Power Steering Gear, Removing and Installing

Power steering gear, removing and installing





Special tools and equipment
^ 3094 Hose clamps
^ VAG 1331 Torque wrench
^ VAG 1332 Torque wrench
^ VAG 1383 A Engine/transmission jack

Instructions when working on power steering gear
^ Cleanliness is required when working on power steering.
^ Clean all line and hose connections and surrounding area before disconnecting.
^ Do not remove replacement parts from packaging until immediately before they are to be installed.
^ Do not use huffy.
^ Place removed components on a clean surface and cover if not re-installing immediately.
^ Use genuine packaged Volkswagen components.

Removing





- Remove screws -1-.
- Remove cover -A-.





- Remove bolt -1- from universal joint.
- Remove universal joint off steering gear.





- Clamp hose from reservoir with hose clamp 3094.





- Use hose clamp 3094 hose on power steering pump.
- Remove noise insulation panel.
- Place drip tray underneath.





- Press tie rod end off steering arm.
A - Ball joint separator (commercial type) e.g. Kukko No. 128/2
- Disconnect hoses from steering gear and seal with plastic bag and adhesive tape.





- Seal threaded holes on power steering gear with plastic sealing plugs -1- and -2-.





- Remove hex bolts -1- and -2-.

Vehicles with TDI engine
- Separate exhaust system from subframe.

Continued for all vehicles
- Support subframe with engine/transmission jack VAG 1383 A.
- Remove hex bolts -1-.





- Remove hex bolts -2- and -3-.
- Lower subframe with engine/transmission jack VAG 1383 A.
- Remove bolts -1- for power steering gear.
- Remove power steering gear toward right.

Installing

Notes:
^ Use new sealing rings for hose/line connections.
^ Coat steering gear seals with lubricant, (e.g. soft soap), before installing the steering gear.
^ After installing the steering gear to the universal joint shaft make sure the seal lies against the cover without kinking and the opening to the footwell is correctly sealed. Otherwise noises may be created and/or allow water to pass through.
^ Make sure sealing surfaces are clean.

- Install power steering gear onto subframe.





Threaded sleeve -1- must seat in hole on subframe.
Installation is the reverse of removal.

Fastener/location Tightening torques
Power steering gear to subframe 20 Nm (15 ft. lbs.) plus additional 90° turn
Use new bolts!
Subframe to body 100 Nm (74 ft. lbs.) plus additional 90° turn
Use new bolts!
Universal joint to steering gear 30 Nm (22 ft. lbs.)
Use new bolts!
Banjo bolt to steering gear M14x15 40 Nm (30 ft. lbs.)
Banjo bolt to steering gear M16x15 45 Nm (33 ft. lbs.)
Pendulum support to gearbox 40 Nm (30 ft. lbs.)plus additional 90° turn
Use new bolts!
tie rod to steering arm 45 Nm (33 ft. lbs.)
Use new nuts!