Disassembling and Assembling

Power steering gear, disassembling and assembling (Vehicles with 6-cyl. engine)





The power steering gear is not serviceable. For complaints, determine the cause with the help of pressure and leakage tests. If a malfunction exists replace the power steering gear.

CAUTION:
^ Do not re-use fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in these procedures - replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

Notes:
^ Always replace all self-locking nuts and bolts
^ Do not attempt to weld or straighten steering components
^ Only use steering gear grease, Part No AOF 063 000 04 to grease the steering rack
^ Hydraulic fluid Part No G 002 000
^ System capacity: approx. 1 liter (1.056 US qt.)
^ If reservoir fluid is low check steering system for leaks
^ If leaks occur at line connections, tighten connections, wipe area dry and recheck for leaks

1. Tie rod end
^ Check that dust caps are seated correctly and not damaged
2. 40 Nm (30 ft. lbs.)
3. Clamp
^ Tighten with VAG 1275
^ Always replace
4. Boot
^ Check for damage
^ Can be replaced with steering gear installed
^ Must not be twisted after toe adjustment
5. Clamp
^ Repair instructions refer to Item 3
6. O-ring
^ Always replace
7. Tie rod
^ 100 Nm (74 ft. lbs.)
^ Grease joint with steering gear grease AOF 063 000 04
8. Steering damper bracket
9. O-ring
^ Always replace
10. Dished washer
11. Clamp
Repair instructions refer to Item 3
12. Boot
Repair instructions refer to Item 4
13. Power steering gear
^ Grease rack with steering gear grease AOF 063 000 04
^ The steering gear is supplied as a replacement part complete with tie rods and boots
14. Nut
^ 10 Nm (7 ft. lbs.)
To loosen and tighten counter hold on steering damper piston rod hex
15. Bushing
16. Rubber mounting
^ Two-part
17. Steering damper
18. 38 Nm (28 ft. lbs.)
19. Socket head bolt
^ 18 Nm (13 ft. lbs.)