Audi TT (2007 year). Manual - part 261

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 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

21

The four-chamber extruded section is located 
beneath the sill moulding.A special repair method 
was developed for damaged outer chambers. When 
repair work is needed, the extruded section is split 
vertically so that the two rear chambers including 
the centre ridge of the four-chamber profile remain. 

A dual-chamber genuine part developed specially 
for this repair solution is welded to the remainder of 
the sill profile using a continuous MIG weld seam at 
the top and bottom. In addition, the U-shaped chan-
nel in the genuine part is filled with an adhesive 
bead which provides additional strength and elimi-
nates noise transmission between the two sills.

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MIG weld seam

Adhesive bead

New part

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

22

Repair concept

Steel repairs

The rear end of the Audi TT is only area where it is 
possible to carry out repair work involving only steel 
parts and where the aluminium-steel joint is fully 
intact. 

This repair work can be carried out on the

–   rear end section
–   rear side member (body side section undamaged)
–   rear floorpan

Basically, the repair procedure is the same as for all-
steel-bodied vehicles. Due to the danger of contact 
corrosion in aluminium body parts, however, special 
safety precautions must be taken. Grinding dust of 
steel parts, particularly flying sparks caused by cut-
ting or welding work, must not be allowed to drop 
onto the aluminium parts.

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body parts which must be covered when carrying out steel repairs

Damage to be 
repaired

This also applies to painted aluminium parts! Red 
hot steel parts can damage the paintwork and steel 
particles can come into contact with the aluminium 
body parts, leading to contact corrosion on the 
undamaged aluminium body. 
Therefore, the complete bodyshell must be pro-
tected carefully when carrying out steel repairs. This 
is done by using suitable protective covers and by 
masking the body with masking tape. Furthermore, 
cutting work may only be performed using a body 
saw. If grinding work is needed, this must be done 
using grinding discs which produce little or no fly-
ing sparks. The spot welding machine should be 
used for welding work where possible, because it 
produces less weld spatter during the welding proc-
ess.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

23

Aluminium-steel repairs

In the case of body side or rear-end damage, both 
aluminium and steel body parts may become dam-
aged. This is the case, for example, when the body 
side section (aluminium) and rear wheel arch (steel) 
are damaged. After removing the damaged parts, 
the new genuine parts are installed in accordance 
with the repair procedures described in the previous 
sections. Joining of steel and aluminium parts must 
be carried out with the greatest care in order to 
eliminate the possibility of future contact corrosion.

Two-component car body adhesive DA 001 730 A1 
and rivets or screws are used for joining. As in 
series production, an insulating layer is placed 
between the two materials to prevent contact corro-
sion. When welding steel body parts, the aluminium 
parts must be carefully covered and masked! 

Reference

All body repair work must be performed in 
accordance with the guidelines set out in the 
current workshop literature!

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

24

Repair concept

Workshop equipment 

A special tool is required for repair work on alumin-
ium-bodied vehicles. The basis is work scope 2010. 

In addition to the special equipment and machines 
for stud welding, dent removal, bonding and rivet-
ing, the aluminium welding technology is of special 
importance. 

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Aluminium body dent removal tools VAS 5196 and VAS 6049

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Cordless punch riveter VAS 5279A

Aluminium inert gas welder VAS 6388

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383_028

Aluminium inert gas welder V.A.G 2001B

There are now two appliances with modern control 
systems which
are ideal for welding work on the Audi aluminium 
body. 
The welding appliances, when used properly, pro-
duce perfect aluminium welded joints which have 
optimum strength. 

Reference

For further information on the workshop equip-
ment for Audi aluminium-bodied vehicles, refer 
to the workshop literature and the Audi Service 
Net.