Volkswagen Workshop Service and Repair Manuals

Assembly overview - mechanical steering box

t	Removing and installing steering box → Chapter

t	The steering box is not intended to be repaired. In the event of concerns install a new steering box.

t	To lubricate steering box, only use steering box grease -A0F 063 000 04-. However, do not over-apply grease to steering box. Air equalisation bores must remain free. Otherwise the bellows will be damaged.

t	Always renew self-locking nuts and bolts.

t	Welding and straightening work on steering components is not permitted.

1 -	Hexagon nut, 30 Nm

2 -	Clamp for rubber bush

3 -	Rubber bush

4 -	Track rod ball joint

q	Pressing off steering arm → Fig..

5 -	Hexagon nut, 50 Nm

6 -	Self-locking hexagon nut, 35 Nm

7 -	Right track rod

q	Adjustable.

q	Remove steering box to renew.

q	Bolting onto steering rack → Chapter.

q	Pressing off steering arm → Fig..

8 -	Steering box

q	Adjusting → Chapter

q	Removing and installing → Chapter

q	On new steering boxes, set steering to centre position prior to installation and screw track rods on to prescribed length → Chapter.

q	Modification: As of 01.91, reduced number of teeth in steering pinion/universal joint shaft connection point → Fig..

9 -

Subframe

10 -	Securing bolts for steering box

q	Tap out downwards if necessary.

11 -	Hexagon nut with bolt, 30 Nm

12 -	Shaft with universal joint for steering column

q	Modification: As of 01.91, reduced number of teeth in steering pinion/universal joint shaft connection point → Fig..

13 -	Bellows for drive shaft

q	Centre of assembly mark must lie at centre of bulkhead cut out.

q	Modification: As of 04.87, lower diameter increased → Fig..

14 -	Hexagon bolt, 30 Nm

15 -

Boot

q	Pull on and off over track rod.

q	Can be renewed with steering box installed

q	Must not be twisted after toe setting has been adjusted

16 -	Clamping ring

17 -	Left track rod

q	Not adjustable

q	Modification: Only an adjustable track rod is supplied as spare part, check length and adjust if necessary → Fig..

q	Remove steering box to renew.

q	Bolting onto steering rack → Chapter.

q	Pressing off steering arm → Fig..

18 -	Lock nut, 50 Nm

19 -	Self-locking hexagon nut, 35 Nm

Bellows for steering column universal joint shaft modified Lower diameter on bellows -A- has been enlarged.

Up to 03.87	Ø 46.2 mm
As of 04.87, chassis No. …400001	Ø 53.5 mm

Pod -B- on steering box has been adapted accordingly and is round at upper edge. If bellows is renewed in a vehicle, pod on steering box must also always be renewed to achieve perfect sealing. After installing pod, joint between pod and steering box must be sealed with sealant -D2- to prevent moisture from entering steering box. New steering boxes are only supplied with new pod, so that new belows also always has to be used On RHD vehicles with double-flanged exhaust pipe (as of 08.85, only GTI and GTI 16V without catalytic converter), front exhaust pipe and relevant heat shield must also be replaced in addition to pod to ensure sufficient clearance between exhaust system and bellows. If front pipe is not renewed, bellows may become porous after just a short while, and perfect sealing is no longer guaranteed.

Modified toothing on steering box steering pinion and steering column drive shaft 1 -  Steering pinion previously: 40 teeth  -  As of 01.91: 18 teeth 2 -  Lower joint yoke previously: 40 teeth  -  As of 01.91: 18 teeth 3 -  Steering box

Pressing track rod off steering arm A -  Track rod ball joint puller (commercial type) e.g. -Kukko 128/2-.

Checking track rod length, adjusting if necessary (left track rod, spare part) –  Check dimension -a- on left-hand track rod and adjust as required. Dimension a = 410 ± 1 mm.   Note Track adjustment on vehicle is carried out only on right track rod.