Volkswagen Workshop Service and Repair Manuals

If complaints are received determine cause with the help of pressure tests, leakage test and fault finding programme, running gear No. 10. If a fault exists the power assisted steering box can be serviced.

Notes:

• ◆ If reservoir fluid level is low then check steering system for leaks.
• ◆ In the case of leaks at the pipe connections first tighten connections and wipe dry then recheck for leaks.
• ◆ The steering box can be serviced if the pinion seal or the rack seals in steering box housing are leaking.
• ◆ To check the rack seals loosen the hose clip on the bellows and push bellows to one side.
• ◆ Renew self-locking nuts and bolts. Welding and straightening work on steering components is not permitted.
• ◆ To grease the rack only use steering box grease Part No. AOF 063 000 04.
• ◆ Type of oil: Hydraulic oil G 002 000

• ◆ Oil system capacity: 0.7 ... 0.9 ltr.
• ◆ Supply and pressure pipe routing
  .

• Track rod ball joint, right
• ◆ Splitting
• ◆ Checking:

=> Maintenance

Modification

• ◆ Modified Golf estate ball joints => Page 48-45

• 50 Nm
• Hose clip
• Bellows
• ◆ Remove ball joint before removing
• ◆ Check for wear (cuts, cracks), ensure sealing surfaces and sealing lips are clean and undamaged
• ◆ The end diameters are larger than the bellows for TRW power assisted steering boxes
• ◆ Must not be installed on TRW power assisted steering box

• Hose clip
• ◆ Renew - use pliers to open
• ◆ Tensioning => Page 48-49
• ◆ Must not be installed on a TRW power assisted steering box
• Left-hand track rod
• ◆ Removing and installing
  => Page 48-47
• ◆ Track rod bellows seat diameter
  ZF: 15 mm ø
  TRW: 12.7 mm ø
• ◆ Must not be installed on a TRW power assisted steering box
• ◆ Adjusting length
  
• Hose clip
• ◆ Renew - use pliers to open
• ◆ Tensioning => Page 48-49
• ◆ Must not be installed on a TRW power assisted steering box

• Right-hand track rod
• ◆ Removing and installing
  => Page 48-47
• ◆ Vehicle alignment => Page 44-1
• ◆ Track rod bellows seat diameter
  ZF: 15 mm ø
  TRW: 12.7 mm ø
• ◆ Must not be installed on a TRW power assisted steering box
• Track rod ball joint, left
• ◆ Splitting
• ◆ Checking:

=> Maintenance

Modification

• ◆ Modified Golf estate ball joints => Page 48-45

• Self-locking hexagon nut, 30 Nm
• Pressure balance pipe
• Self-locking hexagon nut, 30 Nm
• Clamp

• Rubber mounting
• ◆ Internal diameter
  ZF: 50 mm
  TRW: 44 mm
• Power assisted steering box
• ◆ Removing and installing => Page 48-34
• ◆ Adjusting => Page 48-109
• ◆ Checking steering moment

=> Fault finding, running gear No. 10

• ◆ Steering box with extra servo assistance only available for vehicles up to 66 kW
• ◆ Steering moment on 16 V and VR 6 vehicles is approx. 2 Nm higher

• 30 Nm
• Lower universal joint
• Cover disc
• Sealing ring
• ◆ Renew
• Union nut, 30 Nm
• Data plate and company initials