Volkswagen Workshop Service and Repair Manuals

From 8.77

Cannot be installed in vehicles built before 8.77. All repair instructions are valid for this steering box.

• Support mounting for steering box
• ◆ Replace
• Rubber mounting left
• Clip
• Washer
• Nut
• ◆ Self locking, renew 30 Nm
• Nut
• ◆ Self locking, renew 30 Nm
• Rubber mounting, right

Replace support for steering box

• ‒ Supports which are cracked or repaired by welding can be replaced individually.
• ‒ Remove engine, gearbox and steering box to replace the support. Use a frame template or set square.
• ‒ Observe all safety regulations when welding.

Separate and remove remaining pieces

• ‒ → Cut through support at front bend.
• ‒ Place lower part with studs at rear on cross member. (See figure "arrow").
• ‒ Do not damage contact surfaces on cross member or weaken by excessive grinding.

Prepare new part

• ‒ → Detach lower part of the support from the new part. Drill 7 mm dia. holes for plug welds. For arrangement, see "figure".

Fitting support

• ‒ → Using the frame template or set square, align and clamp tightly.

→ Weld in support for steering box

→ Weld in support for steering box

Areas:

A - 3 SG plug welds

B - 4 SG plug welds

C - 3 SG plug welds

D - 5 SG plug welds

E - 7 SG plug welds

F - SG continous weld

Reworking:

• ‒ Clean area to be repaired and apply with priming coat. Renew permanent underseal and cavity sealing.