Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Puller VW 771

• ◆ 3 - Kukko 204/2 Puller with tensioning bar

Dismantling

Column tube and steering column can only be dismantled once they had been removed from the vehicle. Removing and installing column tube and steering column .

• ‒ → Remove nut -2- (left-hand thread) and nut -3- and take off slide rod -1-.

• ‒ → Pulling off multi-spline adapter sleeve and removing steering lock housing.

Only use puller with leg clamp (e.g. Kukko 204/2 commercial type).

• ‒ Unscrew drive shaft from steering column.
• ‒ Remove steering column from column tube.

• ‒ → Pulling lower bearing out of column tube

•      1 -     Internal puller e.g. Kukko 21/3

• ‒ → Remove nut -2- (left-hand thread) and nut -3- and take off slide rod -1-.

• ‒ → Unhook spring e.g. with water pump pliers.

• ‒ → Remove clamping bolt -4- (Left-hand thread) from operating lever.
• ‒ Take off clamping plate -5- and washer.
• ‒ Pull out clamping bolt -4-.
• ‒ Remove mounting bracket -6- from column tube.

Assembling

• ‒ → Insert mounting bracket -6- in mounting on column tube.

Observe installation position: Plate tabs (arrows) must be guided under the spring pin -7-.

• ‒ → Insert clamping bolt -4- with clamping plates -5- and washers.
• ‒ Bolt clamping bolt -4- to operating lever -8- (left-hand thread).

• ‒ → Position operating lever against upper stop (arrow) and tighten clamping bolt to 22 ... 24 Nm (left-hand thread).

• ‒ → Install slide rod -1- with locking plate -3-, if necessary loosen nut -4-. Upper or lower slots can be used.

Installing the locking plate -3- at an angle is permissible.

The installation position of the locking plate is determined by the position of the hexagon on tensioning bolt -4-.

• ‒ Tighten -4- (6 Nm).
• ‒ Tighten nut -2- (left-hand thread 8 Nm).
• ‒ Tighten nut -5- (6 Nm).

• ‒ Hook spring in e.g. with water pump pliers.
• ‒ Drive lower steering column bearing in with a synthetic head hammer.
• ‒ Slide support ring onto steering column.
• ‒ Guide steering column into column tube from above.
• ‒ Fit lower spring and universal joint shaft onto steering column and secure (25 Nm).
• ‒ Fit steering lock housing and bolt loosely together with new shear head bolt.

• ‒ Fit upper spring onto steering column.
• ‒ → Place splined adapter sleeve on steering column and fit hexagon nut.
• ‒ Tighten hexagon nut on steering column to 50 Nm.
• ‒ Remove nut again.
• ‒ Install steering column with column tube in vehicle.
• ‒ Tighten shear head bolts for column tube and steering lock housing until head shears off.