up to stop.

Scheme 102

Make sure that pressure does not increase above 3.0 t!

If necessary coat drive axle splines and triple roller star with polycarbamide grease G 052 142 A2.

Insert securing ring, be sure to fit properly.

Slide joint piece over rollers and secure.

Press 70 g drive axle grease from repair kit into triple roller joint.

Press 70 g drive axle grease from repair kit into protective joint boot.

Install CV boot.

Install clamp.

Outer Constant Velocity Joint, Checking

It is necessary to disassemble the joint whenever replacing the grease or if the ball surfaces show wear or damage.

Removing

Before disassembling mark ball hub position in relation to the ball cage and housing with an electric scriber or oil stone -arrow-.

Tilt ball hub and ball cage and remove balls one after another.

Turn cage until two cage windows -arrow- rest on joint body.

Lift out cage with hub.

Swing a hub segment in a cage window.

Fold hub out from cage.

Note. 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.

Installing

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

Press quantity of grease specified in table into joint body.

1. 90mm diameter outer joint, grease quantities, refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__filling-joints-with-grease) .
2. 98 mm diameter outer joint, grease quantities, refer to «FILLING JOINTS WITH GREASE»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__filling-joints-with-grease) .

Insert cage with hub into joint body.

Note. Cage must be installed laterally correct.

Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be established again.

Install new circlip in shaft.

Distribute remaining grease in the joint boot.

Scheme 103

1. Outer Constant Velocity Joint Replace only as complete unit. Removing, refer to «Removing Outer Constant Velocity Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Installing: Drive onto shaft using plastic hammer until compressed circlip seats. Checking, refer to «OUTER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__outer-cv-joint-checking) .
2. Bolt 70 Nm + 90° turn Always replace after removing it. NOTE: Vehicle must not be standing on its wheels when loosening or tightening.
3. Securing Ring Always replace after removing it. Insert in shaft groove.
4. Thrust Washer Installed position, refer to «Installed Location: Spring Washer and Thrust Washer on Outer Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__installed-location-spring-washer-and-thrust) .
5. Dished Washer Installed position, refer to «Installed Location: Spring Washer and Thrust Washer on Outer Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__installed-location-spring-washer-and-thrust) .
6. Clamp Always replace after removing it. Tensioning, refer to «OUTER CV JOINT, REMOVING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
7. CV Boot Check for tears and scuffing. Material: Hytrel (Polyelastomer).
8. Clamp Always replace after removing it. Tensioning, refer to «OUTER CV JOINT, REMOVING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
9. Drive Axle
10. Clamp Always replace after removing it. Tensioning, refer to «OUTER CV JOINT, REMOVING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
11. Protective Joint Boot for Triple Roller Joint Check for tears and scuffing.
12. Clamp Always replace after removing it. Tensioning, refer to «Installed Location: Spring Washer and Thrust Washer on Outer Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__installed-location-spring-washer-and-thrust) .
13. Triple Roller Star with Rollers The chamfer -arrow- points to drive axle splines.
14. Securing Ring Always replace after removing it. Insert in shaft groove.
15. Joint Piece
16. Securing Ring Always replace after removing it.

Disassembling

Special tools and workshop equipment required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 408 A
4. Punch VW 411
5. Sleeve VW 416 B
6. Thrust pad VW 447 H
7. Hose clamp pliers V.A.G 1275
8. Torque wrench V.A.G 1331
9. Torque wrench V.A.G 1332
10. CV joint boot clamp tool V.A.G 1682
11. Assembly tool T10065
12. Slide hammer - complete set VW 771
13. Puller T10382

Secure the drive axle with protective covers in a vise clamp.

Fold back boot.

Align the T10382 so that the flat side of the plate T10382/1 faces the spindles T10382/2.

Attach the T10382 to the VW 771.

Remove the CV joint from the drive axle using the T10382 and VW 771.

Scheme 104

1. T10382/1
2. T10382/2

Driving on Outer CV Joint

INSTALLED LOCATION: SPRING WASHER AND THRUST WASHER ON OUTER JOINT

1. Dished washer
2. Thrust washer

Install the new circlips.

Slide new CV boot onto drive axle if necessary.

Drive it onto shaft with plastic hammer until securing ring engages.

Disassembling

Open both clamps at inner joint and slide back CV boot.

Remove joint from drive axle.

Remove securing ring.

1 - Pliers (commercially available)

Insert drive axle in vise.

Press the triple roller star off the drive shaft.

Pull off CV boot from shaft.

Clean shaft, joint and groove for oil seal.

Assembling

Slide small clamp for joint protective boot onto shaft.

Slide CV boot onto shaft.

Slide joint piece onto shaft.

Mount Triple Roller Star

Conical-Type Drive Axle

Note. The chamfer on star faces toward shaft, this is used as an assembly aid.

Connect triple roller star on shaft and press on up to stop.

Make sure the pressure does not increase above 3.0 t.

If necessary, coat the drive shaft splines and triple roller star with lubricating paste G 052 142 A2.

Insert securing ring, be sure to fit properly.

Press half of the joint grease from the repair set into the triple roller joint.

Slide joint piece over rollers and secure.

Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

Install CV boot.

Mount Triple Roller Star

Cylindrical-Type Drive Axle

Connect triple roller star on shaft and press on up to stop.

Scheme 105

Make sure the pressure does not increase above 3.0 t.

If necessary, coat the drive shaft splines and triple roller star with lubricating paste G 052 142 A2.

Insert securing ring, be sure to fit properly.

Press half of the joint grease from the repair set into the triple roller joint.

Slide joint piece over rollers and secure.

Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

Install CV boot.

Push the protective boot onto the joint and mount the clamp, refer to MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED. .

Scheme 106

1. Outer Constant Velocity Joint Replace only as complete unit. Removing, refer to «Removing Outer Constant Velocity Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) . Installing: Drive onto shaft using plastic hammer until compressed circlip seats. Checking, refer to «OUTER CV JOINT, CHECKING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__outer-cv-joint-checking) .
2. Bolt 70 Nm + 90° turn Always replace after removing it. NOTE: Vehicle must not be standing on its wheels when loosening or tightening.
3. Securing Ring Always replace after removing it. Insert in shaft groove.
4. Clamp Always replace after removing it. Tensioning, refer to «OUTER CV JOINT, REMOVING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
5. CV Boot Check for tears and scuffing. Material: Hytrel (Polyelastomer).
6. Clamp Always replace after removing it. Tensioning, refer to «OUTER CV JOINT, REMOVING»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
7. Drive Axle
8. Clamp Always replace after removing it. Tensioning, refer to «FRONT AXLE OVERVIEW»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
9. Protective Joint Boot for Triple Roller Joint Check for tears and scuffing.
10. Clamp Always replace after removing it. Tensioning, refer to «FRONT AXLE OVERVIEW»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe) .
11. Triple Roller Star with Rollers The chamfer -arrow- points to drive axle splines.
12. Securing Ring Always replace after removing it. Insert in shaft groove.
13. Adapter
14. Joint Piece
15. Cap Removing, refer to «Removing the Cap from the Triple Roller Joint»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__removing-the-cap-from-the-triple) . Installing, refer to «DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, MOUNTED ON TRANSMISSION STUB SHAFT»(/audi/tt/8j-2006-2010/remont/suspension-front/#front-suspension-coupe__drive-axle-with-triple-roller-joint) .

Disassembling

Special tools and workshop equipment required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 408 A
4. Punch VW 411
5. Sleeve VW 416 B
6. Thrust pad VW 447 H
7. Hose clamp pliers V.A.G 1275
8. Torque wrench V.A.G 1331
9. Torque wrench V.A.G 1332
10. CV joint boot clamp toolV.A.G 1682
11. Assembly tool T10065
12. Slide hammer - complete set VW 771
13. Puller T10382

Secure the drive axle with protective covers in a vise clamp.

Fold back boot.

Align the T10382 so that the flat side of the plate T10382/1 faces the spindles T10382/2.

Attach the T10382 to the VW 771.

Remove the CV joint from the drive axle using the T10382 and VW 771.

1. T10382/1
2. T10382/2

Driving On Outer CV Joint

Install the new circlips.

Slide new CV boot onto drive axle if necessary.

Drive it onto shaft with plastic hammer until securing ring engages.

Disassembling

Open clamping sleeve on inner joint and slide protective boot back from adapter.

Pull off joint piece from drive axle.

Remove securing ring.

1 - Pliers (commercially available)

Insert drive axle in vise.

Press the triple roller star off the drive axle.

Pull off CV boot from shaft.

Clean shaft, joint and groove for oil seal.

Assembling

Slide small clamp for joint protective boot onto shaft.

Slide CV boot onto shaft.

Slide joint piece onto shaft.

Mount Triple Roller Star

Conical-Type Drive Axle

The chamfer on star faces toward shaft, this is used as an assembly aid.

Connect triple roller star on shaft and press on up to stop.

Make sure the pressure does not increase above 3.0 t.

If necessary, coat the drive shaft splines and triple roller star with lubricating paste G 052 142 A2.

Insert securing ring, be sure to fit properly.

Press half of the joint grease from the repair set into the triple roller joint.

Slide joint piece over rollers and secure.

Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

Install CV boot.

Mount Triple Roller Star

Cylindrical-Type Drive Axle

Connect triple roller star on shaft and press on up to stop.

Make sure the pressure does not increase above 3.0 t.

If necessary, coat the drive shaft splines and triple roller star with lubricating paste G 052 142 A2.

Insert securing ring, be sure to fit properly.

Press half of the joint grease from the repair set into the triple roller joint.

Slide joint piece over rollers and secure.

Press the remaining half of the drive axle grease from the repair kit into the rear side of the triple roller joint.

Slide the protective boot onto the adapter and ensure the boot engages correctly in the groove on the adapter -arrow-.

Scheme 107

Mount and tension the clamp until a proper seal is guaranteed.

REMOVING THE CAP FROM THE TRIPLE ROLLER JOINT

1. Three arm extractor, for example Kukko 45-2
2. VW 447 H

MOUNTING THE CAP ONTO THE TRIPLE ROLLER JOINT

1. T10243

Mount the cap far enough onto the joint until the ridge -arrow A- fits into the groove -arrow B-.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. Ring Spanner Insert V.A.G 1332/10
2. Hose clamp pliers V.A.G 1275
3. Wheel hub support T10149
4. Sleeve VW 426
5. Punch VW 412
6. Assembly tool T10219
7. Vehicle Diagnostic, Testing and Information System VAS 5051B with corresponding diagnostic cable.
8. Socket XZN 24T10361
9. Angle wrench V.A.G 1756
10. Locating pins T10096
11. Engine/transmission jack V.A.G 1383 A
12. Tube from assembly tool T10244/3
13. Ball joint puller 3287 A
14. Spreader 3424
15. Wedge T10161
16. Tensioning strap T10038
17. Slide hammer - complete set VW 771
18. Puller T10382

Scheme 120

Special tools and workshop equipment required

1. Installation device 3372
2. Thrust plate VW 401
3. Punch VW 407
4. Thrust piece VW 432
5. Assembly tool T10214
6. Assembly tool T10267

Scheme 121

Special tools and workshop equipment required

1. Torque wrench V.A.G 1332
2. Spring compressor V.A.G 1752/1
3. Spring holder V.A.G 1752/4
4. Shock absorber set T10001

Scheme 122

Special tools and workshop equipment required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 408 A
4. Punch VW 411
5. Sleeve VW 416 B
6. Thrust pad VW 447 H

Scheme 123

Special tools and workshop equipment required

1. Circlip pliers VW 161 A
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332
4. CV joint boot clamp tool V.A.G 1682
5. Assembly tool T10065

See also:
• DESCRIPTION AND OPERATION
• DESCRIPTION AND OPERATION
• SHOCK ABSORBER
• SHOCK ABSORBER, FWD
• SHOCK ABSORBER
• SHOCK ABSORBER, AWD
• Removal and Installation
• Removal and Installation
• STEERING GEAR ASSEMBLY OVERVIEW
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Description and Operation
• WHEN WHEEL ALIGNMENT IS NECESSARY
• AUTOMATIC HEADLAMP VERTICAL AIM CONTROL OVERVIEW
• Removal and Installation
• Removal and Installation
• Seat Frames
• Interior Trim
• WHEEL BEARING, LIFTING TO CURB WEIGHT POSITION
• HEX BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING
• 12-POINT BOLT BETWEEN DRIVE AXLE AND WHEEL HUB, LOOSENING AND TIGHTENING
• SUBFRAME, STABILIZER BAR, TRANSVERSE LINK, BALL JOINT, AND LEVEL CONTROL SYSTEM SENSOR ASSEMBLY OVERVIEW
• STABILIZER BAR
• SUBFRAME, SECURING
• TRANSVERSE LINK MOUNTING BRACKET
• LEVEL CONTROL SYSTEM SENSOR
• TRANSVERSE LINK WITH MOUNTING BRACKET
• TRANSVERSE LINK BONDED RUBBER BUSHING
• BALL JOINT
• BALL JOINT, CHECKING
• SUBFRAME BONDED RUBBER BUSHINGS
• SUBFRAME
• WHEEL BEARING UNIT
• WHEEL BEARING HOUSING
• SUSPENSION STRUT
• ELECTRONIC DAMPING CONTROL MODULE
• FILLING JOINTS WITH GREASE
• DRIVE AXLE, BOLTED INNER JOINT
• DRIVE AXLE WITH CV JOINT, INSERTED INNER JOINT
• DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I, MOUNTED ON TRANSMISSION STUB SHAFT
• OUTER CV JOINT, CHECKING
• STAINLESS STEEL CLAMPS FOR HYTREL PROTECTIVE JOINT BOOTS, TENSIONING
• INNER CV JOINT, CHECKING
• LOCATION OF SPACER RING AND SPRING WASHER ON OUTER JOINT
• MOUNT AND TENSION STAINLESS STEEL CLAMP USING CLAMPING DEVICE V.A.G 1682 AS ILLUSTRATED.
• Installed Location: Spring Washer and Thrust Washer on Outer Joint
• Removing the Cap from the Triple Roller Joint