Audi Workshop Service and Repair Manuals

Removing and installing steering pinion with steering moment sender   Note This repair is not possible at present. Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331- Removing –  Remove steering box → Chapter. –  Clean steering box in area of steering pinion, screw plug and adjuster screw.

–  Clamp steering box in a vice as shown. 1 -  Bracket VW 540/2 2 -  Press tool 3253/6 (2x) –  Remove thrust piece at steering pinion end → Chapter. –  Turn steering box in straight-ahead position. –  Unclip sensor wiring at steering box housing.

–  Remove screw plug -arrow-.

–  Unscrew hexagon nut -arrow- from steering pinion. The rack will move to the end stop. –  Turn steering to straight-ahead position again.

–  Remove seal -1- from cover. –  Detach cover -2-. –  Carefully remove seal from steering box housing. Make sure that sealant residue does not enter sensor or housing.

Avoid touching electronic components -arrow-.   Note

The sensor wiring in the steering box housing is fitted with a securing element -arrow- for the coil spring. Make sure that the coil spring is not twisted when removing the sensor wiring.

–  Now unplug sensor wiring connector at steering pinion. To do this, press the connector contact out of the coil spring housing using a screwdriver (width of blade 3 mm) as shown in illustration. –  Mark position of steering pinion in relation to steering box housing.

–  Now pull steering pinion with steering moment sender out of steering box housing. Secure coil spring to stop it turning by using adhesive tape or similar.

Installing –  Lubricate bearing -arrow- and the splines of the steering pinion using -G 052 192 A1-. Do not apply grease on or near sensor.

The new steering pinion with steering moment sender is fitted with a locating element -arrow-. This locating element must not be pulled out before the sensor wiring has been secured. –  Insert steering pinion into steering box housing.

–  Turn the steering pinion until the coil spring with the sensor wiring -arrow- can be locked in position. The mark made when removing must align with the mark on the steering box housing. –  Pull locating element out of coil spring. –  Plug connector into coil spring housing. The connector is coded and can only be fitted in one position.

–  Tighten steering pinion with new hexagon nut. The rack will move to the end stop. –  Apply LOCTITE -5910- sealant onto thread of screw plug. –  Fill screw plug with grease -G 052 192 A1-, then install and tighten screw plug. –  Turn steering to straight-ahead position again.

–  Apply only a very thin coat of grease -G 052 168 A1- when lubricating the seal -arrow- in the cover. –  Install cover with new seal. Remaining installation steps are carried out in reverse sequence. –  Install and adjust thrust piece at steering pinion end → Chapter. –  Install steering box → Chapter. Perform a basic setting for the steering angle sender -G85- using vehicle diagnostic, testing and information system -VAS 5051B- after installing. –  Perform adaption and basic setting for steering moment sender -G269- using vehicle diagnostic, testing and information system -VAS 5051B-. Tightening torques → Chapter „Exploded view of electromechanical steering box (generation 1)“ –  Check wheel alignment → Chapter