200 Quattro Wagon L5-2226cc 2.22L SOHC Turbo (MC) (1989)
Disassembling
NOTE: If upper valve housing oil seal is leaking, replace the steering gear assembly.
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clamp steering gear assembly in vise (use jaw covers) at end housing
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remove hydraulic lines from steering gear assembly
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remove clamps and slide boot off
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using a drift inserted in steering gear mounting hole, drive end tube out of housing as far as possible
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pull end tube completely out of housing
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loosen two mounting bolts for cover plate to release some tension on gear
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remove self-locking nut on end of steering rack piston rod
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remove valve housing from end housing by removing bolts and tapping valve housing with plastic hammer
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remove cover plate, spring and spacer from end housing (thrust washer and sleeve can be removed also)
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remove bolts holding steering gear housing to end housing and take off end housing
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tilt steering gear housing and remove piston, piston seal and shims
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remove rack from housing by pulling firmly on toothed portion
Fig. 1 Supporting ring, removing
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insert longer end of a punch a (part of tool 3086) into end of tool
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stand housing on end on a block of wood, insert tool 3086 and tap lightly on end of tool with a hammer to remove supporting ring and piston rod
seal
NOTE: The end tube, steering gear housing, steering rack and end housing must all be thoroughly cleaned before reassembly.
Assembling
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lightly grease the steering rack, the steering rack bushing and the inner portion of steering gear housing in area of rack bushing
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grease, Part No. AOF 063 000 04
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lightly oil the end tube 0-rings
Fig. 2 Piston rod seal, installing
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attach shorter end of punch into tool 3086
NOTE: Install the piston rod seal together with the 0-ring and supporting ring.