Removal and Replacement

Power steering gear, removing and installing

Notes for repair work on power steering gear
^ Servicing is restricted to replacement of rubber boots and tie rods.
^ Absolute cleanliness is required when working on the power steering.
^ Thoroughly clean all unions and the adjacent areas before disconnecting.
^ After removal, place parts on a clean surface and cover them over if repairs are not to be performed immediately.
^ Only use lint-free cloths.
^ Only remove replacement parts from packaging immediately prior to installation.
^ Only use genuine packed parts.
^ Do not reuse hydraulic fluid which has been drained off.
^ Always replace seals.
^ Dispose of used components properly

Removing

CAUTION! Turn steering wheel to center position (wheels straight-ahead) and do not turn while performing repair work, as otherwise coil connector of airbag module could be damaged.





- To prevent unintentional turning, secure steering wheel in straight-ahead position with adhesive tape.





- Remove plastic nuts - 1 - and cover - A -.





- Remove hex bolt - 1 -.
- Pull universal joint off steering gear.





- Remove noise insulation.
- Remove bracket for hydraulic line at left-side of subframe, if necessary. Tightening torque: 3.5 Nm.
- If installed, detach headlight range control linkage at left control arm.





- Clamp off intake hose (fluid reservoir/power steering pump) using special tool - 3094 -.





- Remove return line from fluid reservoir and drain hydraulic fluid into a suitable container.
- Seal return opening at fluid reservoir with a plug.

Note: Leave nut screwed several turns onto tie rod end to protect thread.





- Detach tie rods from steering arms using puller Kukko 129/0.
- Place tray underneath vehicle to catch hydraulic fluid.





- Disconnect expansion hose - 2 - from steering gear and seal off with a plastic bag and adhesive tape.
- Seal off threaded hole at steering gear (e.g. with plastic screw plug).
- Return line - 1 - can be disconnected after lowering subframe.





- Unbolt pendulum support on transmission side.





- Install engine/transmission jack V.A.G1383A with attachment -1359/2-.
- Loosen bolts - 1 -.
- Remove subframe bolts - 2 - and -3 -.
- If necessary, remove hex nut for retaining clip on stabilizer bar clamp (left-side). Tightening torque: 22 Nm





- Carefully pry steering gear from main subframe using a tire iron or similar.
- Lower subframe.

Note the side noise insulation panel and bracket for hydraulic line (left-side) when lowering subframe.





- Remove return line at clamp - 1 - and disconnect rotary slide valve housing - 2 -.
- Remove steering gear bolts and steering gear toward rear.

When installing, note the following:
Before inserting subframe bolts, position steering gear on subframe and insert bolts for steering gear.





Threaded sleeve - 1 - must be seated in hole in subframe.

CAUTION! Wheel alignment must be checked after installing steering gear.

Note:
^ When securing line connections, make sure lines do not contact or rub against other components.
^ Do not attach universal joint of steering column to steering gear pinion until vehicle is standing on ground and wheels are set to straight-ahead position.





- Measure distance - a - to check whether steering gear is in center position.

Check distance - a - on left side of steering gear.

a - = 33.5 mm; adjust if necessary by turning steering pinion.





- Insert steering gear with guide sleeve - 1 - into subframe and hand-tighten bolts.





- Attach return line to clamp on steering gear.

Note: On front-wheel drive vehicles, there must be a clearance of 10 mm between return line - / - and steering gear - 3-.

- Connect return line to rotary slide valve housing using new seals.
- Check correct positioning of sealing collar at steering gear pinion.
- Raise subframe and, at the same time, guide steering gear pinion into opening in floor of vehicle.
- Secure subframe with old bolts.

Note: Replace old subframe bolts when checking and adjusting wheel alignment.

- Attach expansion hose to rotary slide valve housing using new seals.
- Attach pendulum support and exhaust system bracket.
- Install tie rods in steering arms and secure in place. If the joint pin is also turned when tightening, counterhold with Torx key T40.
- Connect return line to fluid reservoir.
- Remove hose clamp from intake hose.
- Install noise insulation.





- Push universal joint onto steering pinion and secure with new bolt - 1 -, 30 Nm.
- Install cover.
- Fill with hydraulic fluid.