Audi TT MK1 Quattro Restoration Subframe Underbody Overhaul Hints, Tips and Full Overview.

In this video I discuss the process of restoring the underbody and subframes of a 2002 MK1 Audi TT Quattro. This process will be almost identical to that of a MK4 platform VW Golf R32. The video shows an overview of key areas and how you may tackle the job with part numbers highlighted throughout. Be aware that some may now be superseded, obsolete or aftermarket alternatives available. The video is not intended to be a step by step guide but more of an overview of the pitfalls, hints and tips should you wish to carry out the process yourself.
Please note many of the following nuts/bolts are recommended as one time use and should therefore be replaced each time they are removed.
Torque settings:
Rear:
Shock absorber to trailing arm (vehicle must be standing on its wheels and loaded with the weight of one person sitting in the rear seat) 110Nm
Coupling rod (drop link) to stabiliser bar: 25Nm
Shock absorber to body: 60Nm
Tightening torque for wheel bolts: 120Nm
Rear anti roll bar bracket bolts: 20Nm
Drive shaft bolts: 40Nm
Calliper carrier bolts: 65Nm
Calliper to carrier bolts: 35Nm
Disc backing plate bolts: 10Nm
Control arm bolts (inner/outer/upper/lower) 70Nm plus an additional 90deg 1/4turn
Trailing arm to mounting bracket bolt: 90Nm
Trailing arm mounting bracket bolts to body: 75Nm
Light level sensor nyloc nuts: 4Nm
Rear light levelling sensor bracket to subframe screws: 9Nm
Subframe to body mounting bolts: 110Nm plus an additional 90 deg 1/4 turn
Haldex support bracket centre bolts: 60Nm
Haldex support bracket mounting bolts:
Hex socket M10x55 head bolt, 40Nm + 45°
Hex socket M10x40 head bolt, 40Nm plus an additional 45 / turn
Aluminium diff support bracket to diff casing bolts: 60Nm
Aluminium diff support side to subframe bolts: 60Nm
Prop/drive shaft to coupling bolts: 60Nm
Exhaust clamp nuts: 40Nm
Fuel Tank Strap bolts: 26Nm
Front:
Top strut nut: 60Nm
Top strut lower nut: 60Nm
Drop link upper nut: 90Nm
Drop link lower nut: 90Nm
Brake line strut bracket bolt: 10Nm
Strut to hub pinch bolt: 60Nm plus an additional 90deg 1/4 turn
Front drive shaft inner bolts: initial 10Nm/Final 70Nm
Lower ball joint nuts: 75Nm
Subframe bolts to body: 100Nm plus an additional 90 deg or 1/4 turn
Dog bone to subframe bolts: 25Nm
Dog bone large bolt to box: 50Nm
Dog bone small bolt: 50Nm
Ball joint to hub: 45Nm (V6 roadster 75Nm)
Subframe to steering rack bolts: 20Nm plus an additional 90deg 1/4 turn
Track rod end hex nut: 50Nm
Anti roll bar clamp bolt: 25Nm
Light level sensor bracket to wishbone bolt 25Nm
Light level sensor link nyloc nut: 4Nm
Charge cooler pipe mounting bolts: 20Nm
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Tools (recommendations only as there may be variations and alternatives):
Trolley Jack
Axle stands/lift
Wooden block
Spring compressors
Haldex spanner
Wheel brace/breaker bar
Metric socket set
Spline set
Torx bit set
Allen head set
1/2” & 1/4” Ratchet plus extensions
Metric ring spanner set
11mm brake pipe spanner
10mm ratchet ring spanner
Torque wrench
Various screwdrivers
Pry bar
Wire brush
Release/penetration oil
Access to a press
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Recommended Supliers:
Autodoc
CB Auto
Carparts4Less
TPS
Pullman Volkswagen
AwesomeGTI