With Servotronic
Power steering gear with Servotronic, servicing
CAUTION: Keep work area and components clean. Do not attempt to weld or straighten steering components.
Note: The power steering uses hydraulic oil, Part No. G 002 000. Components marked with an asterisk (*) are included in the repair kit and should always be replaced when servicing the system. Moisten all seals with hydraulic oil before installing.
1. Steering gear housing/steering gear
Removing and installing refer to
Adjust toe after removing and installing
2. Seal*
Always replace
Pulling out see Fig. 3 and Fig. 4
3. Circlip
Can only be removed and installed with steering rack removed
4. Retaining ring
Slide on steering rack to stop
Install in groove
5. Boot
Can only be replaced with steering gear installed
Adjust toe after replacing
6. Clamp
Use screw-type clamps for repair
Threads face toward bulkhead
7. O-ring*
Always replace
8. Adjusting screw
Adjusting steering gear play see Fig. 7
9. Hex bolt 20 Nm (15 ft lb)
10. Cover
Mount on steering gear housing
The two adjacent holes face forward (direction of travel)
11. 0-ring*
Always replace
Diameter: 35 x 2 mm
Install in annular groove of steering gear housing
12. 0-ring*
Always replace
27 x 2.5 mm
Install in annular groove of 0-ring retainer
13. 0-ring retainer
Removing see Fig. 5
14. Compression spring
Install in thrust piece
15. Thrust piece
16. Bolt 3 Nm (27 in. lb)
Mounts Servotronic to rotary valve housing
Not marked with locking compound
17. Servotronic solenoid valve
Cannot be removed and installed with steering gear installed
18. 0-ring*
Always replace
12 x 1.5 mm
19. 0~ring*
Always replace
7 x 1 mm
20. Strainer*
Always replace
21. Washer
22. Socket-head bolt 20 Nm 115 ft lb)
23. Valve housing
24. 0-ring retainer*
Always replace
Driving out see Fig. 1
Driving in see Fig. 2
Fill space between sealing lip and dust lip with multi-purpose grease
25. Spring pin*
Always replace
2.5 x 6 mm
Pull out with pliers before re moving rotary valve housing
26. Rotary valve/steering pin ion
Drive out of steering gear housing see Fig. 6
27. 0-ring*
Always replace
60 x 2 mm
28. 0-ring*
Always replace
9 x 2 mm
29. Cap 50 Nm (37 ft lb)
Secure with two punch marks offset 180°
30. Support ring*
Always replace
Pull onto cap
Installation position see Fig. 8
31. 0-ring
Always replace
44 x 2.5 mm*
Pull onto cap
32. Steering rack
Remove cap and slide steering rack to left, out of steering gear housing
Watch out for scoring in area of steering rack seal
Installing refer to
Fig. 1 Driving out rotary valve housing 0-ring retainer:
Fig. 1
Driving in rotary valve housing 0-ring retainer:
Fig. 2
Drive in fully.
Fig. 3
Install commercial inside puller (e.g. Kukko 21/4) in seal.
Fig. 4
Clamp steering gear housing in vise with jaw covers.
Thread VW771 with VW771/15 onto inside puller and drive out steering rack seal.
Removing 0-ring retainer:
Fig. 5
Remove using standard circlip pliers.
Driving out rotary valve/steering pinion:
Fig. 6
Hold pin ion by hand and drive out of steering gear housing using firm blows from soft-faced hammer.
Adjusting steering play:
Fig. 7
Notes: Two technicians are required to make the adjustment. Adjust with the engine not running and the vehicle standing on the ground. Illustration shows the steering gear removed.
Put wheels in straight ahead position.
Turn steering wheel back and forth (about 30° around center axis) and listen for rattling or knocking noise from steering gear.
Second technician:
Carefully turn adjusting screw (arrow) clockwise into cover, until rattling and knocking noise can no longer be heard from inside vehicle.
Road test.
Repeat adjustment if necessary.
Installation position of support ring:
Fig. 8
1. Cap
2. Support ring
3. 0-ring
Steering rack, installing
Note: Before installing steering rack, wash out steering gear housing with solvent and blow dry with compressed air. Clean steering rack. Before installing, coat installation sleeve components, steering rack and steering rack seals with hydraulic oil. All new repair kits include an installation sleeve.
Insert steering rack seal by hand into steering gear housing and drive in fully.
Install circlip using circlip pliers.
Assemble installation sleeve parts -a- and-b-, with both parts on level surface, as shown.
By hand, press installation sleeve parts -a- and -b- into steering gear housing to stop.
Use commercially available mandrel to drive installation sleeve -b- into steering gear housing and remove at opposite end.
Slide steering rack in from opposite end through steering gear housing and through installation sleeve -a-.
Hold installation sleeve -a- in place by hand until flat end of steering rack has passed through.
Remove installation sleeve -a- from steering rack.
Screw on cap by hand, so that steering rack cannot fall out (preventing damage to seal).