Without Servotronic
Power steering gear, servicing
CAUTION: Keep work area and components clean. Do not attempt to weld or straighten steering components.
Notes: 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
Removing see Fig. 1 and Fig. 2
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 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. 5
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
35 x 2 mm
Install in groove in steering gear housing
12. 0-ring*
Always replace
27 x 2.5 mm
Install in groove in 0-ring retainer
13. 0-ring retainer
Disassembling see Fig. 3
14. Compression spring
Install in thrust piece
15. Thrust piece
16. Washer
17. Socket-head bolt 20 Nm (15 ft lb)
18. Valve housing
19. Seal*
Replacing refer to
20. Support washer
21. Spring pin*
Always replace
2.5 x 6 mm
Pull out with pliers before removing rotary valve housing
22. Rotary valve/steering pinion
Driving Out of steering gear housing see Fig. 4
23. 0-ring*
Always replace
60 x 2 mm
24. O-ring*
Always replace
9 x 2 mm
25. Cap
50 Nm (37 ft lb)
Secure with two punch marks offset 180°
26. Support ring*
Always replace
Pull onto cap
Installation position see Fig. 6
27. o-ring*
Always replace
44 x 25 mm
Pull onto cap
Installation position see Fig. 6
28. 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 Installing seal puller
Install standard commercial inner puller (e.g. -KUKKO 21/4-) in sealing lip.
Fig. 2 Removing steering rack seal
Clamp steering gear housing in vise with jaw covers.
Screw VW771 with VW771/15 onto inner puller and drive out steering rack seal.
Fig. 3 Removing 0-ring retainer
Remove with standard commercial circlip pliers.
Fig. 4 Driving out steering pinion
Hold steering pinion by hand and drive out of steering gear housing with forceful taps of soft-faced hammer.
Fig. 5 Adjusting steering gear play
Note: 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.
Fig. 6 Installation position of support ring
1. Cap
2. Support ring
3. 0-ring
Seal in rotary valve housing, replacing
Drive seal out of housing.
Place new seal on special tool VW431 with sealing lip pointing toward tool.
Install special tool VW431 with seal in rotary valve housing.
Place special tool VW421 onto special tool VW431 and drive seal in fully.
Fill space between sealing lip and dust lip with multi-purpose grease.
Insert assembled bushing (protective sleeve -2- and installation sleeve -3-, included in repair kit) into seal.
Press installation sleeve -3- out of protective sleeve.
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 pants -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).