Steering Gear, Generation 1 and 2, through MY 2008

Steering Gear, Generation 1 and 2, through MY 2008

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Torque Wrench (V.A.G 1332)

• Engine/Transmission Jack (V.A.G 1383 A)

• Ball Joint Puller (3287 A)

Removing

• The generation 2 steering gear is no longer available as a replacement part.

• Install a generation 3 steering gear if replacing a steering gear.

• In addition to this, the electrical wiring set from the E-box to the steering gear must be changed. It will be included with the new steering gear.

• The electrical wiring set is delivered complete together with the wiring for the service interval display.

• If the vehicle does not have a service interval display, then the 3-pin connector, not being used, must be sealed off with a flat terminal housing with contact seal (1J0 973 803).

- Disconnect battery.

- Remove foot well trim, to do so remove nuts - arrows -.





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





- Remove the front wheels.

- Loosen the tie rod nut, but do not remove yet.

CAUTION!
To protect thread, screw nut on pin a few turns.

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





- Remove lower noise insulation.

- Remove pendulum support from transmission, to do so remove bolts - 14 -.





- Remove bracket for exhaust system from the subframe.

- Remove bolts - arrows - from heat shield.





- Remove heat shield from subframe.

- Now remove bolts - 3, 6, 11 and 16 - for the steering gear and stabilizer bar.





- Locate the subframe and brackets. Refer to => [ Subframe and Brackets, Securing ] Procedures

- Place the (V.A.G 1383 A) under the subframe.





- Place a block of wood - 1 -, for example, between (V.A.G 1383 A) and the subframe.

- Loosen bolts - 4 and 5 - and lower subframe with brackets slightly. Observe electrical wires when doing this.





- Remove heat shield - 1 - above exhaust system.





- Remove bolts - arrows -.

- Remove cable guide from subframe - arrow -.





- Unclip all other cable mounting points on steering gear.

- Disconnect all electrical connections from steering gear.

- Lower the subframe with the (V.A.G 1383 A) until the steering gear can be removed.

- Set down steering gear as depicted in the illustration.





This prevents damage to the control module - 1 -.

Installing

Installation is in reverse order of removal.

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

• Coat seal on steering gear with lubricant, for example 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.

Before fastening the bolts for subframe, position steering gear on subframe and fasten bolts for steering gear and stabilizer.

- Clamp off the electrical connections to the steering gear.

- Install lower noise insulation.

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

- Bolt universal joint to steering gear.

- Connect battery.

- Perform the steering angle sensor (G85) basic setting with the vehicle diagnosis, testing and information system (VAS 5051).

After installation, position of steering wheel must be checked with a road test.

If the steering wheel is crooked or new steering gear was installed, the toe on the front axle must be checked and adjusted if necessary.

- Align vehicle. Refer to => [ Vehicle Alignment Procedure Overview ] Vehicle Alignment Procedure Overview.

If a new steering gear is installed, the power steering control module (J500) must be adapted using the (VAS 5051 ).

- Perform power steering control module (J500) basic setting using (VAS 5051).

• If parking assist 2 is installed in the vehicle, the power steering control module must be recoded after installing new steering gear.

• Parking assist 2 is only in installed vehicles with Generation II steering gear.

Tightening Specifications





Tightening specification, pendulum support to the transmission

CAUTION!
From MY 2008, Heli-Coil inserts are installed in the threads for the pendulum support threaded connection in the 02Q manual transmissions.

On these and all other transmissions, use strength class 10.9 bolts.

If, in the 02Q manual transmissions, there is not Heli-Coil insert, then use 8.8 strength class bolts and the appropriate tightening specification.