Suspension, Wheels, Steering Audi TT 8N

* On vehicles with 225/45 R 17 tires on wheels with 32 mm rim offset the track widths are 2 mm less.

* Wheelbase and track widths have a tolerance of ± 6 mm

General information

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

The wheel bearings must not be subjected to load when the 12-point nut is loose.

If the wheel bearings are subjected to the full weight of the vehicle they will be overloaded, resulting in reduced service life. Please note the following

1. Lift vehicle enough to relieve load on front wheels.
2. Loosen 12-point nut or flange bolt.

Never move vehicles after the drive axle has been removed; this will result in wheel bearing damage. If the vehicle does have to be moved, always note the following

1. Install an outer joint in place of the drive axle.
2. Secure the outer joint by tightening to the specified torque for the drive axle.

Bonded rubber bushings can only be turned to a limited extent. The bolt connections on the suspension links should only be tightened when the vehicle is standing on the ground.

If the wheel alignment has to be checked and adjusted at a later time, all nuts and bolts which need to be loosened to make adjustments should initially be tightened to the specified torque. After the wheel alignment has been checked and adjusted, nuts and bolts must then be fully tightened by turning them through the specified angle.

Damaged threads, repairing

Damaged threads can be repaired with wire inserts (Heli-coil).

For information on which threads can be repaired please refer to the exploded views of components.

Metal particles remaining in the vehicle body must be embedded in wax.

Front gas-filled struts, emptying

A - Emptying by drilling

Scheme 861

1. Clamp gas-filled shock absorber vertically in vise, with piston rod pointing downward.

1. Drill a 3mm diameter hole - arrow A - through outer tube of strut.

Note. Gas will escape during drilling.

1. Continue drilling until inner tube is penetrated (approx. 25mm deep).
2. Drill a second 6mmdiameterhole - arrow B - through outer and inner tubes of strut.
3. Hold strut over an appropriate container for catching oil and move the piston rod up and down several times through the entire stroke until no more oil comes out.

B - Opening strut with a pipe cutter

Scheme 862

1. Drill a 3mmdiameterhole - arrow - through outer tube of strut, or saw through side of tube.

Note. Gas will escape while drilling or sawing.

1. Apply pipe cutter (e.g. 150/3 Stahlwille Express) as shown in illustration and cut through outer tube.
2. Pull piston rod upward, at the same time holding the inner tube securely with pliers and pressing it downward, so that it remains in the outer tube when the piston rod is pulled up slowly.
3. Remove piston rod from inner tube.
4. Drain strut tube.

Rear gas-filled struts, emptying

A - Emptying by drilling

Scheme 863

1. Clamp gas-filled strut vertically in vise, with piston rod pointing downward.

1. Drill a 3mmdiameterhole - arrow A - through outer tube of strut.

Note. Gas will escape while drilling.

1. Continue drilling until inner tube is penetrated (approx. 25mm deep).
2. Drill a second 6mmdiameterhole - arrowB - through outer and inner tubes of strut.
3. Hold strut over an appropriate container for catching oil and move piston rod up and down several times through entire stroke until no more oil comes out.

B - Opening strut with a pipe cutter

Scheme 864

1. Drill a 3mmdiameterhole - arrow - through outer tube of strut, or saw through side of tube.

Note. Gas will escape while drilling or sawing.

1. Apply pipe cutter (e.g. 150/3 Stahlwille Express) as shown in illustration and cut through outer tube.
2. Pull piston rod upward, at the same time holding the inner tube securely with pliers and pressing it downward, so that it remains in the outer tube when the piston rod is pulled up slowly.
3. Remove piston rod from inner tube.
4. Drain shock absorber tube.

Power steering gear, draining

Note. Room temperature must be at least 20° C when draining steering gear.

Scheme 865

1. Turn steering pinion in direction of - arrow - until stop.

Scheme 866

1. Clamp steering gear horizontally in a vise.
2. Place appropriate receptacle underneath steering gear.
3. Saw off steering gear at point indicated by - arrow A -.
4. Hold the opened steering gear over the drip tray and allow the hydraulic fluid to drain. If necessary, turn the steering pinion to the opposite stop.

Leaking shock absorbers

Shock absorbers are often replaced because of externally visible leakage. Inspections on the test rig and in the vehicle have shown that in the majority of cases this replacement is not justified.

Slight loss of fluid ("sweating") at the piston rod seal is not a reason for replacing a shock absorber. A shock absorber with slight fluid leakage can be accepted as "OK" under the following conditions

Scheme 867

1. Fluid seepage (shaded part of the illustration) is visible, but the fluid is dull and possibly dried by dust
2. The fluid seepage extends only from the top shock absorber seal (piston rod oil seal) down to the bottom spring plate - arrow -.

Note. Slight fluid leakage is actually beneficial, as it lubricates the piston rod oil seal and thus extends the life of the shock absorber. This applies to shock absorbers on both the front and rear axles.

Noisy shock absorbers

Shock absorbers are often replaced because of rattling noises experienced by the customer. Inspections on the test rig and in the vehicle have shown that in approx. 70% of these cases the complaints and subsequent replacement were not justified.

Proceed as follows for complaints involving rattling or cracking noises

1. Determine where, when and how noises develop during a road test with the customer - if possible road test vehicle on a dry, uneven driving surface.
2. Use trouble shooting table "Noises at front and rear end of vehicle" for troubleshooting "Special Information; "Troubleshooting. Suspension"

Note. These noises are very rarely caused by the shock absorbers.

Shock absorbers, checking when removed from vehicle

Faulty shock absorbers are noticeable during driving due to loud rattling noises - caused by wheel bouncing - particularly on rough driving surfaces. They can also be externally identified by large oil loss.

Note. Shock absorbers are maintenance-free; shock absorber fluid cannot be refilled.

A shock absorber that has been removed from the vehicle can be checked by hand as follows

1. Compress shock absorber by hand.

1. The piston rod should move smoothly over the entire stroke with uniform resistance and without jerking.

1. Release piston rod.

1. For shock absorber with sufficient gas pressure the piston rod will return by itself to its original position.

Note. If this is not the case, the shock absorber does not necessarily need to be replaced. Provided there has been no major loss of fluid, it will still be as effective as a conventional shock absorber. Even without gas pressure, the shock absorber will provide full damping effect as long as there has been no major loss of fluid. However, it may produce more noise.

Shock absorbers, testing on shock tester

Shock absorbers can be tested while still installed in vehicle via the shock tester (shock absorber test tool).. The damping capacity can be assessed on the basis of the pointer or the print-out.

Special tools and workshop equipment required

1. Boge shock tester

or

1. Sachs shock tester V.A.G1975

or

1. Maha shock absorber tester VAS1990

Note. Temperature +10° to +40° C Driver in vehicle. Tire pressure OK. Vehicle driven onto center of wheel plates in straight-ahead position. Front wheels in straight-ahead position. Parking brake not applied, brake pedal not depressed.

Test results

Shock absorbers can only be evaluated as follows

1. Damping effect satisfactory

or

1. Damping effect unsatisfactory

Note. Intermediate values for a reduced damping power cannot be read out. Predicting service life is not permitted. Measured values that involved a contribution of force by spring range end stop, are false.

The following values are valid only for the above mentioned test stands. If the specified values are exceeded, the shock absorber has been weakened by more than 50% - replacement is justified.

Front axle, TT Coupe with Front Wheel Drive (FWD)

Scheme 868

1. a = higher than 50: Damping effect unsatisfactory
2. a = lower than 50: Damping effect satisfactory

Rear axle, TT Coupe with Front Wheel Drive (FWD)

1. a = higher than 54: Damping effect unsatisfactory
2. a = lower than 54: Damping effect satisfactory

Front axle, TT Coupe with All Wheel Drive (AWD)

1. a = higher than 49: Damping effect unsatisfactory
2. a = lower than 49: Damping effect satisfactory

Rear axle, TT Coupe with All Wheel Drive (AWD)

1. a = higher than 50: Damping effect unsatisfactory
2. a = lower than 50: Damping effect satisfactory

Front axle, TT Roadster with Front Wheel Drive (FWD)

1. a = higher than 50: Damping effect unsatisfactory
2. a = lower than 50: Damping effect satisfactory

Rear axle, TT Roadster with Front Wheel Drive (FWD)

1. a = higher than 54: Damping effect unsatisfactory
2. a = lower than 54: Damping effect satisfactory

Front axle, TT Roadster with All Wheel Drive (AWD)

1. a = higher than 50: Damping effect unsatisfactory
2. a = lower than 50: Damping effect satisfactory

Rear axle, TT Roadster with All Wheel Drive (AWD)

1. a = higher than 50: Damping effect unsatisfactory
2. a = lower than 50: Damping effect satisfactory

Threads in longitudinal member, repairing

Under certain circumstances it is possible to repair threads in the captive nuts in the longitudinal member.

1. Each thread can only be repaired once.
2. If a second repair is needed, the captive nut must be replaced.

1. Have thread repair checked by foreman or supervisor.
2. The thread insert must be of same length as thread in body.

Components, assembly overview

1. Removing and installing cross piece for suspension strut «Cross piece for suspension strut»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
2. Removing and installing diagonal member for subframe (Scheme 874)

Scheme 869

1 - Subframe retaining bracket

The captive nut cannot be reworked. If the nut is damaged, the complete mounting bracket must be replaced.

2 - Captive nut in body

1. Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). Thread insert must be of same length as thread in body.

3 - Bushing

1. Two-piece version; note installation position «Installation position of upper and lower halves of subframe bushing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
2. Removing and installing --> «Subframe bushings, replacing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__subframe-bushings-replacing)

4 - Hex bolt M 14 x 1.5 x 63

1. Always replace
2. Tighten to 100 Nm plus an additional 90° ( 1 / 4 turn).
3. Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). Thread insert must be of same length as thread in body.

5 - Self-locking nut

1. M 12 x 1.5
2. Always replace if removed

6 - Rear bushing for control arm

1. Different versions available --> Parts Catalog
2. Removing and installing (Scheme 898)

7 - Hex bolt M 12 x 1.5 x 70

1. 70Nm plus an additional 90° ( 1 / 4 turn).
2. Always replace if removed

8 - Self-locking nut

1. Tightening torque: 75 Nm
2. TT VR6 Roadster: 150 Nm
3. M 12 x 1.5
4. Always replace if removed

9 - Swivel ball joint

1. Checking --> «Ball joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-checking)
2. Removing and installing --> «Ball joint, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-removing-and-installing)
3. Mark installation position; if control arm is replaced, set to center of elongated hole and check toe setting/camber
4. Wheel alignment --> «Wheel alignment»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

10 - Hex nut, tighten to 75 Nm

1. M10
2. Always replace if removed

11 - Control arm

1. Different versions available --> Parts Catalog
2. The same version must be installed on both sides
3. Removing and installing --> «Ball joint, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-removing-and-installing)

12 - Hex bolt, 25 Nm

1. M8 x 20

13 - Linkage for headlight range control

1. Adjustment dimension for bracket with elongated hole «Adjustment dimension for headlight range control linkage at bracket with elongated hole»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
2. Tighten nuts (M6) to 4 Nm.
3. Headlight range control --> «Vehicle level sensor in vehicles with automatic headlight range control»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__vehicle-level-sensor-in-vehicles-with)

14 - Front bushing for control arm

1. Different versions available --> Parts Catalog
2. Removing and installing (Scheme 895)

15 - Hex bolt M 14 x 1.5 x 95

1. 100Nm plus an additional 90° ( 1 / 4 turn).
2. Always replace if removed

The captive nut cannot be reworked. If the nut is damaged, the complete mounting bracket must be replaced.

16 - Coupling link

1. Link between stabilizer bar and suspension strut

17 - Hex nut, tighten to 90 Nm

1. M 12 x 1.5
2. Always replace if removed

18 - Stabilizer bar

Removing and installing --> Stabilizer bar, removing and installing

19 - Hex bolt M 12 x 1.5 x 78

1. 70Nm plus an additional 90° ( 1 / 4 turn).
2. Always replace if removed

20 - Hex bolt, 25 Nm

1. M8x45

21 - Hex bolt, 50 Nm

1. M10x70

22 - Hex bolt, 50 Nm

1. M10x30

23 - Pendulum support

24 - Subframe

1. Removing and installing --> «Subframe, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__subframe-removing-and-installing)
2. Installation position of cross piece «Installation position of subframe cross piece»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

25 - Rubber bushing

26 - Clamp

27 - Hex bolt, 25 Nm

1. M8 x 20

Scheme 870

A - Upper half of bushing without collar, ribs faces body.

B - Lower half of bushing, collar faces bolt head

Scheme 871

Cross piece is not installed on all vehicles.

F - Direction of travel

1 - Subframe

2 - Pop rivet nut, M10

Insert using V.A.G1765B.

3 - Cross piece

Install with marking "L" or "links" on left as seen facing in direction of travel.

Foam strip faces downward - arrow -.

4 - Hex bolt, M10x45

Use new bolts after disassembling.

Use locking fluid D 000 600 A2 when installing.

Tightening torque: 30 Nm plus an additional 90° ( 1 / 4 turn)

Scheme 872

Scheme 873

1. Loosen nuts - 3 - (3x) and - 2 - (1x). Tightening torque: 20 Nm
2. If necessary, re-adjust cross piece - 1 - by loosening nuts - 4 - (2x). Tightening torque: 20 Nm

Scheme 874

1. Remove bolts -1- with locking washer - 2 - (8x). Tightening torque: 35 Nm.
2. Remove diagonal strut - 3 -.

Stabilizer bar, removing and installing

Removing

1. Remove wheels.

Scheme 875

1. Remove noise insulation panel.
2. Remove left and right side noise insulation on subframe.
3. If installed, detach headlight range control linkage at left control arm--> «Vehicle level sensor in vehicles with automatic headlight range control»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__vehicle-level-sensor-in-vehicles-with) .
4. Remove stabilizer bar from coupling rod. Tightening torque: 100 Nm. Use new nuts.

Scheme 876

1. Secure tie rod to suspension strut using tensioning straps T10038 (apply straps next to inner rubber boots). This will prevent the steering column from slipping off from steering gear splines during the next step.

Scheme 877

1. For AWD vehicles and 165 kW engine (code: APX), remove rubber mounting - arrow - at the front exhaust pipe.

Note installation position of rubber mounting for later installation.

Scheme 878

1. Remove bolts - 1 - for steering gear.

Scheme 879

1. Position engine/transmission jack V.A.G1383A with universal mount 1359/2 and a wood block under subframe.
2. Remove diagonal strut (if installed) «Diagonal member for subframe»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) .

1. Remove bolts for pendulum support - 2 -.

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

Scheme 880

1. Carefully pry off subframe for steering gear from main subframe using a tire iron or similar.
2. If necessary, remove hex nut for retaining clip on stabilizer bar clamp (left-side). Tightening torque: 22 Nm
3. Carefully lower subframe.

Note the side noise insulation panel and bracket for hydraulic line on left side when lowering subframe.

1. Remove bolt - 27 -.

Scheme 881

1. Tightening torque: 25 Nm

1. Disengage stabilizer bar clamp - 26 -.
2. Take out stabilizer bar - 18 - rearward.

Installing

1. Secure stabilizer bar - 18 - to subframe from the rear with bushing - 25 - , clamp - 26 - and bolt - 27 -.

1. Tightening torque: 25 Nm.
2. Installation position of stabilizer bar bushing «Removing hex nut from shock absorber»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Rest of installation is the reverse of removal.

Scheme 882

Installation position of stabilizer bar bushing

1 - Stabilizer bar clamp

2 - Stabilizer bar bushing

3 - Stabilizer bar

Vehicle level sensor in vehicles with automatic headlight range control

Vehicles with gas discharge lamps have automatic headlight range control as standard equipment.

The automatic headlight range control requires information regarding compression and rebound travel at the front and rear suspension in order to function correctly.

For this purpose the position of the lower left control arm in relation to the body is transferred to the left front level control system sensor G78 via a coupling rod. This transmits electrical signals to the control module for the headlight range control.

On the rear axle, the signals are transmitted to the control module by the left rear level control system sensor G76.

These signals are required to determine the current height of the vehicle.

The automatic headlight range control reacts to changes in the suspension height (attitude of the vehicle).

Scheme 883

The attitude of the vehicle can vary in the following situations

1. Different load conditions; vehicle empty, vehicle partly or fully loaded
2. Slow or fast driving

Note. The basic headlight setting must always be checked when: The control arm has been removed or replaced Electrical Equipment On Board Diagnostic (OBD) Self-diagnosis of automatic headlight range control Installation work has been performed on the vehicle level sensor The vehicle level sender has been replaced The retaining clip for the coupling rod on the control arm has been detached

Basic setting of headlights Electrical Equipment On Board Diagnostic (OBD) Self-diagnosis of automatic headlight range control; Basic setting

1 - Bracket

2 - Hex nut, 8 Nm

3 - Left front level control system sensor-G78

1. Checked electrically via On Board Diagnostic (OBD)
2. For problems/complaints --> «01 ON BOARD DIAGNOSTIC (OBD)»(/audi/tt/8n-1998-2003/remont/cruise-control-systems/#electrical-equipment)

4 - Coupling rod from left front level control system sensor -G78-; tightening torque to component : 4Nm - 3

5 - Control arm

6 - Hex bolt, 25 Nm

7 - Coupling rod

1. Adjustment dimension for bracket with elongated hole «Adjustment dimension for headlight range control linkage at bracket with elongated hole»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

8 - Hex nut, 4 Nm

9 - Connector

10 - Longitudinal member

11 - Pop-rivet bolt

The pop-rivet bolt can be installed with the pop rivet tongs V.A.G1765B

Scheme 884

Dimension a = 19 mm

Tighten nuts (M6) to 4 Nm.

Ball joint, checking

Checking axial play

Scheme 885

1. Pull control arm firmly downwards and press back up again.

Checking radial clearance

Scheme 886

1. Press wheel firmly inward and outward.

Note. There should not be any noticeable or visible "play" in either of the two checks. Observe lower ball joint while performing 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.

Ball joint, removing and installing

Special tools, testers and auxiliary items required

Scheme 887

1. Ball joint puller 3287 A
2. Ball joint puller Kukko 129/0

Scheme 888

1. Torque wrench V.A.G1332, measuring range 40 to 200 Nm

Removing

All vehicles

1. Remove wheel.
2. Mark positions of nuts.

Scheme 889

1. Remove lower nuts from ball joint.

Scheme 890

1. Remove upper nut from ball joint.

Roadster TT VR6 only

1. Detach control arm from ball joint.

Scheme 891

1. Apply ball joint puller Kukko 129/0 as shown in the illustration and press out ball joint.

Note. Use the ball joint puller specified here and make sure it is seated correctly, otherwise the sleeve in the wheel bearing housing will be pulled out together with the ball joint. Leave nut on a few turns to protect ball joint threads.

All other vehicles

Scheme 892

1. Attach ball joint puller as shown in the illustration and press out ball joint.

Note. Leave nut on a few turns to protect ball joint threads.

Installing

1. Bolt on ball joint to control arm (align nuts to markings).

Note. Commercially available ring insertion tools (18 mm), e.g. Stahlwille 732/10 or Hazet 6630c-18, can be used instead of V.A.G1332/10

1 - Internal Torx T40

1. Insert ball joint into wheel bearing housing.

Scheme 893

1. Install new self-locking nut, and counterhold with Internal Torx T40.

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

1. Align vehicle --> «Wheel alignment»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

Control arm, removing and installing

There are different versions of the control arm --> Parts Catalog

The same version must always be installed on both sides.

If there is a different version in the vehicle, both control arms must be replaced as a pair.

Removing

1. Remove wheel.

1. Remove noise insulation panel.
2. If installed, remove headlight range control linkage at left control arm--> «Vehicle level sensor in vehicles with automatic headlight range control»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__vehicle-level-sensor-in-vehicles-with) .

Scheme 894

1. Mark positions of nuts.
2. Remove bottom nuts from ball joint.
3. Remove hex bolts - 1 - and - 2 - and remove control arm.

Note. Bolt - 1 - is secured from above with a nut.

When installing, note the following points

1. Install control arm into subframe and secure.
2. Bolt on ball joint with control arm (align nuts to marked installation positions. New control arm is bolted in the center).

Bolts with bonded rubber bushings must be tightened on its wheels with vehicle standing.

Otherwise, the rubber bushing will be stressed and have its service life shortened.

1. Align vehicle --> «Wheel alignment»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

Control arm bushings, replacing

There are different versions of the control arm --> Parts Catalog

The same version must always be installed on both sides.

Pressing out is achieved using Workshop press V.A.G1290A.

Note. Use assembly lubricating oil G294 421 A1 when pressing in. Mixture ratio of lubricating oil to water: 1:9. This lubricating oil is non-corrosive and penetrates into the rubber (diffuses) after a short time. It leaves a slightly sticky film, which ensures firm seating of the bushing. Most conventional greases/oils contain acid and cause a film of lubricant to form. This may affect the rubber, or cause the entire bushing to twist in the control arm instead of flexing when the suspension compresses and rebounds.

The following instructions apply to vehicles in which the rear bushing as seen in the direction of travel (the larger of the two bushings) is solid (i.e. without cavities).

On vehicles with the number 8N0407165 or 8N0407166 is marked on the control arm.

When installing, note the following points in particular

Scheme 895

1. Press out bushing.

Pressing in front control arm bushing

Scheme 896

Note installation position of bushing

Scheme 897

1. Press in bushing - arrow -.

Pressing out / pressing in rear control arm bushing

Scheme 898

1. Press in bushing.

The following instructions apply to vehicles in which the rear bushing as seen in the direction of travel (the larger of the two bushings) has kidney-shaped cavities (Scheme 903)

On these vehicles the number 8N0407157 or 8N0407158 is marked on the wishbone.

Shop press V.A.G1290A is used for pressing out.

Pressing out front control arm bushing

1. To create a flat surface, cut off outer rubber part of bushing.
2. Support control arm with this contact surface on plate VW402.

Scheme 899

1. Press out bushing.

Note. Use assembly lubricating oil G294 421 A1 when pressing in. Mixture ratio of lubricating oil to water: 1:9. This lubricating oil is acid-free and penetrates into the rubber after a short time (by diffusion). It leaves a slightly sticky film, which ensures firm seating of the bushing. Most conventional greases/oils contain acid and cause a film of lubricant to form. This may affect the rubber, or cause the entire bushing to twist in the control arm instead of flexing when the suspension compresses and rebounds.

Pressing in front control arm bushing

1. Support control arm eye on a flat surface.

Scheme 900

1. Press in bushing as far as stop.

Scheme 901

1. Press in bushing further until the rubber head on the underside is completely visible - arrow -.

Installation position of rear bushing in left control arm

Scheme 902

A - Part number

B - "Kidney-shaped" recess; the larger recess faces forward in direction of travel

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

F - Direction of travel

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

Installation position of rear bushing in right control arm

Scheme 903

A - Part number

B - "Kidney-shaped" recess; the larger recess faces forward in direction of travel

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

F - Direction of travel

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

Pressing out / pressing in rear control arm bushing

1. Use special tools illustrated and press bushing out/in.

Subframe, removing and installing

Special tools, testers and auxiliary items required

Scheme 904

1. Engine/transmission jack V.A.G1383A with universal mount V.A.G1359/2

1. Torque wrench V.A.G1332, measuring range 40 to 200 Nm

Removing

1. Remove wheels.

1. Remove noise insulation panel.
2. If necessary, detach bracket for hydraulic line at subframe (left-side). Tightening torque: 3.5 Nm.
3. If installed, detach headlight range control linkage on left side of inner transverse link --> «Vehicle level sensor in vehicles with automatic headlight range control»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__vehicle-level-sensor-in-vehicles-with) .

1. Secure tie rods to suspension struts using tensioning straps T10038 (apply straps next to inner rubber boots). This will prevent the steering column from slipping off from steering gear splines during the next step.

Scheme 905

1. Remove nut for coupling rod from stabilizer bar.
2. Remove Torx socket head bolt for noise insulation panel.

1. Mark positions of nuts.
2. Remove bottom nuts from ball joint.
3. Remove diagonal strut (if installed) «Diagonal member for subframe»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) .

1. Remove steering gear bolts - 1 - and pendulum support - 2 -.
2. For vehicles with 165 kW engine (code: APX), remove rubber mounting at front exhaust pipe.
3. Apply engine/transmission jack V.A.G1383A with universal mount 1359/2 under subframe.
4. Remove bolts - 3 - and - 4 - for subframe.

1. If necessary, remove hex nut for securing clamp on stabilizer bar clip (left-side). Tightening torque: 22 Nm

1. Carefully pry subframe for steering gear from main subframe using a tire iron or similar.

Pay attention to side noise insulation panel and bracket for hydraulic line (left-side) when lowering subframe.

1. Carefully lower subframe.

When installing, note the following points

Before inserting subframe bolts, position steering gear on subframe and insert bolts for steering gear.

Scheme 906

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

Commercially available ring insert tools (18 mm), e.g. Stahlwille 732/10 or Hazet 6630c-18, can be used instead of V.A.G1332/10.

1 - Internal Torx T40

1. Insert ball joint in wheel bearing housing.

1. Install new self-locking nut, and counterhold with internal Torx T40.

Note. Make sure sealing boot is free of damage and not twisted.

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

Wheel alignment must be checked and adjusted if steering wheel is not straight.

Subframe bushings, replacing

The bushings can be replaced after lowering the subframe.

Scheme 907

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G1383A
2. Splitter Kukko 15-1 with Kukko 17-1; items. 1, 2 and 4 are not required.
3. Base block VW441
4. Thrust plate VW447 h

1. Torque wrench V.A.G1332, measuring range 40 to 200 Nm

1. Remove noise insulation panel.

1. Remove Torx socket head bolt for noise insulation panel - left arrow -.
2. For vehicles with 165 kW engine (code: APX), remove rubber mounting at front exhaust pipe.

Scheme 908

1. Remove rear bolts - 1 -.
2. By loosening front bolts - 2 - lower subframe far enough until bushings are accessible.

Scheme 909

1. Position splitter tool Kukko15-1 with Kukko17-1, and remove upper half of bushing.
2. Insert thrust pad VW447 h.

Scheme 910

1. Using engine/transmission jack and base block VW441, push subframe upward until lower half of bushing drops out.

1. Installation position of bushing halves

A - Upper half of bushing without collar, ribs faces body.

B - Lower half of bushing, collar faces bolt head

Note. Coat the rubber surfaces of the new bushings with assembly lubricant G 294 421 A1.

Note installation position of bushings see scheme 66.

1. Insert both bushing halves.

Scheme 911

1. Press in new bushings using engine/transmission jack.

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

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

Wheel bearing, assembly overview

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

Bonded rubber bushings can only be turned to a limited extent. The bolt connections on the suspension links should only be tightened when the vehicle is standing on the ground.

The wheel bearings must not be subjected to load when the 12-point nut / flange bolt has been loosened.

If the wheel bearings are subjected to the full weight of the vehicle they will be overloaded, resulting in reduced service life. Please note the following

1. Have a second technician press brake pedal.
2. Lift vehicle far enough to relieve load on front wheels.
3. Loosen 12-point nut / flange bolt.

Never move vehicles after the drive axles have been removed; this will result in wheel bearing damage. If the vehicle has to be moved, always note the following points

1. Install an outer joint in place of the drive axle.
2. Tighten outer joint to 190 Nm.

Drive axle / wheel hub splines

Vehicles with drive axle secured by 12-point nut

1. The drive axle/wheel hub splines can either be "bonded" with locking fluid, or on newer-version wheel hubs, (Part. No. 8N0 407 613 A or B), greased.
2. For example, the wheel hub version determines whether the wheel hub is "bonded" or greased.
3. Stocks of the old-version wheel hubs, Part No. 8N0 407 613, (wheel hub stamped with 8N0 615) can still be used up for drive axles that were "bonded", but these must then still be "bonded" using locking fluid D 185 400 A2.
4. Newer wheel hubs, Part No. 8N0 407 613 A or B, (wheel hub stamped with 8N0 615A or B) must under no circumstances be "bonded". These wheel hubs may be coated only with solid grease G 052 142 A2.

1. It is permissible to have a "bonded" drive axle/wheel hub on one side of the vehicle and a greased drive axle/wheel hub on the other side, because a "bonded" wheel hub may be replaced with a greased one. However, a greased wheel hub must not be replaced with a "bonded" one. Procedure

Note. The tightening torques for the 12-point nut are different: "Bonded" wheel hub: 265 Nm Greased wheel hub: 190 Nm plus an additional 90° 1 / 4 turn Always install a new 12-point nut

Procedure

Vehicles with drive shaft secured by flange bolt

Loosening flange bolt

1. Loosen flange bolt 90°, otherwise the wheel bearing will be damaged.
2. Lift vehicle far enough to relieve load on front wheels.
3. Have a second technician press brake pedal.

Scheme 912

1. Loosen flange bolt - 2 -.
2. Remove wheels.
3. Screw wheel bolts back in.

Installing flange bolt

1. Always replace flange bolt - 2 -.
2. Lightly grease splines on axle stub and contact surface of wheel hub - 1 - / underside of bolt head - 2 - with solid grease G 052 142 A2.

Procedure for installing flange bolt

1. Have a second technician press brake pedal.
2. Raise vehicle.
3. Initial tightening torque: 240 Nm
4. Install wheels and lower vehicle onto its wheels. Observe notes --> «Wheels, instructions for changing/installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheels-instructions-for-changinginstalling) .

1. Turn 90° further.
2. Loosen flange bolt 90° only.
3. Raise vehicle.
4. Have a second technician press brake pedal.

1. Loosen flange bolt 90°.
2. Tighten to 240 Nm.
3. Lower vehicle onto its wheels.
4. Turn 90° further.

Scheme 913

1 - Suspension strut

1. Different versions available --> Parts Catalog
2. The same version must be installed on both sides
3. Remove suspension strut from wheel bearing housing «Disconnecting suspension strut from wheel bearing housing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
4. Assembly overview --> «Suspension strut, assembly overview»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

2 - Hex bolt

1. Always replace if removed

3 - Hex socket head bolt, 8 Nm

4 - ABS wheel speed sensor

1. Before inserting sensor, clean inner surface of installation hole and coat with lubricating paste G 000 650.

5 - Self-locking nut

1. Tightening torque: 45 Nm
2. TT VR6 Roadster: 75 Nm
3. Always replace if removed

6 - Tie rod ball joint

7 - Hex bolt, 10 Nm

8 - Self-locking 12-point nut

Pay attention to notes --> Drive axle / wheel hub splines and table

1. Always replace if removed

9 - Phillips-head screw, 4 Nm

10 - Brake disc (ventilated)

11 - Wheel hub with rotor for wheel speed sensor

Pay attention notes --> Drive axle / wheel hub splines and table

1. Rotor is welded to wheel hub
2. Removing and installing with wheel bearing housing installed --> «Front wheel bearing, pressing out and in (with wheel bearing housing installed)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__front-wheel-bearing-pressing-out-and)

12 - Backing plate

13 - Snap ring

1. Check for proper seating

14 - Wheel bearing

1. Removing and installing with wheel bearing housing installed --> «Front wheel bearing, pressing out and in (with wheel bearing housing installed)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__front-wheel-bearing-pressing-out-and)

Before pressing in wheel bearing, coat entire inner surface of bore in wheel bearing housing with Molypaste Coating entire surface of bore in wheel bearing housing with Molypaste (AOS 115 000 01)

15 - Self-locking nut

1. Tightening torque: 75 Nm
2. TT VR6 Roadster: 150 Nm
3. Always replace if removed

16 - Ball joint

1. Checking --> «Ball joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-checking)
2. Removing and installing --> «Ball joint, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-removing-and-installing)
3. Mark installation position; if control arm is replaced, place in center of elongated hole and check toe setting/camber
4. Wheel alignment --> «Wheel alignment»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

17 - Brake carrier

18 - Brake caliper

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

19 - Guide pins, 25 Nm

20 - Protective cap

21 - Ribbed bolt, 125 Nm

1. Clean ribbing on underside of bolt head
2. Brake line must not be twisted or kinked

22 - Self-locking nut

1. 60Nm plus and additional 90° 1 / 4 turn
2. Always replace if removed

23 - Wheel bearing housing

1. Removing and installing --> «Removing and installing wheel bearing housing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__removing-and-installing-wheel-bearing-housing)

Before pressing in wheel bearing, coat entire inner surface of bore in wheel bearing housing with Molypaste Coating entire surface of bore in wheel bearing housing with Molypaste (AOS 115 000 01)

24 - Drive axle

Pay attention to notes --> Drive axle / wheel hub splines and table

1. Pressing drive axle out of wheel hub; pressing in --> «Drive axles»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) , Drive axles

Scheme 914

1. Insert special tool - 3424 - as shown and force wheel bearing housing apart.

Scheme 915

Note. A grease packet containing 3 grams of grease is included with the wheel bearing kit.

Front wheel bearing, pressing out and in (with wheel bearing housing installed)

Pay attention to notes --> Drive axle / wheel hub splines and table

Scheme 916

Special tools, testers and auxiliary items required

1. Thrust piece 40-105
2. Press tool 3283
3. Collar front/wheel bearing inner race 3423
4. Engine/transmission jack V.A.G1383A with universal mount V.A.G1359/2

1. Puller 2 - Kukko 18/0
2. Torque wrench V.A.G1576, measuring range: 75 to 400 Nm

Scheme 917

1. Foot pump with high pressure hose V.A.G1389A/1

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

To do this, use the conversion kit V.A.G1389/3.

Scheme 918

1. Wheel bearing tool V.A.G1459B
2. Hollow piston cylinder HKZ-15 with thrust piece E-0-204-T (hydraulic)
3. Pull rod E-0-217+218
4. Special nut E-8-214

1. Pressure piece E-5
2. Pressure piece E-10
3. Pressure piece E-13-1
4. Pressure sleeve E-65-1

1. Pressure bolt E-15

Scheme 919

1. Supplementary kit V.A.G1459B/2
2. Support E-40

Preparing wheel bearing housing for pressing-out procedure

1. Remove cap from light-alloy wheels (puller in vehicle tool kit).
2. Lift vehicle far enough to relieve load on front wheels.
3. Loosen nut / bolt securing drive axle.
4. Remove wheels.

Scheme 920

1. Remove coupling rod from suspension strut on both sides of the vehicle.
2. Pull spring clip out from bracket and detach brake hose.
3. Detach wire for speed sensor from suspension strut.

Scheme 921

1. Remove brake caliper from wheel bearing housing.
2. Secure brake caliper to body with wire.
3. Remove brake disc (disc is secured to hub with phillips-head bolt).
4. Remove brake disc splash plate.

1. Mark positions of nuts.
2. Remove bottom nuts from ball joint.
3. Remove control arm from ball joint.

Scheme 922

1. Press out drive axle.

Note. Make sure there is sufficient clearance when pressing out drive axle.

1. Remove drive axle from wheel bearing housing and tie up.

Note. Place engine/transmission jack V.A.G1383/A with universal mount V.A.G1359/2 underneath (to prevent risk of parts dropping out when pulling out wheel hub and wheel bearing).

Scheme 923

1. Insert thrust bolts - 1 - in wheel bearing housing.
2. Attach support - 2 - , hollow piston cylinder - 3 - with pull rod and special nut - 4 -.
3. Hold appliance firmly and pull wheel hub out.

1 - Thrust bolt E-15

2 - Support E-40

3 - Hollow piston cylinder HKZ-15

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

5 - High pressure hose with quick-release coupling

Pulling out wheel bearing

1. Remove securing ring.

Scheme 924

1. Set up thrust piece - 1 - with collar facing wheel bearing, thrust sleeve - 2 - with four stepped internal diameters toward wheel bearing housing and hollow piston cylinder - 3 - with pull rod and special nut - 4 -.
2. Pull out wheel bearing by actuating pump.

1 - Thrust piece E-5

2 - Thrust sleeve E-65-1

3 - Hollow piston cylinder HKZ-15

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

Scheme 925

1. Insert special tool - 3423 - as shown.
2. Screw cross-piece Kukko -18-0- into special tool - 3423 -.
3. Mount special tool - 40-105 - on wheel hub and pull off inner bearing race by turning spindle.

Pressing in wheel bearing

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

Note. A grease packet containing 3 grams of grease is included with the wheel bearing kit.

Scheme 926

1. Set up wheel bearing - 1 - , thrust piece - 2 - (install with collar in bearing) and hollow piston cylinder - 3 - with pull rod on wheel bearing housing.
2. Attach thrust piece - 4 - (with wide collar toward wheel bearing housing) and special nut - 5 - on inner side of wheel bearing housing.
3. Press in wheel bearing by actuating pump.
4. Insert securing ring with long-nose pliers.

1 - Wheel bearing

2 - Thrust piece E-13-1

3 - Hollow piston cylinder HKZ-15

4 - Thrust piece E-10

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

Scheme 927

1. Put wheel hub - 1 - and hollow piston cylinder - 2 - with pull rod on wheel bearing.
2. Fit special nut - 4 - and thrust piece - 3 - (with collar facing special nut) on inboard side of wheel bearing housing.
3. Press in wheel hub by actuating pump.

1 - Wheel hub

2 - Hollow piston cylinder HKZ-15

3 - Thrust piece E-5

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

Pay attention to the following points on installation

Refer to notes --> Drive axle / wheel hub splines and table

1. Clean inner splines of wheel hub.
2. Screw on new 12-point nut as far as possible.
3. Secure brake caliper to wheel bearing housing. --> «46 BRAKES - MECHANICAL COMPONENTS»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
4. Attach coupling rod to suspension strut with new nut.

1. Lower vehicle, but make sure that wheels do not yet touch ground.

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

1. Have a second technician press the brake pedal.
2. Tighten 12-point nut.

Removing and installing wheel bearing housing

Refer to notes --> Drive axle / wheel hub splines and table

Scheme 928

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G1332, measuring range 40 to 200 Nm
2. Torque wrench V.A.G1576, measuring range 75 to 400 Nm
3. Spreader tool 3424
4. Press tool 3283

1. Engine/transmission jack V.A.G1383A

Removing

1. Remove trim cap from light-alloy wheels (puller in vehicle tool kit).
2. Lift vehicle far enough to relieve load on front wheels.
3. Loosen 12-point nut.
4. Remove wheels.

1. Detach coupling rod from suspension strut on both sides of vehicle.
2. Pull spring clip out from bracket and detach brake hose.
3. Detach wire for speed sensor from suspension strut.

1. Remove brake caliper from wheel bearing housing.
2. Secure brake caliper to body with wire.
3. Detach brake disc (disc is secured to hub with phillips-head bolt).
4. Remove brake disc splash plate.

1. Mark positions of nuts.
2. Remove bottom nuts from ball joint.
3. Remove control arm from ball joint.
4. If ball joint has to be removed, refer to --> «Ball joint, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-removing-and-installing) .

Scheme 929

1. Remove nut from tie rod ball joint.

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

1. Remove tie rod from steering arm with puller Kukko129/0.
2. Disconnect connector from ABS wheel speed sensor.

1. Press out drive axle.

Note. Make sure there is sufficient clearance when pressing out drive axle.

1. Remove drive axle from wheel bearing housing and tie up.

Scheme 930

1. Remove bolt and nut securing wheel bearing housing/suspension strut.

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

Scheme 931

1. Insert special tool 3424 into slot - arrow -.
2. Turn ratchet through 90° and detach from 3424.
3. Pull wheel bearing housing downward off shock absorber tube.

When installing, note the following points in particular: notes --> Drive axle / wheel hub splines and table.

Refer to notes--> Drive axle / wheel hub splines and table

1. Clean inner splines of wheel hub.
2. install new 12-point nut as far as possible.
3. Secure brake caliper to wheel bearing housing --> «46 BRAKES - MECHANICAL COMPONENTS»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
4. Insert connector and wire for ABS wheel speed sensor in brackets.

1. Lower vehicle, but make sure that wheels do not touch ground yet.

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

1. Have a second technician press the brake pedal.
2. Tighten 12-point nut.

Front wheel bearing, pressing out and in (with wheel bearing housing removed)

Refer to notes --> Drive axle / wheel hub splines and table

Scheme 932

Special tools, testers and auxiliary items required

1. Punch VW408A
2. Thrust piece 40-105
3. Box wrench (46 mm) 3252
4. Assembly tool 3253/1

1. Thrust plate VW401
2. Collar front /wheel bearing inner race 3423

Scheme 933

Special tools, testers and auxiliary items required

1. Thrust plate VW447 i
2. Thrust disc VW412
3. Arbor (50 mm dia.) VW432
4. Thrust pad VW442

1. Press appliance VW459/2
2. Punch VW407

Scheme 934

1. 2 Puller Kukko 18/0

Note. (Items 1, 3 and 4 are not required).

Scheme 935

Scheme 936

1. Make sure circlip is seated properly when installing.
2. Remove circlip using commercially available pliers.

Scheme 937

Remove inner bearing race

1. Insert special tool - 3423 - as shown.
2. Screw cross-piece Kukko -18-0- into special tool - 3423 -.
3. Mount special tool -40-105- on wheel hub and remove inner bearing race by turning spindle.

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

Note. A grease packet containing 3 grams of grease is included with the wheel bearing kit.

Scheme 938

Note. After the wheel bearing is pressed in, circlip must be replaced Removing and installing circlip

Scheme 939

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

Scheme 940

1 - Self-locking hex nut, 60 Nm

2 - Stop shell

3 - Body (suspension strut dome)

4 - Hex nut, 60 Nm

1. Always replace

5 - Suspension strut bearing

1. Coat with assembly lubricant G 294 421 A1.

6 - Deep-groove thrust ball bearing

7 - Spring plate

8 - Coil spring

1. Note color code
2. Surface of spring coil must not be damaged
3. Removing and installing suspension strut --> «Suspension strut/coil spring, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
4. Removing and installing coil spring --> «Suspension strut/coil spring, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Note different spring/shock absorber versions; refer to vehicle data sticker «Explanation on weight codes (PR Numbers)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__explanation-on-weight-codes-pr-numbers)

9 - Protective sleeve

10 - Stop buffer

11 - Shock absorber

1. Different versions --> Parts Catalog
2. The same version must be installed on both sides
3. Note different spring/shock absorber versions; refer to vehicle data sticker «Explanation on weight codes (PR Numbers)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__explanation-on-weight-codes-pr-numbers)

12 - Coupling link

1. Link between stabilizer bar and suspension strut

13 - Self-locking nut

1. 90 Nm
2. Always replace if removed

14 - Hex bolt, 10 Nm

15 - Bracket

1. For brake hose

16 - Spring clip

17 - Clamp

18 - Hex bolt

1. Always replace if removed

19 - Self-locking nut

1. 60Nm plus an additional 90° 1 / 4 turn
2. Always replace if removed

20 - Wheel bearing housing

1. Remove suspension strut from wheel bearing housing «Removing suspension strut from wheel bearing housing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__removing-suspension-strut-from-wheel-bearing)
2. Wheel bearing: overview --> «Wheel bearing, assembly overview»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

Removing suspension strut from wheel bearing housing

1. Insert special tool - 3424 - as shown and force wheel bearing housing apart.

Scheme 941

Special tools, testers and auxiliary items required

1. Shock absorber set T10001
2. Spring compressor V.A.G1752/1
3. Special socket wrench 21 mm 3186
4. 2 Spring holders (80-165 mm) V.A.G1752/4

1. Spreader 3424
2. Engine/transmission jack V.A.G1383A

Removing and installing suspension strut

There are different shock absorber versions --> Parts Catalog

The same version must always be installed on both sides.

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

1. Remove wheels.

1. Remove coupling rod from suspension strut on both sides of the vehicle.
2. Pull spring clip out from bracket and detach brake hose.
3. Detach wire for speed sensor from suspension strut.
4. Remove noise insulation panel.

1. Unbolt drive axle from flange shaft on transmission.

Initial tightening torque: 10 Nm

Tightening torque: 70 Nm

1. Secure drive axle with wire.
2. Remove bolt and nut securing wheel bearing housing/suspension strut.

Scheme 942

Note installation position of bolt. (See illustration).

1. Insert special tool 3424 into slot - arrow -.
2. Turn ratchet 90° and remove from 3424.
3. Press brake disc toward suspension strut by hand.

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

1. Pull wheel bearing housing downward from strut tube.

Scheme 943

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

Scheme 944

Remove hex nut for upper strut mounting

1 - Commercially available ratchet

2 - T10001/8

3 - T10001/11

4 - T10001/5

When installing, note the following points

Scheme 945

1. Before inserting suspension strut, coat suspension strut mounting - arrows - with assembly lubricant G294421A1.

1. Install suspension strut and secure to suspension strut dome. Tightening torque: 60 Nm

1 - Commercially available ratchet handle

2 - T10001/8

3 - T10001/11

4 - T10001/5

Scheme 946

1. Place suspension strut on wheel bearing housing.
2. Remove wire from wheel bearing housing.
3. Using engine/transmission jack, carefully raise wheel bearing housing until bolt securing suspension strut/wheel bearing housing can be inserted.

Note. Do not press against the ball joint with the engine/transmission jack.

1. At the same time, push brake disc by hand toward suspension strut.

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

1. Remove spreader tool - 3424 -.

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

Further installation of suspension strut is performed in reverse order.

Removing and installing coil spring

Note different spring/shock absorber versions; refer to vehicle data sticker Explanation on weight codes (PR Numbers)

Scheme 947

1. Compress coil spring with Spring compressor V.A.G1752/1- until the upper spring plate is free.
2. Remove hex nut from piston rod.
3. Remove individual parts of suspension strut and coil spring with Spring compressor V.A.G1752/1-.

1 - Commercially available ratchet handle

2 - T10001/8

3 - T10001/11

4 - T10001/5

5 - Spring compressor V.A.G1752/1

6 - 2 spring holders (80-165 mm) V.A.G1752/4

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

Scheme 948

1. Make sure that coil spring is seated correctly in adapter V.A.G1752/4 - arrow -.

Installing

1. Put coil spring with spring compressor V.A.G1752/1 onto bottom spring plate.

Scheme 949

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

Installation of suspension strut is performed in reverse order.

Drive axle, removing and installing (version with bolted flange on inner joint)

Refer to --> General information , --> Drive axle / wheel hub splines and table

Removing

1. Remove trim cap from light-alloy wheels (puller in vehicle tool kit).
2. Loosen securing nut (or bolt) 90°, otherwise the wheel bearing will be damaged.
3. Lift vehicle far enough to relieve load on front wheels.
4. Have a second technician press brake pedal.

1. Loosen securing nut (bolt) completely.
2. Remove wheel.
3. Remove drive axle from flange shaft on transmission.

1. Mark positions of nuts.
2. Remove bottom nuts from ball joint.
3. Remove control arm from ball joint.

Scheme 950

1. Press out drive axle. Position tool as shown in illustration.

Note. Make sure sufficient clearance when pressing out drive axle.

1. Remove drive axle.

Installation is performed in reverse sequence; note the following

Refer to notes --> Drive axle / wheel hub splines and table

1. Clean inner splines of wheel hub.
2. Screw on new 12-point nut or flange bolt as far as possible.
3. Lower vehicle, but make sure that wheels do not touch the ground yet.

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

1. Have a second technician press the brake pedal.
2. Tighten 12-point nut or flange bolt.

Drive axle, removing and installing (version with splines on inner joint)

Refer to --> General information , --> Drive axle / wheel hub splines and table

Removing

1. Remove trim cap from light-alloy wheels (puller in vehicle tool kit).
2. Loosen securing nut (or bolt) 90°, otherwise the wheel bearing will be damaged.
3. Lift vehicle far enough to relieve load on front wheels.
4. Have a second technician press the brake pedal.

1. Loosen securing nut (bolt) completely.
2. Remove wheel.

1. Mark positions of nuts.
2. Remove bottom nuts from ball joint.
3. Remove control arm from ball joint.

1. Press out drive axle. Position tool as shown in illustration.

Note. Make sure there is sufficient clearance when pressing out drive axle. Do not allow the drive axle to hang down under its own weight, as this would bend the inner joint too far and damage it.

A second person is required for the next step

Scheme 951

1. Place aluminum wedge T10161 between transmission housing and inner triple roller joint.
2. Force drive shaft out of gearbox with a firm blow to wedge tool T10161.
3. Remove drive axle.

Installation is performed in reverse sequence; note the following

Refer to notes --> Drive axle / wheel hub splines and table

1. Clean inner splines of wheel hub.
2. Circlip for drive axle must always be replaced if it has been removed.
3. Screw in new flange bolt as far as possible.
4. Lower vehicle, but make sure that wheels do not touch the ground yet.

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

1. Have a second technician press the brake pedal.
2. Tighten flange bolt.

Scheme 952

Grease quantity and type

Constant velocity joints are packed with grease G 000 603

Regrease joint when replacing boot.

1 - Outer constant Velocity (CV) joint

1. Replace only as complete unit
2. Removing «Removing outer constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__removing-outer-constant-velocity-joint)
3. Installing «Installing outer constant velocity (CV) joint with flange bolt»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
4. Greasing --> «Drive axle with Constant Velocity (CV) joint, servicing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Checking --> «Outer Constant Velocity (CV) joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__outer-constant-velocity-cv-joint-checking)

2 - Hex bolt

1. Always replace if removed

Tightening torque Procedure for installing flange bolt

Observe instructions for removing and installing Vehicles with drive shaft secured by flange bolt

3 - Self-locking 12-point nut

Refer to notes --> Drive axle / wheel hub splines and table

4 - Outer constant Velocity (CV) joint

1. Replace only as complete unit
2. Removing «Removing outer constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__removing-outer-constant-velocity-joint)
3. Installing: drive onto shaft with plastic hammer until compressed circlip seats

5 - Circlip

1. Always replace
2. Insert in groove on shaft

6 - Spacer ring (plastic)

1. Installation position «Installation position of spacer ring and convex washer (wheel end)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

7 - Convex washer

1. Installation position «Installation position of spacer ring and convex washer (wheel end)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

8 - Hose clamp

1. Always replace
2. Tightening «Tightening hose clamp on outer joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__tightening-hose-clamp-on-outer-joint)

9 - CV Boot

1. Check for tears and scuffing
2. Material: Hytrel (polyelastomer)

10 - Hose clamp

1. Always replace
2. Tightening «Tightening hose clamp at small diameter of boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

11 - Axle shaft

12 - Socket-head bolt

Initial tightening torque: 10 Nm

Tightening torque: 70 Nm

13 - Lock plate

14 - CV boot for inner constant velocity (CV) joint

1. Material: Rubber
2. With vent hole
3. Check for tears and scuffing
4. Drive off CV joint using a drift

1. Apply sealant D454300A2 between joint and cover «Coat sealing surface of cover and cap with D454300A2.»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) .

15 - Inner constant velocity (CV) joint

1. Replace only as complete unit
2. Pressing off «Pressing off inner constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__pressing-off-inner-constant-velocity-joint)
3. Pressing on «Pressing on inner constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__pressing-on-inner-constant-velocity-joint)
4. Greasing --> «Drive axle with Constant Velocity (CV) joint, servicing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Checking --> «Inner Constant Velocity (CV) joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__inner-constant-velocity-cv-joint-checking)

16 - Circlip

1. Always replace
2. Remove and install with VW161 a

17 - Cover

1. Always replace
2. Drive off CV joint using a drift
3. Apply sealant D454300A2 between joint and cover «Coat sealing surface of cover and cap with D454300A2.»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) .

Scheme 953

1. Drive joint off axle shaft with a firm blow from an aluminum hammer.

Scheme 954

Note. First drive off boot with drift. Support ball hub.

Scheme 955

1. Press on joint as far as stop.
2. Install circlip.

Note. Chamfer on internal diameter of ball hub (splines) must face contact shoulder on axle shaft.

Scheme 956

1. Screw old bolt into CV joint as shown.
2. Use plastic hammer to drive joint onto shaft until circlip engages.

Scheme 957

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

Scheme 958

1. Apply pliers V.A.G 1682 as shown. Make sure that the jaws of the pliers seat in the ends of the hose clamp - arrows B -.
2. Tighten hose clamp by turning spindle with torque wrench (keep pliers straight).

Note. Due to the hard material of the CV joint boot (as opposed to rubber), a stainless steel hose clamp is required; this can only be tightened using pliers V.A.G1682. Tightening torque: 25 Nm. Use torque wrench with 5 to 50 Nm range (e.g. V.A.G1331). Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary. If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clamp with the specified tightening torque.

Scheme 959

Scheme 960

1 - Convex washer

2 - Spacer ring (plastic)

Scheme 961

1. Apply sealant on clean surface of cover and cap (hatched area). Route continuous bead of sealant (2 to 3 mm diameter) around inside of holes - arrow -.
2. Align cover and cap with bolt holes and drive or press onto joint.
3. Wipe off surplus sealant.

Outer Constant Velocity (CV) joint, checking

The joint should be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage.

Removing

Scheme 962

1. Before disassembling, mark position of ball hub in relation to ball cage and joint body with an electric scribe or oil stone (arrow).
2. Swing ball hub and ball cage.
3. Remove balls one after the other.

Scheme 963

1. Turn cage until two cage windows - arrow - are level with joint body.
2. Lift out cage with hub.

Scheme 964

1. Swing a segment of the hub into one of the cage windows.
2. Pivot hub out of cage.

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

Installing

1. Pack half the total quantity of grease into the joint body.
2. Insert cage with hub into joint body.

Note. The cage must be inserted in the correct position (i.e. sides facing in same direction as original position).

1. Press in balls one after the other from opposite sides, taking care to re-establish the original position of the hub relative to the cage and the joint body.
2. Install new circlip in shaft.
3. Distribute remaining grease in boot.

Inner Constant Velocity (CV) joint, checking

The CV joint should be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage.

Scheme 965

1. Swing ball hub and ball cage.
2. Press out CV joint in direction of - arrow -.
3. Press balls out of cage.

Note. Ball hub and joint are paired and must be marked before disassembling. Make sure the balls run in the same tracks after assembly.

Scheme 966

1. Align ball hub with cage as shown - arrows - and pivot hub out of cage.
2. Check joint, ball hub, ball cage and balls for pitting and signs of seizure.

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

Installing

Scheme 967

1. Insert hub into cage via the two chamfers. No specific installation position is required. Push balls into cage.
2. Insert hub with cage and balls at a right angle to the joint.

Scheme 968

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

Scheme 969

1. Swing in ball hub; at the same time the hub must be pressed out of the cage - arrows - far enough to allow the balls to fit into the ball tracks.

Scheme 970

1. Swing in hub with balls by applying firm pressure on cage - arrow -.

Checking function of constant velocity joint

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

Scheme 971

Special tools, testers and auxiliary items required

1. CV joint boot clamp tool V.A.G1682
2. Pliers 3340
3. Thrust plate VW402
4. Punch VW411 I

1. Thrust disc VW412
2. Tube 37M mm dia. VW 416b

Scheme 972

1. Sleeve press tool VW522

Scheme 973

1. Torque wrench V.A.G1332 (measuring range: 5 to 50Nm)

Outer joints are packed with grease G 000 603

Inner triple roller joints are packed with grease G 000 605

Grease quantities and types

Regrease joint if required when replacing the boot.

Scheme 974

1 - Outer constant velocity (CV) joint

1. Replace only as complete unit
2. Removing «Removing outer constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__removing-outer-constant-velocity-joint)
3. Installing «Installing outer constant velocity (CV) joint with flange bolt»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) and «Installing outer constant velocity (CV) joint with flange bolt»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
4. Greasing «Grease quantities and types»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Checking --> «Outer Constant Velocity (CV) joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__outer-constant-velocity-cv-joint-checking)

2 - Hex bolt

1. Always replace if removed

Tightening torque Procedure for installing flange bolt

Observe instructions for removing and installing Vehicles with drive shaft secured by flange bolt

3 - Outer constant velocity (CV) joint

1. Replace only as complete unit
2. Removing «Removing outer constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__removing-outer-constant-velocity-joint)
3. Installing: drive onto shaft with plastic hammer until compressed circlip seats
4. Greasing «Grease quantities and types»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Checking --> «Outer Constant Velocity (CV) joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__outer-constant-velocity-cv-joint-checking)

4 - Self-locking 12-point nut

5 - Axle shaft

6 - Boot for triple roller star

7 - Hose clamp

8 - Socket-head bolt

Initial tightening torque: 10 Nm

Tightening torque: 70 Nm

9 - Cover

10 - Triple roller star

Chamfer - arrow - faces toward drive axle splines

1. Rollers are not removable

11 - Circlip

1. Replace
2. Insert in groove on shaft

12 - O-ring

1. Always replace

13 - Cover

1. Always replace

14 - Hose clamp

1. Always replace
2. Tightening «Tightening hose clamp at small diameter of boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

15 - CV Boot

1. Check for tears and scuffing
2. Material: Hytrel (polyelastomer)

16 - Hose clamp

1. Always replace
2. Tightening «Tightening hose clamps on outer CV joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__tightening-hose-clamps-on-outer-cv)

17 - Convex washer

1. Installation position «Installation position of spacer ring and convex washer»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__installation-position-of-spacer-ring-and)

18 - Spacer ring (plastic)

1. Installation position «Installation position of spacer ring and convex washer»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__installation-position-of-spacer-ring-and)

19 - Circlip

1. Always replace
2. Insert in groove on shaft

Removing outer constant velocity (CV) joint

1. Drive joint off axle shaft with a firm blow from an aluminum hammer.

Venting CV boot

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

Tightening hose clamps on outer CV joint

1. Apply pliers V.A.G 1682 as shown. Make sure that the jaws of the pliers seat in the ends of the hose clamp - arrows B -.
2. Tighten hose clamp by turning spindle with torque wrench (keep pliers straight).

Note. Due to the hard material of the CV joint boot (as opposed to rubber), a stainless steel hose clamp is required; this can only be tightened using CV joint boot clamp tool V.A.G1682. Tightening torque: 25 Nm. Use torque wrench with 5 to 50 Nm range (e.g. V.A.G1331). Make sure thread of spindle on pliers moves freely. Lubricate with MoS2 grease if necessary. If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clamp with the specified tightening torque.

Installation position of spacer ring and convex washer

1 - Convex washer

2 - Spacer ring (plastic)

Scheme 975

1. Bend open retaining tabs slightly and pry off cover.

Scheme 976

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

The joint may be noisy if these parts are not marked and reinstalled in their original positions.

Use a waterproof felt-tip pen for marking.

1. Remove rubber ring - arrow - from groove.

1 - Joint body

2 - Triple roller star

3 - Drive axle

Note. The rollers must not be pressed off the triple roller star

Scheme 977

1. Remove circlip.

Scheme 978

1. Open hose clamp.
2. Cut open joint boot and remove from shaft.

Note. The rollers on the triple roller star must not be pressed off or damaged.

1. Insert axle shaft in press.

Scheme 979

1. Hold axle shaft, then press triple roller star off axle shaft.
2. Pull joint body off shaft.
3. Clean shaft and joint body.

Assembling

1. Clamp axle shaft in vise using soft jaws.
2. Push new boot onto shaft.
3. Push joint body onto shaft.

Installing triple roller star

Chamfer on spider faces toward shaft and is used as an assembly aid.

Scheme 980

1. Place triple roller spider onto shaft as per markings and drive home onto stop.
2. Install new circlip; make sure correct seating.
3. Grease joint «Grease quantities and types»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) .
4. Slide joint body over rollers and hold in position.

1. Install joint boot.

1. Install hose clamp.

Scheme 981

1. Insert O-ring - arrow - into groove.
2. Install cover and bend down retaining tabs.

Drive axle with triple roller joint AAR 3300i, servicing (bolted flange / splines on inner joint)

Grease filling of joints

Note. Regrease joint when replacing boot.

Scheme 982

1 - Hex bolt with washer

1. Always replace if removed
2. Loosening and tightening «Vehicles with drive shaft secured by flange bolt»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__vehicles-with-drive-shaft-secured-by)

2 - Hose clamp

1. Always replace
2. Tightening «Tightening large hose clamp for rubber boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering), see scheme 166 or «Tightening small hose clip for rubber boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

3 - Boot for CV joint

1. Check for tears and scuffing

4 - Hose clamp

1. Always replace
2. Tightening «Tightening large hose clamp for rubber boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) «Tightening stainless-steel hose clamps for Hytrel boots»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__tightening-stainless-steel-hose-clamps-for-hytrel)

5 - Axle shaft

6 - Hose clamp

1. Always replace
2. Tightening «Tightening large hose clamp for rubber boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering), see scheme 166 or «Tightening small hose clip for rubber boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

7 - Boot for CV joint

1. Check for tears and scuffing

8 - Triple roller connection with rollers

1. Chamfer - arrow - faces toward drive axle splines

9 - Circlip

1. Always replace
2. Insert in groove on shaft

10 - Socket-head bolt

1. Initial tightening torque: 10Nm
2. Tightening torque(M8): 40Nm
3. Tightening torque(M10): 70Nm

11 - Joint body (version with splines)

1. Before installing, grease splines on stub shaft with G052735

12 - Circlip

1. Always replace
2. Insert in groove on shaft

13 - Joint body (version with bolted flange)

14 - Hose clamp

1. Always replace
2. Tightening «Tightening large hose clamp for rubber boot»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) «Tightening stainless-steel hose clamps for Hytrel boots»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__tightening-stainless-steel-hose-clamps-for-hytrel)

15 - Convex washer

1. Installation position «Installation position of spacer ring and convex washer»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

16 - Spacer ring (plastic)

1. Installation position «Installation position of spacer ring and convex washer»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

17 - Circlip

1. Always replace
2. Insert in groove on shaft

18 - Outer constant velocity (CV) joint

1. Replace only as complete unit
2. Removing «Removing outer constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
3. Checking --> «Outer Constant Velocity (CV) joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__outer-constant-velocity-cv-joint-checking)
4. Greasing: see table «Grease filling of joints»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Installing
2. Drive joint onto shaft with plastic hammer until circlip engages

Removing outer constant velocity joint

1. Drive CV joint off drive axle with a firm blow from an aluminum hammer.

1 - Convex washer

2 - Spacer ring (plastic)

Venting rubber boot

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

Please note the following

1. Before tightening the hose clamps, vent the boot to equalize pressure by briefly lifting the lip.

Tightening stainless-steel hose clamps for Hytrel boots

1. Apply pliers V.A.G 1682 as shown. Make sure that the jaws of the pliers seat in the ends of the hose clamp - arrows B -.
2. Tighten hose clamp by turning spindle - A - with torque wrench (keep pliers straight).

1. Tightening torque: 20 Nm

Note. Make sure thread of spindle on pliers moves freely. Lubricate with MoS 2 grease if necessary. If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clip when applying the specified tightening torque.

Scheme 983

Scheme 984

Special tools, testers and auxiliary items required

1. Thrust plate VW401
2. Thrust plate VW402
3. Punch VW408A
4. Punch VW411

1. Tube 37 mm dia. VW416B
2. Thrust pad VW447H

Scheme 985

1. Assembly tool T10065

Disassembling

1. Open hose clamp on shaft and push back boot.
2. Pull joint body off drive axle.

Scheme 986

1. Remove circlip (use commercial-type pliers -1- or VW161A).
2. Insert axle shaft in press.

Scheme 987

1. Press triple roller star off axle shaft.
2. Pull joint boot off shaft.
3. Clean shaft, joint body and groove for seal.

1. Push small hose clamp for boot onto shaft.
2. Push joint boot onto shaft.
3. Push joint body onto shaft.

Installing triple roller star (tapered drive shaft version)

1. Chamfer on star faces toward shaft and is used as an assembly aid.

Scheme 988

1. Install triple roller star on shaft and press on as far as stop.

Installing triple roller star (cylindrical drive shaft version)

Scheme 989

1. Install triple roller star on shaft and press on as far as stop.

Both drive shaft versions (continued)

1. Make sure pressure does not exceed 3.0t!
2. If necessary, coat splines of drive axle and triple roller star with polycarbamide grease G052142A2.
3. Install circlip (ensure proper seating).
4. Slide joint body over rollers and hold in position.

1. Press 70 g of drive axle grease from repair kit into triple roller star.
2. Press 60 g of drive shaft grease from repair kit into boot.
3. Install joint boot.
4. Install hose clip.

Checking outer constant velocity joint

The joint should be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage.

Removing

1. Before disassembling, mark position of ball hub in relation to ball cage and joint body with an electric scribe or oil stone - arrow -.
2. Swing ball hub and ball cage and take out balls one after the other.

1. Turn cage until two cage openings - arrow - are level with joint body.
2. Lift out cage together with hub.

1. Swing one segment of the hub into one of the cage openings.
2. Pivot hub out of cage.

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

Installing

Installation is performed in reverse sequence; note the following

1. Pack half of the total quantity of grease into the joint body.
2. Install cage with hub into joint body.

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

1. Press in the balls one after the other from opposite sides, taking care to re-establish the original position of the hub relative to the cage and the joint body.
2. Install new circlip in shaft.
3. Distribute remaining grease in boot.

Rear axle, removing and installing

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G1383A

Scheme 990

1. Brake filler and bleeder unit VAS 5234

Removing

Scheme 991

1. Remove fasteners - 1 - to - 8 - and remove guard plate for rear axle.
2. Remove wheels.

Scheme 992

1. Unclip brake cables - arrows -.
2. Unfasten clamps - 2 - of brake hose retainer and detach brake lines from axle beam. Seal lines with plugs.

Scheme 993

1. Remove bolts - A - and attach brake caliper housing to body with wire.

Scheme 994

1. Disconnect connector - 1 - from speed sensor.
2. Unclip speed sensor wire from bracket.

Note. Use engine/transmission jack V.A.G1383- with attachment -1359/2- when removing and installing axle beam.

Scheme 995

1. Remove bolt -2- on left and right sides.
2. Lower engine/transmission jack and take out coil spring.
3. Support rear axle.

Using engine/transmission jack V.A.G1383A (for example)

1. Remove bolts - 1 - for mounting bracket on rear axle on both sides and lower rear axle.

Installing

Greasing bonded rubber bushing

1. Before installing rear axle, grease kidney-shaped cavities of bonded rubber bushings with assembly paste G052150A2.

Installation is carried out in reverse order.

The vehicle must be standing on its wheels when tightening the bolt connections with bonded rubber bushings.

Otherwise, the rubber bushing would be subject to torsion and its service life shortened.

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

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

Rear axle body, assembly overview

Note. The axle beam and stub axles must not be straightened or welded. Always replace self-locking nuts.

Scheme 996

1 - Wheel bolt, 120 Nm

2 - Phillips-head screw

3 - Brake disc

4 - Protective cap

1. Always replace if removed

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

This is essential for optimum function and service life.

5 - Self-locking 12-point nut, 220 Nm

1. Always replace if removed

6 - Wheel hub with wheel bearing

Wheel bearing and wheel hub are combined in one housing.

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

1. Removing and installing --> «Wheel bearing/wheel hub unit, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheel-bearingwheel-hub-unit-removing-and)

7 - Hex bolt, 50 Nm plus an additional 90 / turn° 1 4

1. Always replace if removed

8 - Splash plate

9 - Bracket for parking brake cable

10 - Parking brake cable

11 - Self-locking nut, 45 Nm plus an additional 90 / turn° 1 4

1. Always replace if removed

12 - Hex bolt, 30 Nm plus an additional 90 / turn° 1 4

1. Always replace if removed
2. Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). Thread insert must be of same length as thread in body.

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

13 - Hexagon bolt, 45 Nm plus an additional 90 / turn° 1 4

1. Always replace if removed

14 - Mounting bracket for rear axle

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

15 - Bracket for parking brake cable

16 - Bonded rubber bushing

1. Removing and installing --> «Bonded rubber bushing, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
2. Lubricate kidney-shaped cavities with assembly paste G 052 150 A2

17 - Axle beam

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

18 - ABS wheel speed sensor

19 - Socket head bolt, 8 Nm

20 - Hex bolt, 20 Nm plus an additional 45 / turn° 1 8

21 - Vibration damper

22 - Spring plate

Material: Zinc

1. Check spring plate for damage

23 - Coil spring

1. Note different coil spring versions; see vehicle data sticker «Explanation on weight codes (PR Numbers)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__explanation-on-weight-codes-pr-numbers)

24 - Spring plate

25 - Hex bolt, 40 Nm plus an additional 90 / turn° 1 4

1. Always replace if removed

26 - Hex bolt, 30 Nm plus an additional 90 / turn° 1 4

1. Always replace if removed
2. Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). Thread insert must be of same length as thread in body.

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

27 - Shock absorber

Checking function --> Shock absorbers, absorber overview (Front Wheel Drive (FWD) vehicles)

1. Different versions available --> Parts Catalog
2. The same version must be installed on both sides

28 - Hex nut

1. Always replace if removed
2. Vehicle must be standing on its wheels when tightening nut

29 - Stub axle

1. Must not be straightened
2. Thread-cutting is not permitted

30 - Stone deflector

31 - Hex socket head bolt, 65 Nm

1. Always replace if removed

32 - Brake caliper

Explanatory notes on weight codes (PR Nos.)

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

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

Scheme 997

Vehicle data sticker (example)

1. A - is the PR No. for the front axle
2. B - is the PR No. for the rear axle

The vehicle data sticker can be found in the spare wheel recess and in the service book.

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

Scheme 998

Special tools, testers and auxiliary items required

1. Assembly tool 3301
2. Support arm bearing inst. tool 3346
3. Press tool 3416/1
4. Press tool 3416/2

1. Support tube 3416/3
2. Slide hammer-complete set VW771

Removing

1. Unclip brake cable - arrows -.
2. Unfasten clamps - 2 - from brake hose retainer.
3. Remove hex bolt - 1 - securing bonded rubber bushing.

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

Scheme 999

1. Insert special tool and knock guide bushing out of axle beam.

Installing

Front of bonded rubber bushing has a marking - 1 -.

Scheme 1000

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

1. Identify position of mark - 1 - on bonded rubber bushing.

Scheme 1001

1. Attach special tool to bonded rubber bushing.

Scheme 1002

1. Bring bonded rubber bushing with special tool into position at rear axle.
2. Make sure that the mark aligns with edge of trailing arm.
3. Pull in bonded rubber bushing by turning spindle.
4. Check position of bonded rubber bushing after installing.

Greasing bonded rubber bushing

1. Before installing rear axle, grease kidney-shaped cavities of bonded rubber bushings with assembly paste G052150A2.

Further installation of rear axle is performed in reverse order.

Shock absorber/spring, removing and installing

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G1383A

Scheme 1003

1. Shock absorber set T10001

Removing spring

1. Disconnect connector - 1 - from speed sensor.
2. Unclip speed sensor wire from bracket.

Scheme 1004

1. With vehicle standing on its wheels, remove bolts - 1 -. If necessary, lift vehicle until bolts are accessible.
2. Raise vehicle to working height, thus relieving tension off coil spring.
3. Remove spring.

Installing spring

1. Check whether lower spring plate (zinc) is damaged.
2. Replace if necessary.
3. Install spring together with upper spring plate.

Note installation position.

Scheme 1005

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

Scheme 1006

1. Use transmission jack V.A.G1359/2- to press rear axle upward.
2. Bolt shock absorber to body. Tightening torque: 30 Nm plus an additional 90° 1 / 4 turn.

Use new bolts!

Removing shock absorber

1. With vehicle standing on its wheels, remove bolts - 1 -. If necessary, lift vehicle until bolts are accessible.
2. Raise vehicle to working height, thus relieving tension off coil spring.
3. Remove hexagon bolt - 2 - securing shock absorber to axle.

For ease of illustration the procedure is shown with the wheel removed.

1. Remove shock absorber.

Installation is carried out in reverse order.

The vehicle must be standing on its wheels when tightening the bolt connections with bonded rubber bushings.

Otherwise, the bushing would be subject to torsion and its service life shortened.

Scheme 1007

1 - Gas-filled shock absorber

1. Different versions available --> Parts Catalog
2. The same version must be installed on both sides

Checking function

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

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

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

2 - Protective cap

3 - Protective tube

4 - Stop buffer

5 - Shock absorber mount

6 - Self-locking hex nut, 25 Nm

1. Always replace if removed
2. Removing «Removing hex nut from shock absorber»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

7 - Cover

Scheme 1008

1 - Commercially available ratchet handle

2 - Socket T10001/9

3 - T10001/11

4 - Socket T10001/1

Special tool 3079 can also be used.

Scheme 1009

For vehicles with front wheel drive

1 - Left Rear Level Control System Sensor - G76

Is tested electrically via self-diagnosis

If malfunctions occur --> 01 ON BOARD DIAGNOSTIC (OBD)

2 - Mounting bracket

3 - Coupling rod

4 - Bracket

5 - Rear axle beam

6 - Hex bolt, 20 Nm

Scheme 1010

1 - Phillips-head screw

2 - Brake disc

3 - Protective cap

1. Always replace if removed

An appropriate seal can only be achieved with a new protective cap. Only then can an optimal function and long service life be guaranteed

4 - Self-locking 12-point nut, 220 Nm

1. Always replace if removed

5 - Wheel hub with wheel bearing

Wheel bearing and wheel hub are combined in one housing.

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

6 - Axle beam

7 - Brake caliper

8 - Stub axle

1. Must not be straightened
2. Thread-cutting prohibited.

Wheel bearing/wheel hub unit, removing and installing

Special tools, testers and auxiliary items required

Scheme 1011

1. Installation sleeve wheel brg. 3420

Scheme 1012

1. Puller Kukko 20/ 2 and Kukko 204/ 2

Scheme 1013

Loosen protective cap from its seat by tapping lightly on claw.

Scheme 1014

Removing brake caliper

1. Remove securing bolts - A - from brake caliper.
2. Remove brake caliper and tie up on body.
3. Remove phillips-head screw for brake disc and remove brake disc.
4. Remove twelve-point nut.

Scheme 1015

A - Puller with leg clamp, e.g. Kukko 20/ 2

Scheme 1016

Always use puller with leg clamp, e.g. Kukko 204/ 2 (commercially available).

Scheme 1017

1. Install wheel bearing/wheel hub unit onto stub axle as far as it will go.
2. Install special tool 3420 and pull in wheel hub/wheel bearing unit as far as stop.

Scheme 1018

1. Remove special tool 3420.
2. Use a new 12-point nut and tighten to 220 Nm.

Scheme 1019

Note. Always replace damaged (dented) protective caps. Damaged (dented) protective caps may allow moisture to enter the bearing. For this reason it is important to use the tool shown in the illustration.

Installation is in reverse sequence.

Rear axle, assembly overview

Note. Always replace self-locking nuts/bolts. Always replace corroded nuts/bolts.

Scheme 1020

1 - Subframe

1. Assembly overview --> «Trailing arm and transverse links, assembly overview»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

2 - Final drive

1. Servicing --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#5-6-speed-manual-transmission-02m-02y-awd)

3 - Cross member

4 - Stabilizer bar

1. If necessary, repair paint damage and apply corrosion protection coating

5 - Gas-filled strut

1. Different versions available --> Parts Catalog
2. The same version must be installed on both sides
3. Assembly overview --> «Spring and suspension strut, assembly overview (All Wheel Drive (AWD) vehicles)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
4. Removing and installing --> «Spring, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__spring-removing-and-installing)

6 - Wheel bearing

1. Removing and installing --> «Wheel bearings, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheel-bearings-removing-and-installing)

7 - Trailing arm

1. Assembly overview --> «Trailing arm and transverse links, assembly overview»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

8 - Transverse link

1. Different versions available --> Parts Catalog
2. The same version must be installed on both sides
3. Assembly overview --> «Trailing arm and transverse links, assembly overview»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

9 - Coil spring

1. Assembly overview--> «Spring and suspension strut, assembly overview (All Wheel Drive (AWD) vehicles)»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

10 - Drive shaft

1. Repair notes --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#5-6-speed-manual-transmission-02m-02y-awd)

11 - Twelve-point bolt, 60 Nm

Diagonal strut, removing and installing

Removing

1. Remove CD cover --> «66 EXTERIOR EQUIPMENT»(/audi/tt/8n-1998-2003/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 1021

1. Remove bolts - 1 - and - 2 -.
2. Remove diagonal struts.

Installing

1. Installation is carried out in reverse sequence.

Spring, removing and installing

Special tools, testers and auxiliary items required

1. Spring compressor V.A.G1752/1

Scheme 1022

1. 2 spring holders (80-165 mm) V.A.G1752/4

1. Engine/transmission jack V.A.G1383A

Great force are applied when compressing springs. Note the following safety precautions

Removing left spring

1. Remove wheel.

Scheme 1023

1. Attach 2 spring holders (80-165 mm) V.A.G1752/4 to spring compressor V.A.G1752/1.

Scheme 1024

1. Insert the spring compressor V.A.G1752/1-.

Scheme 1025

1. Turn spring compressor spindle until spring is slightly compressed.
2. Check that spring retainers are properly positioned on spring coils.
3. Stop compressing the spring at the latest when the spring coils touch one another.

Scheme 1026

1. Unclip speed sensor wire from bracket.
2. Open cover - 2 - for connector - 1 -.
3. Remove ABS wheel speed sensor from trailing arm housing.
4. Detach headlight range control linkage if necessary --> «Vehicle level sensor in vehicles with automatic headlight vertical aim control»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering) .

1. Place engine/transmission jack V.A.G1359/2 under the wheel bearing housing and raise it slightly.

Scheme 1027

1. Remove hex bolt - arrow -. Tightening torque: 110 Nm.

Use new bolt.

1. Slowly lower engine/transmission jack again.
2. Remove spring from vehicle together with spring compressor.

Installing left spring

1. Insert spring into spring retainers.
2. Turn spring compressor spindle until spring is slightly compressed.
3. Check that spring compressors are properly positioned on spring coils.
4. Stop compressing the spring at the latest when the spring coils touch one another.

Installation position of spring

Scheme 1028

For vehicles with no fixed stop on stop buffer - 2

The end of the spring coil - 3 - must be positioned at 9 o'clock.

1 - Spring

2 - Stop buffer

F - Direction of travel

Installation position of spring

For vehicles with fixed stop on stop buffer - 2

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

1. Loosen spring by turning spindle counter-clockwise.

Scheme 1029

1. Check the spring for correct installation position while loosening it.
2. Do not use an impact wrench or similar.

The spring retainers will become jammed in the spring if the spindle is turned too far.

1. Remove spring compressor out of spring.

Scheme 1030

1. If necessary, remove coupling rod - arrow - from stabilizer bar.

The lower bolt for the shock absorber is then easier to install.

The remaining installation steps are carried out in reverse sequence.

The vehicle must be standing on its wheels when tightening the bolt connections with bonded rubber bushings.

Otherwise, the bushing would be subject to torsion and its service life shortened.

Use new bolts.

Removing and installing right spring

1. Removal and installation is the same as the left side.

Shock absorber, removing and installing

Removing

1. Remove wheel.

1. Unclip wheel speed sensor wire from bracket.
2. Open cover - 2 - for connector - 1 -.
3. Remove ABS wheel speed sensor from trailing arm housing.

Scheme 1031

1. Partially remove wheel housing liner.
2. Place transmission jack V.A.G1359/2 under the wheel bearing housing and raise it slightly.

Scheme 1032

1. Remove upper bolt securing shock absorber - arrow -.

Scheme 1033

1. Remove lower bolt securing shock absorber - arrow -.
2. Remove shock absorber out of vehicle.

Installing

Installation is carried out in reverse sequence.

1. Secure coupling rod to stabilizer bar. Tightening torque: 25 Nm

The vehicle must be standing on its wheels when tightening the bolt connections with bonded rubber bushings.

Otherwise, the bushing would be subject to torsion and its service life shortened.

Use new bolts.

Note. Make sure sufficient clearance between splash plate and brake disc.

1. Install rear wheels. Tightening torque for wheel bolts: 120Nm

Removing

1. Remove rear wheels.
2. Remove rubber mounting for exhaust pipe at center of vehicle.

Scheme 1034

1. Position engine/transmission jack V.A.G1383A with universal mount 1359/2 and a wood block support underneath the center muffler.

Scheme 1035

1. Disconnect exhaust system at double clamp - arrows -.

Scheme 1036

1. Remove bolts - arrow - for exhaust pipe bracket and heat shield on left and right sides at rear of vehicle. Tightening torque: 25 Nm
2. Lower transmission jack slightly.
3. Remove exhaust system.
4. If necessary, remove clip for heat shield by unscrewing using a screwdriver or long-nose pliers.

1. Remove heat shield.
2. Remove bolts 14. Tightening torque: 20 Nm. Tighten both bolts to an initial torque of 5 Nm.

Scheme 1037

1. Remove nuts - 12 -. Tightening torque: 25 Nm
2. Remove coupling rod - 16 - from stabilizer bar - 13 -.
3. Remove stabilizer bar clamp - 15 - and stabilizer bar - 13 -.

Installing

1. Installation is carried out in reverse sequence.

Note. Do not tighten nut - 12 - until shock absorbers have been installed.

Scheme 1038

Centering tailpipe in bumper cut-out

1. Align rear muffler to give equal clearance - a - and - b - between bumper cut-out and tailpipe. If necessary loosen rear muffler mounting to center tailpipe.

For vehicles with a joint between the front and rear muffler, release the clamp if necessary.

Refer to notes in -->

1. «26 EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/tt/8n-1998-2003/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-mechanical-engine-codes-amu-bea) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMU, BEA
2. «26 EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/tt/8n-1998-2003/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-engine-mechanical-engine-codes-atc-awp) for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): ATC, AWP
3. «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/tt/8n-1998-2003/remont/blowers-superchargers-turbochargers/#18l-4-cyl-5v-turbo-generic-scan-tool-engine-codes-amu-bea-atc-awp) for 1.8 LITER 4-CYL. 5V TURBO GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC, AWP

225 HP version

Scheme 1039

1. Install new clamps so that the ends of the bolts do not protrude beyond the bottom of the clamp. (The illustration shows the clamp looking from front to rear.) Tightening torque of bolts: 40 Nm.

180 HP version

Scheme 1040

1. Install new clamps so that the ends of the bolts do not protrude beyond the bottom of the clamp. (The illustration shows the clamp looking from front to rear.) Tightening torque of bolts: 40 Nm.

Exhaust system, checking for leaks

1. Start engine and let it idle.
2. Plug tailpipes while checking for leaks (e.g. with cloth or plug).
3. Listen for leaks at joints between cylinder head/exhaust manifold, exhaust manifold/turbocharger, turbocharger/front exhaust pipe etc.
4. Repair any leaks found.

Scheme 1041

1 - Hex bolt, 60 Nm

1. Always replace if removed

2 - Mounting bracket for suspension strut

3 - Gas-filled strut

1. Different versions available --> Parts Catalog
2. The same version must be installed on both sides
3. Removing and installing --> «Shock absorber, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__shock-absorber-removing-and-installing)

Checking function

1. Can be replaced individually

4 - Stabilizer bar

1. Removing and installing --> «Stabilizer bar, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

5 - Self-locking nut, 25Nm

1. Always replace if removed

6 - Hex bolt, 110 Nm

1. Always replace if removed

7 - Coupling rod

8 - Trailing arm

9 - Spacer

1. Only installed in vehicles with heavy-duty suspension

10 - Stop buffer

1. 10 Nm

11 - Coil spring

1. Check for paint damage, repair paint damage if necessary
2. Note color code
3. Different versions available
4. Removing and installing --> «Spring, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__spring-removing-and-installing)

12 - Spring plate

13 - Thread in longitudinal member

If damaged, thread of captive nut can be repaired with Helicoil thread insert.

14 - Thread in cross member

If damaged, thread of captive nut in cross member can be repaired with Helicoil thread insert.

Trailing arm and transverse links, assembly overview

Note. Never subject the wheel bearing to load when the drive axle has been removed! If the vehicle is to be lowered onto its wheels and moved, an outer CV joint of a drive axle must be installed temporarily. Load-bearing components or parts of the suspension must not be welded or straightened. Always replace self-locking nuts. Always replace corroded nuts/bolts.

Scheme 1042

1 - Socket head bolt, 40Nm

2 - Subframe

1. Removing and installing --> «Subframe, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

3 - Drive axle

1. Pulling drive axle out of wheel hub and pressing in --> Removing and installing drive axles--> «Drive shaft, servicing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

4 - Hex bolt M 12 x 1.5 x 80

1. Always replace if removed

5 - Hex bolt M 12 x 1.5 x 75

1. Always replace if removed

6 - Upper transverse link

1. Different versions available
2. The same version must always be installed on both sides --> «Ball joint replaced by bonded rubber bushing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-replaced-by-bonded-rubber)
3. Removing and installing --> «Transverse links, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__transverse-links-removing-and-installing)

7 - Ball joint

1. Check rubber boot for tears and damage
2. New version: bonded rubber bushing --> «Ball joint replaced by bonded rubber bushing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-replaced-by-bonded-rubber)
3. Removing and installing --> «Ball joints, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joints-removing-and-installing)

8 - Socket head bolt, 65 Nm

9 - Brake caliper

1. Servicing --> «46 BRAKES - MECHANICAL COMPONENTS»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

10 - Hex bolt, 10 Nm

11 - Self-locking 12-point nut

Refer to notes --> Drive axle / wheel hub splines and table

1. Always replace if removed

12 - Phillips-head screw, 4 Nm

13 - Brake disc

14 - Wheel hub with rotor for wheel speed sensor

1. Rotor is welded to wheel hub
2. Checking lateral run-out of rotor --> «45 ANTI-LOCK BRAKE SYSTEM»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
3. Removing and installing --> «Bonded rubber bushing, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

15 - Circlip

1. Check for proper seating

16 - Wheel bearing

1. Replace; is destroyed when pressed out
2. Removing and installing --> «Wheel bearings, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheel-bearings-removing-and-installing)

17 - Splash plate

18 - Self-locking nut

1. 70Nm plus an additional 90° 1 / 4 turn
2. Always replace if removed

19 - Lower transverse link

1. Different versions available
2. Removing and installing --> «Transverse links, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__transverse-links-removing-and-installing)
3. The same version must always be installed on both sides --> «Ball joint replaced by bonded rubber bushing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-replaced-by-bonded-rubber)

20 - Ball joint

1. Check rubber boot for tears and damage
2. New version: bonded rubber bushing --> «Ball joint replaced by bonded rubber bushing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joint-replaced-by-bonded-rubber)
3. Removing and installing --> «Ball joints, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__ball-joints-removing-and-installing)

21 - Hex bolt, 90 Nm

1. Always replace if removed

22 - Bonded rubber bushing

1. Removing and installing --> «Trailing arm bushing, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

23 - Trailing arm

1. Removing and installing --> «Trailing arm, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

24 - Hex bolt, 75 Nm

1. Always replace if removed

25 - Mounting bracket for rear axle

1. After installation, check total toe setting of rear axle and align if necessary.
2. Toe setting can be adjusted by moving mounting bracket

26 - Spacer

1. Only installed in vehicles with heavy-duty suspension

27 - Bump stop

1. 10 Nm
2. Different versions available

Ball joint replaced by bonded rubber bushing

Ball joints were replaced by bonded rubber bushings in model year 2003. The different types of joints and transverse links must not be installed together in the same vehicle.

Scheme 1043

For vehicles with all wheel drive

1 - Subframe

2 - Bracket

3 - Upper transverse link

4 - Coupling rod

5 - Self-locking nut, 4 Nm

Always replace if removed

6 - Lower transverse link

7 - Clamp (mark position of clamp)

8 - Rivet

Replaced by self-tapping screw

Tightening torque: 9 Nm

9 - Left Rear Level Control System Sensor - G76

Is tested electrically via self-diagnosis

If malfunctions occur --> 01 ON BOARD DIAGNOSTIC (OBD)

Do not remove coupling rod from ball head

Wheel bearings, removing and installing

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G1383A

1. Foot pump with high pressure hose V.A.G1389A/1

If there is a hand pump V.A.G1389/1 available in the dealership it can be converted to a foot-operated pump.

1. Wheel bearing tool V.A.G1459B
2. Hollow piston cylinder HKZ-15 with thrust piece E-0-204-T (hydraulic)
3. Pull rod E-0-217+218
4. Special nut E-8-214

1. Thrust piece E-5
2. Centering piece with clamp E-76-2

1. Supplementary set for VAG 1459B V.A.G1383A
2. Thrust sleeve E-44
3. Support E-40
4. Thrust piece E-6-1

1. Thrust piece E-13-1
2. Thrust piece E-39

1. First remove drive axle.

Removing and installing drive axle--> Drive axles, removing and installing

1. Remove wheel.

Scheme 1044

1. Remove securing bolts - 1 - from brake caliper and remove brake caliper.
2. Remove phillips-head screw for brake disc and remove brake disc.
3. Remove ABS wheel speed sensor from trailing arm housing.

Pressing out wheel hub

Scheme 1045

1. Insert thrust piece 1 as shown in illustration.

1 - Thrust piece E-39

Position thrust piece so that it makes full contact with bolt heads - 2 -.

Scheme 1046

1. Attach centering piece with clamp E-76-2.

1 - Hollow piston cylinder HKZ-15 with thrust piece E-0-204-T (hydraulic)

2 - Centering piece with clamp E-76-2

Scheme 1047

1. Attach support - 1 - , hollow piston cylinder - 2 - with pull rod - 3 - and special nut - 4 -.

1 - Support E40

2 - Hollow piston cylinder HKZ-15

3 - Pull rod E-0-217

4 - Special nut E-8-214

5 - High pressure hose with quick-release coupling

6 - Thrust piece E-39

1. Build up pressure with foot-operated pump.
2. Check that all tools are correctly centered.

Note. Place engine/transmission jack V.A.G1383/A underneath (danger of accident from parts dropping out when wheel hub is pulled out).

1. Press wheel hub out of wheel bearing by pumping.

Pressing out wheel bearing

Scheme 1048

1. Remove circlip.
2. Position thrust piece - 1 - on rear side of wheel bearing.
3. Apply hollow piston cylinder - 2 - with pull rod - 3 - and special nut - 4 -.
4. Build up pressure with foot-operated pump.

1. Check that all tools are correctly centered.

Scheme 1049

1. Press out wheel bearing by pumping.

1 - Thrust piece E-5

2 - Hollow piston cylinder HKZ-15

3 - Pull rod E-0-217

4 - Special nut E-8-214

5 - Support E-44

1. Pull inner bearing race off wheel hub.

Pressing in wheel bearing

1. Position wheel bearing on wheel bearing housing.

Scheme 1050

1. Place thrust piece - 1 - on rear side of wheel bearing housing.
2. Attach hollow piston cylinder - 2 - with pull rod - 3 - , special nut - 4 - and thrust piece -5-.
3. Build up pressure with foot-operated pump.
4. Check that all tools are correctly centered.

1. Press in wheel bearing by pumping.

1 - Thrust piece E-6-1

2 - Hollow piston cylinder HKZ-15

3 - Pull rod E-0-217

4 - Special nut E-8-214

5 - Thrust piece E-13-1

1. Install circlip.

Pressing in wheel hub

1. Position wheel hub on wheel bearing.

1. Attach centering piece with clamp E-76-2.

Scheme 1051

1. Place thrust piece - 1 - on rear side of wheel bearing housing.
2. Attach hollow piston cylinder - 2 - with pull rod - 3 - , special nut - 4 - and thrust piece -5-.
3. Build up pressure with foot-operated pump.
4. Check that all tools are correctly centered.

1. Press in wheel hub by operating foot pump.

The shoulder - arrow - on thrust piece E-5 must face toward special nut - 4 -.

1 - Thrust piece E-5

2 - Hollow piston cylinder HKZ-15

3 - Pull rod E-0-217

4 - Special nut E-8-214

Installing

Installation is carried out in reverse sequence.

Tightening torques

Inner joint of drive axle to final drive flange

Brake caliper to trailing arm --> 46 BRAKES - MECHANICAL COMPONENTS

Wheel bolt --> Wheels, instructions for changing/installing

12-point nut on wheel hub

Use new 12-point nut.

Tightening procedure Installing drive axle

Scheme 1052

Special tools, testers and auxiliary items required

1. Assembly tool 3301
2. Support arm bearing installation tool 3346
3. Assembly tool 3348/1
4. Tube T10030/2

Removing

1. First remove spring.

Removing and installing spring --> Spring, removing and installing

Scheme 1053

1. Remove brake line bracket - 1 - from trailing arm.

Scheme 1054

1. Unclip brake line from brackets - arrows -.
2. Mark position of mounting bracket on body.

Scheme 1055

1. Remove mounting bracket from body.
2. Mark position of mounting bracket in relation to trailing arm (with felt tip pen or similar).

Scheme 1056

Note - arrows - and dotted line

1 - Trailing arm

2 - Mounting bracket

Scheme 1057

Remove bonded rubber bushing from trailing arm

1. Attach tools as shown in illustration.
2. Pull out bonded rubber bushing by turning spindle.

Installing bonded rubber bushing

1. Attach tools as shown in illustration.

Scheme 1058

1. Pull in bonded rubber bushing by turning the spindle.

Installing trailing arm

Installation is carried out in reverse sequence.

If the position of the mounting bracket in relation to the trailing arm was not marked, the correct position must be determined Setting position of mounting bracket in relation to trailing arm .

Ball joints, removing and installing

Special tools, testers and auxiliary items required

1. Assembly tool 3350/1
2. Assembly tool 3346/2
3. Thrust piece T10030/1A
4. Assembly tool 3301

1. Press tool VW 454
2. Tube VW 421
3. Engine/transmission jack V.A.G1383A
4. Adjusting tool (front axle) T40021

1. Adjusting tool (rear axle) T40022
2. Universal grease G 052 735 A5

1. Refer to vehicle data sticker to check whether 1KE or 1KF brake system is installed in vehicle.

Scheme 1059

Vehicle data sticker (example)

The vehicle data sticker can be found at the rear of the spare wheel well and in the Service book.

In this example, a 1KF brake system is installed

This information is required for a later step in the procedure.

1. Lift vehicle on lifting platform.
2. Remove rear wheels.
3. Remove top or bottom transverse link --> «Transverse links, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__transverse-links-removing-and-installing) .

Scheme 1060

1. Position transmission jack V.A.G1359/2 underneath trailing arm, using a block of wood - arrow -.

Continued for vehicles with 1KF brake system Vehicles with 1KF brake system

Continued for vehicles with 1KE brake system Vehicles with 1KE brake system

Vehicles with 1KF brake system

Vehicles with slightly worn brake disc

Scheme 1061

1. Remove hex socket head bolts - 2 -.

Tightening torque: 65 Nm

Vehicles with heavily worn brake disc

1. Remove hex bolts - 1 -.

Tightening torque: 35 Nm

Always replace bolts.

Continued for both brake disc conditions

1. Detach brake caliper and tie up with wire.

Do not suspend the brake caliper on the brake line.

1. Remove brake disc.

Vehicles with 1KE brake system

On vehicles with 1KE brake system the brake caliper does not have to be removed.

Removing lower ball joint

1. Lubricate spindle with universal grease G 052 735 A5.
2. Attach tools as shown in illustration.

Scheme 1062

1. Pull out ball joint by turning spindle.

Installing lower ball joint

1. Attach tools as shown in illustration.

1. Draw in joint centrally by turning the spindle.

Removing upper ball joint

1. Lubricate spindle with universal grease G 052 735 A5.
2. Attach tools as shown in illustration.

Scheme 1063

1. Pull out ball joint by turning spindle.

Installing upper ball joint

1. Attach tools as shown in illustration.

Scheme 1064

1. Pull in ball joint - 1 - by turning spindle.
2. Install brake disc (if removed).

Tightening torque of phillips-head screw: 4Nm

1. Check that there is sufficient clearance between splash plate and brake disc.
2. If necessary, ensure correct clearance.

1. Install brake caliper (vehicles with 1 KF brake system only).

Tightening torque for bolt - 2 - : 65 Nm

Tightening torque for bolt - 1 - : 35 Nm

1. Install top or bottom transverse link «Installing transverse links»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__installing-transverse-links) .

1. First remove spring.

Removing and installing spring --> Spring, removing and installing

Scheme 1065

1. Disengage parking brake cable from brake caliper.
2. Pull parking brake cable out of trailing arm.
3. Remove drive axle.

Removing and installing drive axle--> Drive axles, removing and installing

Scheme 1066

1. Unclip speed sensor wiring - arrow - from bracket.
2. Remove ABS wheel speed sensor from trailing arm housing.

1. Remove brake line bracket from trailing arm.
2. Unclip brake line from bracket - 1 -.

1. Remove securing bolts - 1 - from brake caliper and remove brake caliper.
2. Tie brake caliper on body.
3. Remove phillips-head screw for brake disc and remove brake disc.

Scheme 1067

1. Remove bolt - 2 - for transverse link.

3 - Upper transverse link

4 - Lower transverse link

5 - Trailing arm

Scheme 1068

1. Position transmission jack under trailing arm.
2. Remove shock absorber bolt.
3. Mark position of mounting bracket on body.

1. Remove mounting bracket from body - arrows -.
2. To do this, unscrew brake line connection.

The mounting bracket must be transferred if the trailing arm is to be replaced.

The installation position of the mounting bracket must then be adjusted as described on Setting position of mounting bracket in relation to trailing arm .

Setting position of mounting bracket in relation to trailing arm

Dimension - a - is 53.5 ± 2 mm

1 - Mounting bracket

2 - Trailing arm

Scheme 1069

Installation is carried out in reverse sequence.

The vehicle must be standing on its wheels when tightening the bolt connections with bonded rubber bushings.

Otherwise, the bushing would be subject to torsion and its service life shortened.

After installation the camber and toe settings must be checked using wheel alignment equipment.

Tightening torques

Brake caliper to trailing arm --> 46 BRAKES - MECHANICAL COMPONENTS

Mounting bracket to trailing arm --> Trailing arm and transverse links, assembly overview

Mounting bracket to body --> Trailing arm and transverse links, assembly overview

Transverse link to trailing arm --> Trailing arm and transverse links, assembly overview

Shock absorber to trailing arm

Inner joint of drive axle to final drive flange

12-point nut to wheel hub

Use new 12-point nut.

Tightening procedure Installing drive axle

Wheel bolt --> Wheels, instructions for changing/installing

Transverse links, removing and installing

The transverse link is available in different versions

The same version must always be installed on both sides.

1. Lift vehicle on lifting platform.
2. Remove rear wheels.

Removing sensor

1. If the vehicle has automatic headlight vertical range control, mark the installation position of clamp - 7 - on transverse link - 6 - and transfer the marking to the new transverse link.

Note installation position of coupling rod - 4 - in relation to sensor arm.

1. Loosen nuts - 5 -.

4 - Coupling rod

5 - Self-locking nut, 4 Nm

Always replace if removed

Hex nut N011 183 12

6 - Lower transverse link

7 - Clamp

Note. When attaching linkage - item1 - to level sensor, use a 9 mm open-ended wrench with dimension - A - to avoid damaging the seal.

The linkage is only attached to the sensor after the new transverse link has been installed.

Scheme 1070

1. Dimension A: 4 mm

Tightening torque: 3.5 Nm

Installing sensor

Install in reverse order.

Scheme 1071

1. Make sure that distance - X - is correct before installation.

X = 153 mm

Sequence for left side of vehicle

1. Unclip speed sensor wire from bracket.
2. Open cover -2- for connector - 1 -.
3. Remove ABS speed sensor from trailing arm housing.

1. Remove bolts - 1 - and - 2 -.

Note correct positions of bolts (they are installed in different directions).

Refer to information on --> General information

Tightening torque: 70 Nm plus an additional 90° 1 / 4 turn

Always replace nuts and bolts when re-assembling.

3 - Upper transverse link

4 - Lower transverse link

5 - Trailing arm

1. Remove bolt - 5 -.

Tightening torque

Always replace bolt when re-assembling.

Scheme 1072

1. Remove bolts - 1 - and - 2 -.

Refer to information on --> General information

Tightening torque --> Trailing arm and transverse links, assembly overview

Always replace nuts and bolts when re-assembling.

The new bolts are installed from front to rear.

3 - Upper transverse link

4 - Lower transverse link

1. Pull trailing arm outwards slightly.

1. Remove lower transverse link - 4 -.

1. Position transmission jack V.A.G1359/2 underneath trailing arm, using a block of wood - arrow -.
2. Raise transmission jack until the trailing arm is approximately horizontal.

1. Remove bolts securing upper transverse link.
2. Lower transmission jack again.

Scheme 1073

1. Push upper transverse link - 1 - as far as possible horizontally and vertically into subframe - 2 -.

Scheme 1074

1. Pull trailing arm outward slightly.
2. Remove upper transverse link - 1 - from trailing arm first, then from subframe.

Installing transverse links

1. First, the upper transverse link must be inserted in the subframe.

1. Push upper transverse link - 1 - as far as possible horizontally and vertically into subframe - 2 -.
2. Align upper and lower ball joints with mountings on subframe so that rubber boots do not get damaged when transverse links are installed.

1. Pull trailing arm outwards slightly.
2. Push transverse link - 1 - over bushing.

1. Install new bolt - 1 - and secure with a new nut.

1. Install new bolt - 1 - and secure with a new nut.
2. Push lower transverse link - 4 - over bushing on trailing arm and secure with a new bolt - 2 - and new nut.

1. Install new bolt - 1 - and secure with a new nut.

1. Pull trailing arm outward slightly and position lower transverse link - 4 - at subframe.
2. Install new bolt - 2 - and secure with a new nut.

Installation of the transverse links is in reverse order of removal --> Transverse links, removing and installing .

The vehicle must be standing on its wheels when tightening the bolt connections with bonded rubber bushings. --> General information

Otherwise, the bushing would be subject to torsion and its service life shortened.

Scheme 1075

1. Note direction in which bolts - 1 - are installed; - arrow - points in direction of travel.
2. If installed, install headlight range control linkage on upper transverse link «Installing sensor»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__installing-sensor).
3. Clip sensor wiring back into position see scheme 284.
4. Check that there is sufficient clearance between splash plate and brake disc.

1. If necessary, ensure correct clearance.
2. Install wheels --> «Wheels, instructions for changing/installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheels-instructions-for-changinginstalling) .

The bolts for the transverse links must only be tightened when the vehicle is standing on its wheels.

1. After installation the camber and toe settings must be checked using wheel alignment equipment.
2. Basic setting must be performed for vehicles with headlight range control --> «01 ON BOARD DIAGNOSTIC (OBD)»(/audi/tt/8n-1998-2003/remont/cruise-control-systems/#electrical-equipment)

Work steps for right side of vehicle

The procedure for the right side of the vehicle is the same as for the left side Sequence for left side of vehicle .

1. Install wheels --> «Wheels, instructions for changing/installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheels-instructions-for-changinginstalling) .

The bolts for the transverse links must only be tightened when the vehicle is standing on its wheels.

1. After installation the camber and toe settings must be checked using wheel alignment equipment.

Subframe with rear final drive, assembly overview

1 - Socket head bolt, 60Nm

2 - Bonded rubber bushing for rear final drive

1. Removing and installing --> «Bonded rubber bushings for rear final drive, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

3 - Socket head bolt, 60Nm

4 - Bonded rubber bushing for subframe

1. Replacement parts are supplied in a sealed plastic bag
2. Do not use bonded rubber bushings which have been stored unsealed.
3. Removing and installing --> «Subframe bushings, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

5 - Hex bolt M 12 x 1.5 x 85

1. 110Nm plus an additional 90° 1 / 4 turn
2. Always replace if removed

6 - Subframe

1. Removing and installing --> «Subframe, removing and installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

7 - Support for rear final drive

8 - Socket head bolt, 60Nm

9 - Hex socket head bolt, 40 Nm + 45°

1. M10x55

10 - Hex socket head bolt, 40 Nm plus an additional 45 / turn° 1 8

1. M10x40

11 - Rear final drive

1. Servicing --> «39 FINAL DRIVE, DIFFERENTIAL»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#5-6-speed-manual-transmission-02m-02y-awd)

12 - Self-locking nut, 25 Nm

1. Always replace if removed

13 - Stabilizer bar

14 - Hex bolt, 20 Nm

15 - Clamp

16 - Coupling rod

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G1383A

Scheme 1076

1. Support T10031

Removing

1. First remove spring.

Removing and installing spring --> Spring, removing and installing

1. Remove wheels.

Scheme 1077

Mark installation position before removing drive shaft - arrows -. This is important because excessive imbalance will occur if the installation position is not correct.

1. Open double clamp behind catalytic converter and remove rear section of exhaust system.
2. Remove drive shaft from final drive.

1 - Drive shaft with vibration dampener

2 - Drive shaft flange

1. Remove heat shield for rear muffler.

1. Disconnect parking brake cable from brake caliper.
2. Pull parking brake cable out of trailing arm.

The parking brake cables do not have to be pulled out of the trailing arms if the subframe is only to be lowered (for example, when replacing bonded rubber bushings).

1. Unclip speed sensor wiring - arrow - from bracket.
2. Remove ABS speed sensor from trailing arm housing.

Scheme 1078

1. Disconnect brake lines - arrow -.

1. Remove lower bolt for suspension strut - arrow -.

Scheme 1079

1. Place transmission jack e.g. V.A.G1383A under rear axle - 1 -.
2. Use support T10031.

Scheme 1080

1. Guide pins - arrow /1 - into holes in subframe.
2. Disconnect vacuum line and electrical wiring.
3. Mark position of mounting bracket on body.

1. Remove mounting bracket from body - arrow -.

Scheme 1081

1. Remove bolts for axle beam - arrows -.
2. Lower rear axle slowly using transmission jack, e.g. V.A.G1383A.

Installing

Installation is in reverse of removal.

1. Tighten bolts for subframe and mounting brackets onto installation position as marked.

After installation the camber and toe settings must be checked using wheel alignment equipment.

Scheme 1082

Special tools, testers and auxiliary items required

1. Assembly tool 3301
2. Tube 31.5 mm dia. VW418A
3. Screw T10030/3
4. Thrust piece T10030/4

1. Tube T10030/6

Removing

1. First remove springs.

Removing and installing spring --> Spring, removing and installing

1. Remove subframe complete with final drive.

Removing and installing subframe --> Subframe, removing and installing

Scheme 1083

1. Set up special tools.

1 - Washer

1. Remove bonded rubber bushing by turning spindle.

Installing

Bonded rubber bushings supplied as replacements parts are packed in a sealed plastic bag.

Do not use bonded rubber bushings which have been stored unsealed.

Scheme 1084

1. Attach special tool to bonded rubber bushing.

1 - T10030/3 Spindle

2 - Washer with chamfer

3 - 10030/4 Thrust piece

Shoulder - arrow - faces toward bonded rubber bushing

4 - Bonded rubber bushing

1. Lubricate bonded rubber bushing with liquid soap or similar.

Scheme 1085

1. Bring bonded rubber bushing and special tool into position at subframe.
2. Pull in bonded rubber bushing by turning spindle.

1 - Washer

2 - Installation position of bonded rubber bushing in subframe

Note. The spindle must be inserted from below when removing and installing front bonded rubber bushings on subframe.

Installation is carried out in reverse sequence.

Scheme 1086

Special tools, testers and auxiliary items required

1. Support arm bushing inst. tool 3346
2. Assembly tool 3301
3. Tube T10030/2
4. Transverse T10030/5

1. Thrust piece 3348/1

Removing

1. First remove spring.

Removing and installing spring --> Spring, removing and installing

1. Remove subframe complete with rear final drive.

Removing and installing subframe --> Subframe, removing and installing

1. Support final drive.
2. Remove socket head bolts.
3. Remove cross member from rear final drive.

Scheme 1087

1. Remove socket head bolt - 1 -.
2. Move final drive approx. 15 to 20mm - arrow -.

2 - Support for rear final drive

Scheme 1088

1. Set up special tools.

1 - Washer

1. Remove bonded rubber bushing by turning spindle.

Installing

Installation position of bonded rubber bushing

Scheme 1089

Arrow on bonded rubber bushing - 1 - must point upward or downward.

Scheme 1090

1. Set up special tools.
2. Install bonded rubber bushing by turning spindle.

1 - Bonded rubber bushing

Installing

Installation of subframe and springs is carried out in reverse order.

Drive axles, removing and installing

Refer to information on --> General information

Special tools, testers and auxiliary items required

Scheme 1091

1. Hub puller 3283

Scheme 1092

1. Angle wrench V.A.G1756

Left and right drive axles

1. Raise vehicle until the weight is off the rear axle.

The wheel should still be touching the ground.

1. Loosen 12-point nut.

Scheme 1093

1. Disconnect drive axle - 1 - from final drive flange shaft - 2 -.

Left drive axle

Scheme 1094

1. Push exhaust system to one side using a suitable lever - arrow -.
2. Remove inner joint of drive axle from final drive.

1 - Exhaust system

2 - Drive axle

The remaining procedure is the same for both sides.

Scheme 1095

1. Press out drive axle.

Note. Ensure sufficient clearance when pressing out drive axle.

1. Take out drive axle.

Installing drive axle

Remove any paint residue and/or corrosion on thread and splines of outer joint.

1. Before installing drive axle, lightly lubricate

1. Splines on outer joint
2. Thread of outer joint
3. Splines in wheel hub
4. Contact surface and thread of 12-point nut

with oil.

1. Insert drive axle.
2. Insert outer joint as far as possible into wheel hub splines.
3. Pull outer joint into wheel hub until it makes contact with wheel bearing.
4. Place inner joint of drive axle in position and tighten bolts in diagonal sequence to 10 Nm.

1. Tighten socket head bolts in diagonal sequence to 40 Nm.
2. Lower vehicle until the wheel touches the ground.
3. Tighten 12-point nut to 200 Nm and then loosen 1 / 2 turn.

Scheme 1096

1. Tighten twelve-point nut.

Tightening torque

50 Nm plus an additional 60° 1 / 6 turn

Note. To tighten 12-point nut we recommend using angle torque wrench V.A.G1756

If no angle torque wrench is available the 12-point nut can be tightened as follows.

1. Lower vehicle until the wheels touch the ground.
2. Tighten 12-point nut to 200 Nm and then loosen 1 / 2 turn.
3. Pre-tighten 12-point nut to 50 Nm.

Scheme 1097

1. Mark edge of one of the 12-point flats on the nut with a line - arrow A -.
2. Make a second mark - arrowB - on the inside of the wheel hub as illustrated.
3. Turn 12-point nut until the two marks are in line.

Scheme 1098

Special tools, testers and auxiliary items required

1. Circlip pliers VW161A
2. Punch VW408A
3. Thrust plate VW401
4. Thrust plate VW402

1. Sleeve-press tool VW522
2. Press block 40-204A
3. CV joint boot clamp tool V.A.G1682
4. Torque wrench 5-50 Nm V.A.G1331

CV joints are packed with G 000 603 grease

Grease quantities and types

Scheme 1099

1 - Self-locking 12-point nut

1. Tightening «Installing drive axle»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__installing-drive-axle)
2. Remove any paint residue or corrosion on thread of outer joint before installing nut.

2 - Outer CV joint

1. Replace as complete unit
2. Removing «Removing outer constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__removing-outer-constant-velocity-joint)
3. Installing: drive onto shaft as far as stop using plastic hammer

3 - Circlip

1. Always replace
2. Insert in groove on shaft

4 - Thrust washer

1. Installation position «Installation position of convex washer and thrust washer at outer joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__installation-position-of-convex-washer-and)

5 - Convex washer

1. Installation position «Installation position of convex washer at inner joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

6 - Hose clamp

1. Always replace
2. Tightening «Tightening hose clamp on outer joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

7 - Boot

1. Check for tears and scuffing
2. Material: Hytrel (polyelastomer)

8 - Hose clamp

1. Always replace
2. Tightening «Tightening small hose clamp»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__tightening-small-hose-clamp)

9 - Axle shaft (solid shaft)

10 - Socket head bolt, 40Nm

11 - Lock plate

12 - Hose clamp

1. Always replace
2. Tightening «Tightening small hose clamp»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__tightening-small-hose-clamp)

13 - Boot for inner CV joint

1. Check for tears and scuffing
2. Drive off using drift

14 - Convex washer

1. Installation position «Installation position of convex washer at inner joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

15 - Inner constant velocity joint

1. Replace as complete unit
2. Pressing off «Pressing off inner constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
3. Pressing on «Pressing on inner constant velocity joint»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)
4. Greasing «Grease quantities and types»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering)

1. Checking --> «Inner Constant Velocity (CV) joint, checking»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__inner-constant-velocity-cv-joint-checking)

16 - Gasket

1. Replace: Pull off protective foil and stick onto joint.

17 - Snap ring

1. Remove and install using VW161 a

1. Drive joint off axle shaft with a firm blow from an aluminum hammer.

Installation position of convex washer and thrust washer at outer joint

1 - Convex washer

2 - Thrust washer

Scheme 1100

1 - Convex washer

Pressing off inner constant velocity joint

Note. First drive off boot with drift. Support ball hub.

Pressing on inner constant velocity joint

1. Press on joint as far as stop.
2. Install lock ring.

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

Tightening hose clamp on outer joint

1. Apply pliers V.A.G 1682 as shown. Make sure that the jaws of the pliers seat in the ends of the hose clamp - arrows B -.
2. Tighten hose clamp by turning spindle with torque wrench (keep pliers straight).

Tightening small hose clamp

1. Tighten hose clamp by turning spindle with torque wrench (keep pliers straight).

Note. Tightening torque: 20 Nm. Use torque wrench - C - (adjustment range 5to 50 Nm), e.g. V.A.G1331. Make sure thread of spindle - A - on pliers moves freely. Lubricate with MoS2 grease if necessary. If the thread is stiff (e.g. due to dirt), the required clamping force will not be attained at the hose clamp when applying the specified tightening torque.

Wheels and tires

The wheel/tire combinations specified by the factory are listed in: AESIS; Library; Additional information; Wheel and Tire Guide.

General notes

For safety reasons, tires should not be replaced individually, instead replace tires by axle (at least).

The tires with deeper tread should always be installed on the front wheels.

The factory recommends using tires of the same make, design and tread pattern on all wheels.

Always replace the rubber valve when installing a new wheel rim or tire.

Tires must be installed with the DOT marking facing outwards (in the case of tires with a directional tread pattern, this only applies to the left-hand side of the vehicle).

If the vehicle is installed with tires with a directional tread pattern, the spare wheel should have a wheel/tire combination for the right-hand side of the vehicle.

Always clean contact surfaces between rims and brake disc.

Special tools, testers and auxiliary items required

Scheme 1101

1. Wheel key lock set T40004

Scheme 1102

1 - Tire

2 - Valve

3 - Light-alloy wheel rim

1. Hole circle diameter 100 mm
2. 7.5J x17, ET (rim offset) 32

4 - Anti-theft wheel bolt, 120 Nm

1. M14x1.5 x 27.5 mm
2. Refer to notes --> «Wheels, instructions for changing/installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheels-instructions-for-changinginstalling)

5 - Adapter for anti-theft wheel bolt

1. T40004 Wheel lock key set

6 - Trim cap

1. With hole for puller

7 - Puller

1. For removing trim cap; contained in vehicle tool kit

8 - Wheel bolt, 120 Nm

1. M14x1.5 x 27.5 mm
2. Refer to notes --> «Wheels, instructions for changing/installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheels-instructions-for-changinginstalling)

9 - Retaining spring for balancing weights

10 - Balancing weights

1. Maximum of 60 grams allowed per rim flange

Scheme 1103

1 - Tire

2 - Valve

3 - Light-alloy wheel rim

1. Hole circle diameter 100 mm
2. 7.5J x17, ET (rim offset) 32

4 - Anti-theft wheel bolt, 120 Nm

1. M14x1.5 x 27.5 mm
2. Refer to notes --> «Wheels, instructions for changing/installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheels-instructions-for-changinginstalling)

5 - Adapter for anti-theft wheel bolt

1. T40004 Wheel lock key set

6 - Trim cap

1. Install onto anti-theft wheel bolt

7 - Hub cap

8 - Trim cap

1. Install onto wheel bolt

9 - Wheel bolt, 120 Nm

1. M14x1.5 x 27.5 mm
2. Refer to notes --> «Wheels, instructions for changing/installing»(/audi/tt/8n-1998-2003/remont/differentials-drive-axles/#suspension-wheels-steering__wheels-instructions-for-changinginstalling)

10 - Retaining spring for balancing weights

11 - Balancing weights

1. Maximum of 60 grams allowed per rim flange

Wheels, balancing on vehicle

1. Switch ignition off.

Note. Incorrectly balanced wheels cause vibration at the steering wheel and at the front of the vehicle see AESIS; Library; Additional information; Wheel and Tire Guide. Position vehicle on the sensor platforms (front axle only for front-wheel drive, both axles for all wheel drive) in order to balance the wheels. Check the manufacturers instructions for operating wheel balancing equipment.

Wheels, instructions for changing/installing

Perform the following steps with the wheel rim removed.

1. Check that the convex seats for the wheel bolts in the rim and the contact surfaces (rim/brake disc and brake disc/wheel hub) are free of corrosion and dirt. Remove any oil, grease and corrosion.
2. Check that the centering hole in the wheel rim and the centering flange on the wheel hub are free from corrosion and dirt. Remove any oil, grease and corrosion and apply Wax Spray D 322 000 A2 to ensure corrosion protection.
3. Check that the wheel bolts and the threads in the wheel hubs are clean. When installing the wheel, the wheel bolts should screw in easily over the full thread length of the threads.
4. Use a wire brush or similar to clean dirty wheel bolts. Damaged or badly corroded wheel bolts must be replaced.

Scheme 1104

1. If slightly corroded wheel bolts are re-used on the vehicle, clean the threads and the convex shoulders on the bolt heads and grease the surfaces in sliding contact using Optimol TA paste, Part No. G052109A2 as follows

A - One-piece wheel bolt

1. Lightly grease thread - 1 - and convex shoulder - 2 -.

B - Two-piece wheel bolt

1. Lightly grease thread - 4 - , and the area between the bolt head contact surface - 3 - and the back of the convex washer - 6 -.
2. Do not apply grease to the convex surface - 5 - that bears against the wheel rim.

Note. Use only Optimol TA paste, Part No. G052109A2. The paste must not come into contact with parts of the brake system.

1. Make sure that the hole in the brake disc lines up with the thread in the hub. The thread of the wheel bolts must not contact the hole in the brake disc.

Installing wheels

1. Secure all wheels as follows
2. Thread in wheel bolts uniformly by hand.
3. While vehicle is still raised, tighten wheel bolts in diagonal sequence.

1. Tightening torque: 50 Nm

1. Lower vehicle onto the ground and tighten wheel bolts in diagonal sequence to final torque.

1. Tightening torque: 120 Nm

Note. Wheel alignment should not be checked until the vehicle has completed 1000 to 2000 km, when the coil springs have had time to settle. Vibrations can also be caused by excessive residual imbalance and/or radial runout of the wheels.

Wheel alignment must always be checked with Audi-approved wheel alignment equipment.

The alignment check must always include both front and rear axles.

1. When making adjustments, try to obtain the specified settings as accurately as possible.

This is important to achieve proper handling and road behavior.

If the position of the rear axle and the overall running direction of the vehicle is not taken into account, this can result in a crooked steering wheel.

Scheme 1105

Steering wheel and steering column are marked.

Do not change this position.

A - Line marking on steering wheel

B - Punch mark on steering column

Otherwise centering of toothed shaft cannot be guaranteed.

Steering columns supplied as spare parts do not have a punch mark.

Tightening torques

Socket-head bolt (12 mm), Item 1: 55 Nm

If the steering column or steering wheel have been replaced, this marking must be made again after checking wheel alignment and test driving the vehicle.

Wheel alignment must be checked

1. If the vehicle shows handling problems.
2. If there is accident damage.
3. If suspension components have been removed
4. If tires are worn unevenly.

* Applies only to vehicles with all wheel drive.

* No alignment check is necessary when old parts are re-installed onto original marked bolt positions. However, alignment must be carried out if the steering wheel is found to be misaligned after a test drive.

Wheel alignment specifications for vehicles with standard suspension (G17, G78, G79, G91, G97)

These specifications are applicable for all engines.

* The wheel on the outside of a curve is turned in less than the inside wheel. This value shows the difference in the steering angles. It can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

These specifications are applicable for all engines.

* Not adjustable

* Slight correction is possible by moving rear axle beam.

Wheel alignment specifications for vehicles with sports suspension (PQZ, G98)

These specifications are applicable for all engines.

* The wheel on the outside of a curve is turned in less than the inside wheel. This value shows the difference in the steering angles. It can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

These specifications are applicable for all engines.

* Not adjustable

* Slight correction is possible by moving rear axle beam.

Rear axle camber varies according to actual suspension height of vehicle.

Scheme 1106

1. Before checking wheel alignment, measure suspension height (dimension "x") between center of wheel and bottom edge of wheel housing on body.

Rear axle camber values as a function of suspension height

Measuring suspension height prior to camber check see scheme 342

Requirements

1. Check suspension, steering and steering linkage for excessive play and damage.
2. Tread depth difference of no more than 2mm on one axle.
3. Tires inflated to correct pressures
4. Vehicle unladen * See note

* "Unladen" means: the weight of the vehicle ready for the road (full tank, spare wheel, vehicle tools and vehicle jack).

1. Wheel alignment platforms and computer measuring equipment can lose their original levelling setting and calibration over a period of time.
2. Wheel alignment platforms and computer equipment should be serviced and calibrated at least once a year.

1. Precision equipment of this type should be treated with appropriate care.

1. If necessary, contact the manufacturer for familiarization with the proper use of the wheel alignment equipment.

Explanation on weight codes (PR Numbers)

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

The suspension version installed in the vehicle is indicated by the relevant PR No. - arrow - on the vehicle data sticker.

Vehicle data sticker (example)

The vehicle data sticker can be found at the rear of the spare wheel well and in the Service book.

Measurement procedure

The following equipment is required

Scheme 1107

1. Electronic wheel alignment unit; e.g. V.A.G1813
2. Make sure that the sliding plates and turntables are not touching the end stop when checking the alignment.
3. Vehicle accurately aligned, suspension bounced and rocked several times
4. The test equipment must be properly adjusted and attached to the vehicle (see equipment manufacturers instructions).

1. Perform wheel rim runout compensation.

Note. Compensation of wheel rim runout: A certain amount of lateral runout at the wheel rims is permissible, but this may already exceed the specified toe-in tolerance. In such cases it is not possible to correctly set the toe-in without performing the wheel runout compensation.

Scheme 1108

1. Insert brake pedal depressor.

Overview of work sequence for measuring wheel alignment

Note. The vehicle must be unladen when measuring wheel alignment.

Observe the following work sequence

1 - Check camber at front wheels and center if necessary --> Camber at front wheels, adjusting and Removing and installing subframe--> Subframe, removing and installing

2 - Check camber at rear wheels.

> Camber at rear wheels, adjusting (All Wheel Drive (AWD) vehicles)

3 - Check toe setting at rear wheels and adjust if necessary.

Vehicles with front wheel drive

The toe setting at the rear wheels is not adjustable.

Notes --> Toe setting at rear wheels, centering (Front Wheel Drive (FWD) vehicles)

Vehicles with all wheel drive

Toe setting is adjustable.

Adjusting toe setting --> Toe setting at rear wheels, adjusting (All Wheel Drive (AWD) vehicles)

4 - Check toe setting at front wheels with vehicle unladen and adjust if necessary --> Toe at front wheels, adjusting .

5 - If settings have been altered at the front wheels, perform zero position compensation for steering angle sensor G85 (only applies to vehicles with ESP) --> 01 ON BOARD DIAGNOSTIC (OBD)

Camber at rear wheels, checking (Front Wheel Drive (FWD) vehicles)

Camber can be checked but not adjusted.

If the measurements are outside the permitted tolerances, the axle beam must be checked for damage and replaced if necessary.

Camber at rear wheels, adjusting (All Wheel Drive (AWD) vehicles)

The camber can be adjusted by means of the hole tolerance at the transverse links.

If the measurements are outside the permitted tolerances, the axle must be checked for damage and replaced if necessary.

1. Loosen bolts securing transverse links to hub carrier.

Tightening torque: 70 Nm plus an additional 90° 1 / 4 turn

Always replace nuts and bolts when re-assembling.

Scheme 1109