Power Steering Gear, Removing and Installing

Power steering gear, removing and installing

Special tools, testers and auxiliary items required:

^ Hose clamps 3094
^ Torque wrench V.A.G. 1331
^ Torque wrench V.A.G. 1332
^ Engine/transmission jack V.A.G 1383 A with universal transmission mount V.A.G 1359/2

The following special tools are necessary for R32

Special tools, testers and auxiliary items required

Assembly tool 3293:

Installing tool 40 - 503:

^ Ball joint puller T10239

Instructions when working on the power steering gear
^ Absolute cleanliness is required when working on the power steering system.
^ 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 cloths.
^ Remove replacement parts from packaging immediately prior to installation.
^ Only use genuine packed parts.

Removing





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





- Remove joint bolt - 1 - from steering shaft joint and remove universal joint steering gear in direction of - arrow -.





- Clamp hose from reservoir using hose clamp 3094.





- Clamp power steering pump hose using hose clamp 3094.
- Remove noise insulation tray.
- Place oil pan under vehicle.





- Press tie rod end off steering arm.

1 - Ball joint puller (commercial type) e.g. Matra V 176

For R32





- Press tie rod end off steering arm.





- If the bushing - 3 - is pressed out while pressing out tie rod, it must be pressed in again.
- Attach special tools as shown in illustration, and tighten spindle to 50 Nm.
The bushing is correctly positioned in steering arm again.
1 - Assembly tool 3293
2 - Installing tool 40 - 503

Continue for all vehicles
- Disconnect hoses from steering gear and seal with plastic bag and adhesive tape.
The return line - 1 - can only be removed after first lowering subframe.





- Seal power steering gear threaded holes with plastic sealing plugs.





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

Vehicles with TDI engine





- Unbolt bracket for front exhaust pipe on subframe - arrow - and separate.

Continue for all vehicles
- Support subframe with engine/transmission jack V.A.G 1383 A.
- Loosen hex bolt - 1 -.





- Remove hex bolts - 2 - and - 3 -.
- Lower subframe using engine/transmission jack V.A.G 1383 A.





- Remove return line clamp - 1 - and line at steering gear - 2 -.
- Remove power steering gear bolts.
- Take power steering gear out towards rear.

Installing

Note:
^ Use new sealing O-rings for hose/line connections.
^ Coat steering gear O-ring seals with lubricant, e.g. liquid soap, before installing steering gear.
^ After installation of steering gear to the universal joint shaft, make sure that the seal lies against the assembly plate without kinking and opening to the footwell is correctly sealed. Water ingress and/or noises may be the result.
^ Make sure sealing surfaces are clean.





- Install power steering gear on subframe.

The threaded sleeve - 1 - must seat on subframe hole.





- Install return line.

A gap of approximately 10 mm must exist between return line and power steering gear.
1 - Return line
2 - Hex nut, 22 Nm
3 - Power steering gear

Installation is continued in reverse sequence