Disassembly
Warning. When disassembling and assembling the steering gear, ensure the ideal cleanliness of the workplace and exclude the ingress of dust, dirt and any foreign body on the parts and inside the steering gear housing.
Remove the rack stop cover.
Remove the rack stop parts set.
Remove pipelines of system of the hydraulic booster and take epiploons and ring linings.
Remove the clamps securing the protective cover of the steering rack, and then remove the protective cover.
Mounting clamp screw
Turn out bolts of fastening of the case of the spool and remove the case. Remove washer and gasket.
Remove the spool.
Press the oil seal out of the steering gear housing using a puller.
Press the gland out of the spool body using tool 3013.
Turn away self-locking bolts and separate parts of a case of the steering mechanism.
Remove the oil seal and rubber buffer from the steering housing flange.
Remove the right half of the steering gear housing and remove the oil seals.
Unscrew the self-locking nut of the rack piston rod, fixing it in a vise.
Remove the piston and spacers.
Remove the rail.
Press out the cylindrical tube with a mandrel and remove the seals.
Using tool 3086 with an extension sleeve, the larger end of which must protrude from the cylindrical tube, press the guide with the gland and the piston rod O-ring out of the cylindrical tube.
Assembly
Fit the piston rod o-ring, guide and gland assembly into the cylindrical tube and press the assembled assembly into the tube using tool 3086 with the extension sleeve positioned so that the short end is visible.
Apply a light coat of grease to the seals and replace them.
Install the cylindrical tube.
Screw mounting sleeve 3086/2 onto the rack piston rod as far as it will go.
Install the rack into the steering box, then remove the mounting sleeve. Apply grease type AOF 063 000 04 to the rack teeth.
Install piston assembly with spacer washers.
Tighten the rack piston rod self-locking nut.
Replace the right half of the crankcase with seals.
Install the gland and rubber flange buffer.
Connect the right and left parts of the steering gear housing and tighten the self-locking bolts.
Press the oil seals all the way into the spool housing and into the steering gear housing using tools VW 545 and VW 4166.
Install the spool.
Install the spool body with O-ring and washer.
Install the protective cover of the rack with power steering pipes and tighten 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 lines with seals and O-rings.
Install the rack stop assembly by directing the cut of the stop bushing along the longitudinal axis of the rail.
Install the stop cover.
After installing the steering gear, adjust the free play of the steering wheel.
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