Table of contents: Disassembly ↓ Assembly ↓
Disassembly
Warning: When disassembling and assembling the steering gear, ensure that the work area is perfectly clean and that no dust, dirt or foreign matter gets onto the parts or into the steering gear housing.
Remove the rack stop cover.
Remove the rack stop assembly.
Remove the power steering system pipes and take out the seals and O-rings.
Remove the clamps securing the steering rack protective cover, then remove the protective cover.
Mounting clamp screw
Unscrew the valve body mounting bolts and remove the body. Remove the washer and gasket.
Remove the valve core.
Press the oil seal out of the steering gear housing using a puller.
Press the seal out of the valve body using the 3013 mandrel.
Loosen the self-locking bolts and separate the steering gear housing parts.
Remove the oil seal and rubber buffer from the steering gear housing flange.
Remove the right half of the steering gear housing and take out the seals.
Loosen the self-locking nut of the rack piston rod, securing it in a vice.
Remove the piston and spacer washers.
Remove the rack.
Press out the cylindrical tube with a mandrel and remove the seals.
Press the guide out of the cylindrical tube together with the seal and piston rod O-ring using tool 3086 with an extension sleeve, the larger end of which should protrude from the cylindrical tube.
Assembly
Install the piston rod o-ring, guide and seal assembly into the cylinder tube and press the assembly into the tube using tool 3086 with the extension sleeve installed so the short end is visible.
Apply a thin layer of grease to the seals and install them in their places.
Install the cylindrical tube.
Screw the mounting sleeve 3086/2 onto the rack piston rod until it stops.
Install the rack into the steering gear housing, then remove the mounting sleeve. Apply grease such as AOF 063 000 04 to the rack teeth.
Install the piston assembly with spacer washers.
Tighten the rack piston rod self-locking nut.
Put the right half of the crankcase back into place together with the seals.
Install the seal and rubber flange buffer.
Connect the right and left parts of the steering gear housing and tighten the self-locking bolts.
Press the seals into the valve body and into the steering gear housing until they stop using the VW 545 and VW 4166 tools.
Install the spool.
Install the valve body with the sealing ring and washer.
Install the protective cover of the rack with the power steering pipes and pull the protective cover so that the distance between the edge of the cover and the end of the right half of the steering gear housing is 210 mm (see photo).
When installing the protective cover of the steering rack, maintain the dimension "a" equal to 210 mm
Connect the power steering pipes with seals and O-rings.
Install the rack stop assembly, aligning the stop bushing cut along the longitudinal axis of the rack.
Install the stop cover.
After installing the steering gear, adjust the steering wheel free play.
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