Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ V.A.G 1383 A Gearbox jack

Instructions when working on the power assisted steering box

• ◆ Absolute cleanliness is required when working on the power assisted steering.
• ◆ Thoroughly clean connections and immediate vicinity before loosening.
• ◆ Place parts on a clean surface and cover if not re-installing immediately.
• ◆ Do not use fluffy cloth.
• ◆ Only unpack parts immediately prior to fitting.
• ◆ Only use genuine packed parts.

Removing

• ‒ → Removing cover -1-.

• ‒ → Remove joint bolt.

• ‒ → Clamp hose from reservoir with hose clamp 3094.
• ‒ Remove 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.

• ‒ → Unclip return supply hose.

Continued for all vehicles

• ‒ → Disconnect hoses from steering box and seal with plastic bag and adhesive tape.
• ‒ Seal power assisted steering box threaded holes with plastic sealing plugs.

•      1 -     Banjo bolt (19 mm AF)
•      2 -     Socket e.g. Hazet 4550

• ‒ Unclip hose retainer from hoses/lines.

• ‒ Remove power-assisted steering box bolts.

• ‒ → Detach pendulum support -1- at gearbox.
• ‒ 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:

• ◆ Use new sealing rings for hose/line connections.
• ◆ 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.

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.