Volkswagen Workshop Service and Repair Manuals

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.

–  Remove cover.   Note t  Do not change position of adjusting screw -arrow-! t  Cover is slightly spring-loaded.

–  Remove thrust piece. 1 -  Expansion pliers (commercial type)

–  Remove plug from bottom of valve body. 1 -  Plug

–  Unscrew Torx bolt for valve body. 1 -  14 mm open jaw spanner, commercially available 2 -  Torx socket insert (commercially available E 10) 3 -  Ratchet (commercially available) 3/8

–  Remove circlip with long-nose pliers -1-.. –  Knock out valve body upwards from below with drift. –  Slide steering rack fully towards valve body.

–  Turn circlip so that pointed end of circlip is positioned in groove -arrow- of housing.

–  First raise circlip with screwdriver, then pull out with pliers. –  Before pulling steering rack out, clean housing opening with compressed air. –  Remove contamination and any metal particles. –  Pull steering rack to right out of housing with steering rack guide. A -  Screwdriver B -  Pliers (commercial type) Removing centre roller bearing for valve body

–  Drive centre roller bearing out upwards. A -  Internal puller, e.g. -Kukko 21/4- B -  Drift When positioning puller -A-, ensure that claws engage correctly beneath roller bearing → Anchor. The puller must not be spread too far, otherwise the roller bearing seating in the housing will be damaged or the roller bearing 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 -  Roller bearing 4 -  Housing 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 → Anchor. 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 -  Housing –  Drive out lower bearing with guide pin, shouldered -VW 439-. Removing inner steering rack oil seal

–  Drive steering rack oil seal out of housing. –  Unbolt pipes from valve body housing to cylinder tube. –  Clean pipes and housing. Check threaded connections for contamination (rubber residues, metal particles).