Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling power assisted steering box (TRW) Dismantling

–  Seal line connections on power assisted steering box if not already done. 1 -  Plastic sealing plug 2 -  Plastic sealing plug –  Clean exterior of power assisted steering box. –  Open clamps and push boot back.

–  Clamp steering box with rack in a vice and unscrew track rod.   Note Use protective jaws, check protective jaws for impurities e.g. metal filings or similar and thoroughly remove. If the steering rack has flattened sides, counter hold with open-ended spanner. Steering rack should not then be tensioned.

–  Mark position of adjustment screw and lock nut in relation to housing -arrow-.

–  Unscrew lock nut together with adjusting screw.   Note t  Do not move position of adjusting screw in relation to lock nut when unscrewing. t  If necessary unscrew adjusting screw together with lock nut using tool -3315/9-. t  Thrust piece/adjusting screw are lightly spring-loaded. 1 -  Commercially available ratchet handle 2 -  Adjustment bolt

–  Mark installed position of thrust piece and remove. 1 -  Expansion pliers (commercial type) 2 -  Thrust piece

–  Remove valve body circlip. 1 -  Long-nose pliers (commercial type)

–  Remove plug from bottom of valve body. 1 -  Commercially available ratchet handle If it is very tight, loosen plug with a hammer and drift.

–  Remove hexagon nut at bottom of valve body. 1 -  Commercially available ratchet handle 2 -  Open-ended spanner (commercial type) –  Knock out valve body upwards from below with drift. –  Remove grease from the valve body splines. –  Pull adhesive foil off the housing. –  Pull steering rack fully to left.

–  Turn securing ring so that the opening of the circlip -arrow- is positioned in the groove of the housing. –  Turn securing ring further (clockwise or anti-clockwise), so that the circlip is turned out of the housing. –  Pull steering rack with steering rack guide out of housing, pull off steering rack guide and place steering rack so that it and the piston seal are not damaged. 1 -  Long-nose pliers (commercial type) Removing valve body oil seal

–  Drive oil seal out upwards. A -  Internal puller, e.g. -Kukko 21/4- B -  Drift When positioning puller -A-, ensure that claws engage correctly beneath oil seal. The puller must not be spread too far, otherwise the oil seal seating in the housing will be damaged or the oil seal can jam in the housing.

To ease fitting the puller it is recommended that a rubber band is placed around the claws. For ease of illustration figure shows the housing sectionalised. 1 -  Internal puller, e.g. -Kukko 21/4- 2 -  Rubber band 3 -  Oil seal 4 -  Friction bearing  -  do not remove –  Drive out lower bearing with guide pin, shouldered -VW 439-. Pulling out inner steering rack oil seal

–  Insert oil seal puller until the mark on the tool -arrow- aligns with the edge of the housing. (Only then will the claws locate behind the support ring). –  Spread tool claws -2- firmly by turning the spindle.   Note When inserting the tool ensure that the cylinder contact surface is not damaged. 1 -  Support ring 2 -  Claws 3 -  Oil seal 4 -  Tool -3315/11-

–  Screw multi-purpose tool -VW 771- into puller. –  Pull out oil seal.