Here's my revised post for manually closing the top. This includes some trouble shooting tips that many people have run into (including myself). This link will take you to the RAC video:
How to Manually Close the Roof of an Audi TT (Mk2) Roadster
Please note the entire presentation is included as a PDF for your reading pleasure. You can download and save it to your smart phone, or similar device, for reference so you always have it handy when you're on the road. Please note that for clarify of the images, the motor bracket has already been removed. It's a U-shaped bracket that goes over the motor and allows the spline shaft to pass through. If you run into any real problems trying to get the roof latched, simply remove the two T25 Torx screws and the Motor Bracket, and then then remove the single T25 Torx holding the motor in place. With the Bracket and Motor out of the way, this will give you full access to the latch.
You can download the entire set of slides shown below in this handy PDF which you can download and save on your smartphone so you always have it handy just in case.
View attachment Manually Closing the TT Roadster Convertible Roof.pdf
Sept 2017 Update - Getting the spline shaft back in.
Once the spline shaft has been removed, there can be a slight misalignment between the internal spline opening in the motor housing and the latch mechanism which will prevent re-installing the spline shaft (rotational misalignment). This is a different problem from the axial misalignment where the two spline openings are not aligned on their common center axis (the axis of the spline shaft) which can occur when the spline shaft is removed and the motor housing can shift slightly to the left.
The trick is to run the motor in order to rotate the motor housing spline opening and align it with the latch mechanism spline opening.
Remove the motor bracket, loosen, do not remove, the single motor mount screw and ensure that the hydraulic valve open. Manually lower the roof into it's fully open position - be sure the flap control rods are disconnected and in the stowed position to they don't get pinched or bent! Then, close the hydraulic valve, reconnect the flap control rods, and close the roof normally using the top control switch (E137).
As the roof starts to come up, the top lock motor (V223) will operate as it attempts to re-position the latches from the latch-stowed position, into the latch-open position. With the spline shaft removed, the motor can rotate freely and since the motor is "dumb" it will continue to rotate as long as you hold the top control switch (E137) since it can't rotate the latch actuator which triggers the (F294) top lock open switch.
At this point, the top should have come up about 1/4 of the way from the stowed position. Without using the crank arm tool, use your fingers to insert the spline shaft into the motor housing gear as far as it will go. Then "bump" or tap the top control switch (on -off - on - off) which will incrementally rotate the spline shaft. After the motor has rotated just slightly, attempt to push the spline shaft fully into position. Continue to "bump" the motor until both internal splines are aligned and the spline shaft can be fully seated.
Once you've fully seated the spline shaft you can continue to close the top normally. After the top is up and secured, remember to re-install the metal washer (felt side against the motor housing), re-insert the spline shaft, install the motor bracket and re-tighten the motor mount Torx screw.
For anyone who wants a lot more detailed information on the Mk2 Roadster, be sure to check out this post -
The Ultimate Audi TT Mk2 (8J) Roadster Compendium
https://www.ttforum.co.uk/forum/viewtop ... &t=1813258
If you're still having intermittent problems with the convertible roof or window operation, a Roof Flap Servo R&R may be necessary -
How to: Audi TT Mk2 (8J) Convertible Top Flap Servo R&R
https://www.ttforum.co.uk/forum/viewtop ... &t=1786641
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How to Manually Close the Roof of an Audi TT (Mk2) Roadster
Please note the entire presentation is included as a PDF for your reading pleasure. You can download and save it to your smart phone, or similar device, for reference so you always have it handy when you're on the road. Please note that for clarify of the images, the motor bracket has already been removed. It's a U-shaped bracket that goes over the motor and allows the spline shaft to pass through. If you run into any real problems trying to get the roof latched, simply remove the two T25 Torx screws and the Motor Bracket, and then then remove the single T25 Torx holding the motor in place. With the Bracket and Motor out of the way, this will give you full access to the latch.
You can download the entire set of slides shown below in this handy PDF which you can download and save on your smartphone so you always have it handy just in case.
View attachment Manually Closing the TT Roadster Convertible Roof.pdf
Sept 2017 Update - Getting the spline shaft back in.
Once the spline shaft has been removed, there can be a slight misalignment between the internal spline opening in the motor housing and the latch mechanism which will prevent re-installing the spline shaft (rotational misalignment). This is a different problem from the axial misalignment where the two spline openings are not aligned on their common center axis (the axis of the spline shaft) which can occur when the spline shaft is removed and the motor housing can shift slightly to the left.
The trick is to run the motor in order to rotate the motor housing spline opening and align it with the latch mechanism spline opening.
Remove the motor bracket, loosen, do not remove, the single motor mount screw and ensure that the hydraulic valve open. Manually lower the roof into it's fully open position - be sure the flap control rods are disconnected and in the stowed position to they don't get pinched or bent! Then, close the hydraulic valve, reconnect the flap control rods, and close the roof normally using the top control switch (E137).
As the roof starts to come up, the top lock motor (V223) will operate as it attempts to re-position the latches from the latch-stowed position, into the latch-open position. With the spline shaft removed, the motor can rotate freely and since the motor is "dumb" it will continue to rotate as long as you hold the top control switch (E137) since it can't rotate the latch actuator which triggers the (F294) top lock open switch.
At this point, the top should have come up about 1/4 of the way from the stowed position. Without using the crank arm tool, use your fingers to insert the spline shaft into the motor housing gear as far as it will go. Then "bump" or tap the top control switch (on -off - on - off) which will incrementally rotate the spline shaft. After the motor has rotated just slightly, attempt to push the spline shaft fully into position. Continue to "bump" the motor until both internal splines are aligned and the spline shaft can be fully seated.
Once you've fully seated the spline shaft you can continue to close the top normally. After the top is up and secured, remember to re-install the metal washer (felt side against the motor housing), re-insert the spline shaft, install the motor bracket and re-tighten the motor mount Torx screw.
For anyone who wants a lot more detailed information on the Mk2 Roadster, be sure to check out this post -
The Ultimate Audi TT Mk2 (8J) Roadster Compendium
https://www.ttforum.co.uk/forum/viewtop ... &t=1813258
If you're still having intermittent problems with the convertible roof or window operation, a Roof Flap Servo R&R may be necessary -
How to: Audi TT Mk2 (8J) Convertible Top Flap Servo R&R
https://www.ttforum.co.uk/forum/viewtop ... &t=1786641
