Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 4 - Kukko 128/2 Puller

• ◆ V.A.G 1383 A Gearbox jack

• ‒ → Removing cover -1-.

• ‒ → Remove joint bolt.

• ‒ → Take wheel bolt covers off and remove both front wheels.

• ‒ → Press track rod end off steering arm.

•      1 -     Ball joint splitter (commercial type) e.g. Kukko No. 128/2

Vehicles ▸09.99

• ‒ → Unclip Lambda probe -1- wiring (arrow) at retainer.

• ‒ → Unbolt exhaust pipe.

• ‒ → Unclip cable (arrows).

Vehicles 10.99 ▸

• ‒ → Unclip Lambda probe cable.

• ‒ → Unbolt exhaust pipe.

• ‒ → Remove bracket for gear change cables from assembly carrier (arrow).

• Only fitted on vehicles with cable operated gear change.

Continued for all vehicles

• ‒ → Detach pendulum support -1- at gearbox.
• ‒ Remove bolts for steering box.
• ‒ Place gearbox jack V.A.G 1383 A under sub-frame.
• ‒ Remove bolts for sub-frame.
• ‒ Lower sub-frame using gearbox jack V.A.G 1383 A.
• ‒ Pull power-assisted steering box off steering column universal joint shaft and take out to side.

When removing the steering box ensure that the pinion splines do not stick or cant in the steering column universal joint shaft.

Installing

Notes:

• ◆ Coat steering box seals with lubricant, e.g. soft soap, before installing steering box.
• ◆ After fitting the steering box to the universal joint shaft ensure that the seal lies against the assembly plate without kinking and that the opening to the footwell is correctly sealed.
  Noises may be created and/or water may ingress.
• ◆ Ensure sealing surfaces are clean.

Install in reverse order

A 2nd mechanic may be required when fitting the pinion to the universal joint shaft.

Replace steering column joint captivated nut with a self-locking nut. The captivation need not be used again.

Before fitting bolts for the sub-frame, position steering box on sub-frame and insert bolts for steering box.

• ‒ Check front wheel alignment and position of steering wheel.