2000 - 2007 Audi TT Outer Sidemember Replacement

Dan Espersen
ALLDATA® Collision^SM
Senior Program Manager

The decision to repair, replace or section a structural component depends mainly on current industry recommendations. With all of the new vehicles being developed and introduced yearly, manufacturers may publish many structural repair and sectioning procedures that we don’t know exist.

This article provides Audi’s repair recommendations and service procedures for the 2000-2007 TT.

Service Information
Always refer to ALLDATA® Collision^SM for safety procedures, identification of material types, recommended refinish materials, removal and installation procedures.

Always refer to AUDI for questions relating to applicable or non-applicable warranty repair information.

CAUTION: Read and follow all of the instructions from the manufacturers line of painting materials, equipment, and protective gear.

Replacement part(s)

• Sidemember
• Pop rivet nuts

Note:

• Before replacing, check whether inner sidemember can be straightened.
• Deformation of up to 10 mm per 100 mm length is permissible.
• Tears up to 100 mm in length may be welded.
• Partial replacement is possible with the separating cuts shown. Step separating area SG continuous seam.
• Install pop rivet nuts using riveting pliers VAG 1765.

Outer sidemember, replacing

Separating locations

1. Separate original joint.
2. Make separating cuts on sidemember according to degree of damage.
3. Removeremainingmaterial.

Preparing new part

1. Make holes in outer joint surface of new part.
2. Drill sidemember for plug-welding.
3. Install pop rivet nuts using riveting pliers VAG 1765.

Welding in

1. Weld in sidemember, RP spot weld seam.

1. Weld in sidemember, SG plug weld seam.
2. Make 4 x 20 mm SG continuous seam instead of bonded joint.

Written by Dan Espersen, ALLDATA Collision Program Manager. Dan is a Gold Pin Member of the Collision Industry Conference (CIC) and holds an AA Degree in Automotive Technology. He has 17 years of experience in the collision industry and 17 years of experience in the automotive industry.

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