Volkswagen Workshop Service and Repair Manuals

Removing and installing steering box, left-hand drive vehicle (1st and 2nd generations) up to model year 2008

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Ball joint puller -3287 A-

Removing steering box   Note t  There are no 2nd generation steering boxes available as spare parts. t  If the steering box has to be replaced, a new 3rd generation steering box will have to be fitted. t  In addition, the electrical wiring harness from the E-box to the steering box will then also have to be renewed. This is included with the order for the new steering box via the → Electronic parts catalogue„ETKA“. t  The electrical wiring harness will be delivered with the cable for the service interval display. t  In vehicles without a service interval display, the unused 3-pin connector must be sealed by a flat contact housing with connector position assurance -1J0 973 803- → Electronic parts catalogue„ETKA“. –  Disconnect battery. → Rep. gr.27

–  Remove footwell trim by removing nuts -arrows-.

–  Remove bolt -1- and pull universal joint -2- off steering box. –  Remove front wheels. –  Loosen nut on track rod ball joint but do not remove completely.   Caution Leave nut screwed on a few turns to protect thread on pin.

–  Press track rod ball joint off wheel bearing housing with -3287A-. –  Remove lower noise insulation → Rep. gr.50.

–  Disconnect pendulum support from gearbox by removing bolts -14-. –  Remove exhaust system retainer on subframe.

–  Remove bolts -arrows- from heat shield. –  Remove heat shield from subframe.

–  Now remove bolts -3, 6, 11 and 16- for steering box and anti-roll bar. –  Fix position of subframe and brackets. → Chapter

–  Position engine and gearbox jack -V.A.G 1383 A- under subframe. –  Place a wooden block -1- or similar between V.A.G 1383 A and subframe.

–  Remove bolts -4 and 5- and lower subframe with brackets slightly, observing electrical wires.

–  Remove heat shield -1- over steering box. –  Remove bolts -arrows-.

–  Remove cable guide from subframe -arrow-. –  Unclip all remaining cable clips on steering box. –  Disconnect all electrical connections on steering box. –  Lower subframe using engine and gearbox jack -V.A.G 1383 A- far enough that the steering box can be removed.

–  Set steering box down as illustrated. This prevents damage to the control unit -1-. Installing steering box Install in reverse order. Threaded sleeves of steering box must seat in holes in left bracket.   Note t  Coat seal on steering box with suitable lubricant, e.g. soft soap, before installing steering box. t  After fitting the steering box to the jointed shaft, ensure that the seal is not kinked when lying against the assembly plate and that the opening to the footwell is correctly sealed. Otherwise, this can result in water leaks and/or noise. t  Ensure sealing surfaces are clean. Before inserting subframe bolts, position steering box on subframe and insert bolts for steering box and anti-roll bar. –  Connect electrical connections to steering box. –  Install lower noise insulation. → Rep. gr.50.   Note Ensure that bellows are not damaged or twisted. –  Bolt universal joint to steering box. –  Connect battery. → Rep. gr.27 –  Carry out basic setting for -G85-Geber für Lenkwinkel- using → Vehicle diagnostic tester. –  Adapt electromechanical steering using → Vehicle diagnostic tester. Running gear Electromechanical power steering 01 - System capable of self-diagnosis Electromechanical steering system Functions Adapting electromechanical steering   Note t  If parking aid 2 is fitted in the vehicle, the power steering control unit -J500- must be recoded following the installation of a new steering box → Vehicle diagnostic tester. t  Parking aid 2 is fitted only in vehicles having 2nd generation steering boxes. After installation, check position of steering wheel during road test. If steering wheel is not in straight-ahead position or if a new steering box was installed, front axle tracking must be checked and if necessary adjusted! –  Check wheel alignment. → Chapter

Specified torques

Component	Specified torque
Subframe to body t  Use new bolts	70 Nm + 90°
Anti-roll bar to subframe t  Use new bolts	20 Nm + 90°
Anti-roll bar to coupling rod t  Use new nut t  Counterhold on multi-point socket of joint pin	65 Nm
Swivel joint to cast steel suspension link t  Use new nuts	60 Nm
Swivel joint to sheet steel or forged aluminium suspension link t  Use new nuts	100 Nm
Shield to subframe t  Bolt M6 is self-locking	6 Nm
Steering box to subframe t  Use new bolts t  Always renew clamp	50 Nm + 90°
Universal joint to steering box t  Use new bolt	30 Nm
Shield to steering box t  Bolt M6 is self-locking	6 Nm
Track rod ball joint to wheel bearing housing t  Use new nut	20 Nm + 90°
Exhaust system bracket to subframe → Engine; Rep. gr.26

Specified torques for pendulum support to gearbox

Caution From model year 08, HeliCoil inserts are installed in the pendulum support connection in the 02Q gearboxes. Identification → Rep. gr.34. Use a bolt with hardness class 10.9 for this and all other gearboxes. If there is no HeliCoil insert in the 02Q gearbox, use bolts with the strength class 8.8 and the corresponding torque setting.

Bolt	Specified torque
M10 x 35 strength class 8.8 t  Use new bolt	40 Nm + 90° further
M10 x 35 strength class 10.9 t  Use new bolt	50 Nm + 90° further
M10 x 75 strength class 8.8 t  Use new bolt	40 Nm + 90° further
M10 x 75 strength class 10.9 t  Use new bolt	50 Nm + 90° further