Steering Gear

Steering Gear

Special tools, testers and auxiliary items required

• Ball Joint Puller (3287 A)

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Torque Wrench 40-200 Nm (V.A.G 1332)

• Engine/ Gearbox jack (V.A.G 1383 A)

• Locating Pins (T10096)

Removing

• The steering gear is removed together with the subframe, stabilizer bar and transverse links.

Before starting work on electrical equipment and removing steering wheel, the following conditions must be fulfilled:

• Disconnect the battery ground cable.

• The wheels must be in the straight-ahead position.

- Set the wheels to the straight ahead position.

- Disconnect the battery.

- Remove the nuts - arrows - and the steering column universal joint cover.






- Remove the bolt - 1 - and remove the universal joint - 2 - from the steering gear.






- Disconnect connector - 2 -, remove electrical wires - 1 - and - 3 -.






- Unclip wiring harness - 4 - from wiring shaft.

- Remove the front wheels.

- Remove the lower noise insulation. Refer to "Underbody Trim Panels and Heat Shields".

- Remove the frame for the noise insulation.

- Loosen nut of track rod ball joint, but do not remove yet.

- Press tie rod end off of wheel bearing housing using - 3287A -.






- Remove exhaust system bracket bolts - arrows -.






- Remove the nut - 1 -.






- On vehicles with level control system sensor, remove nut - 3 - and disconnect connector - 6 -.






- Remove the bolts - 13 - and then remove the pendulum support from the transmission.






- Disconnect oil level thermal sensor (G266) connector - 1 - and unclip electrical wire from bracket - 2 -.






- Mark location of nuts - arrows - on left and right sides of vehicle using a felt-tip pen.






- Remove the nuts - arrows - on left and right side of vehicle.

- Remove transverse link from ball joint.

- Secure the subframe. Refer to => [ Subframe, Securing ] Description and Operation.

- Place (V.A.G 1383 A) with wood blocks - 1 - under subframe and apply slight counterpressure.






- Remove bolts - 4 - and - 5 -.






- Lower subframe with attachments.

• When lowering, ensure the electrical wires have enough clearance.

- Remove wiring guide from subframe.

- Remove the heat shield from the steering gear.

- Remove steering gear bolts - 3 - and - 6 -.






- Remove steering gear from subframe.

Installing

Install in reverse order of removal. Note the following:

Tightening specifications, refer to => [ Subframe, Stabilizer Bar, Transverse Link, Ball Joint and Vehicle Level Sensor Overview ] Subframe, Stabilizer Bar, Transverse Link, Ball Joint and Vehicle Level Sensor Overview

Tightening specifications, refer to => [ Steering Gear Overview ] Steering Gear Overview

The steering gear threaded sleeves must be seated in the subframe holes.

Clamp with nuts must be replaced after each removal. - Item 16 - => [ (Item 16) Clamp with Nuts ] Steering Gear Overview

• Coat seal on steering gear with lubricant, e.g. soft soap, before installing steering gear.

• After attaching steering gear to drive axle, make sure that seal on steering gear is positioned to mounting plate without kinks and opening to foot well is sealed correctly. Ingress of water and/or noises may be the result.

• Make sure sealing surfaces are clean.

• Make sure that the ball joint boot is not damaged or twisted.

- Replace locking element after each removal - Item 11 - => [ (Item 11) Locking Element ] Subframe, Stabilizer Bar, Transverse Link, Ball Joint and Vehicle Level Sensor Overview

- Align nuts - arrows - according to markings made earlier and tighten.






- Install the frame for the noise insulation.

- Install noise insulation. Refer to "Underbody Trim Panels and Heat Shields" In

- Connect the battery.

Applies to vehicles with Generation II steering gear

If a new steering gear was installed, the power steering control module (J500) must be programmed with the vehicle diagnostic tester and the characteristic lines must be downloaded vehicle diagnostic tester "Guided Fault Finding".

Applies to vehicles with Generation III steering gear

If new steering box was installed, the power steering control module (J500) must be adapted with the vehicle diagnostic tester "Guided Fault Finding".

Applies to all vehicles

- An axle alignment is necessary. Refer to the table => [ An Axle Alignment is Necessary When: ] An Axle Alignment is Necessary When:

- If the vehicle has electronic damping (Audi Magnetic Ride), then program the control position. Refer to vehicle diagnostic tester.

- If the vehicle has automatic head lamp range control, then perform a basic setting on the headlamps.

- If a axle alignment was performed, calibrate steering angle sensor (g85) with vehicle diagnostic tester (VAS 5051B) => [ Wheel Alignment ] Wheel Alignment.