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Repairing TRW power-assisted steering > < Installing

Golf Mk2

Assembly overview - power assisted steering box (TRW)
   
Assembly overview - power assisted steering box (TRW)
In event of complaints, determine the cause with the help of the pressure test and leakage test, and → fault finding programme running gear No. 10. Repairing power steering box → Chapter
  Note
t  Renew self-locking nuts and bolts.
t  Welding and straightening work on steering components is not permitted.
t  Use only steering box grease -A0F 063 000 04- for greasing steering rack.
t  Fluid type: Up to 03.89 ATF, as of 04.89 hydraulic fluid -G 002 000-.
t  Fluid capacity in system: 0.7 ... 0.9 l.
t  All parts marked with a 1) must not be attached to ZF power assisted steering boxes.
1 - Hexagon bolt, 30 Nm
2 - Power steering box
q   Removing and installing → Chapter
q   Adjusting → Chapter
q   Vehicles with 16V and VR6 engines have a higher steering torque of approx. 2 Nm.
q   Modified steering pinion (with shoulder) → Fig..
3 - O-ring
q   Renew.
4 - Union nut, 30 Nm
5 - Self-locking hexagon nut, 35 Nm
6 - Track rod ball joint
q   Pressing off → Chapter.
7 - Hexagon nut, 50 Nm
8 - Hose clamp 1)
q   Renew - open with pincers
q   Tightening → Anchor.
9 - Bellows 1)
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
10 - Hose clamp
q   Renew - open with pincers
q   Tightening → Anchor.
11 - Left track rod 1)
q   Removing and installing → Chapter
q   Adjusting to length → Chapter
q   Diameter of track rod on seat for bellows TRW: 12.7 mm, ZF: 15 mm.
q   Rally Golf, modified inner joint → Fig..
12 - Pressure balancing pipe
13 - Right track rod 1)
q   Removing and installing → Chapter
q   Adjust track only on right track rod, setting values → Chapter.
q   Diameter of track rod on seat for bellows TRW: 12.7 mm, ZF: 15 mm.
q   Rally Golf, modified inner joint → Fig..
14 - Self-locking hexagon nut, 30 Nm
15 - Clamp
16 - Bonded rubber bush 1)
q   Inner diameter TRW: 44 mm ZF: 50 mm.

   
Universal joint wih relocated bore for clamping bolt
Dimension a = 11.0 mm
If universal joint shaft is renewed in vehicles with steering box without shoulder -B- on steering pinion, notch -A- on steering pinion may have to be reworked by 1 mm under certain circumstances.
Installation of a steering box with shoulder -B- on pinion in combination with a previous universal joint shaft (dimension a = 12.1 mm) remains possible.
  N48-10115
Rally Golf, modified inner joint
The Rally Golf's power assisted steering box is equipped with modified track rods. Steering angle at inner joints is reduced as a result.
Distinguishing features:
1 - Track rod inner joint for Rally Golf
 - Contact surface -arrow A- without shoulder
2 - Track rod inner joint for Golf/Jetta
 - Contact surface -arrow B- with shoulder
  N48-10125

Repairing TRW power-assisted steering > < Installing