Boot

Boot

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

• Ring socket wrench (V.A.G 1332/7)

• Hose clamp pliers (V.A.G 1921)

• Locking pliers (VAS 6199)

• Ball joint puller (T40010 A)

Removing

Replace the boot each time it is removed.


If the bellow is faulty, moisture and dirt will penetrate into steering gear. There must be a noticeable grease film present on steering rack in area of splines. If grease film is not present, steering gear must be replaced. Steering gear must also be replaced if there is corrosion or steering gear is damaged or worn out.

- Remove the front wheel. Refer to => Wheel
and Tire Guide 44 Removal and Installation.

- Set the wheels to the straight ahead position.

- Remove the noise insulation. Refer to => Body
Exterior 66 Description and Operation.

- Clean the power steering gear and subframe in the boot area.


• While doing this, no dirt must enter the steering gear through the faulty bellows.

- Unscrew the nut - 1 - from the joint pin - 2 - on the tie rod end as far as required to make it flush with the threading on the joint pin. Counterhold when loosening.






• Turn the nut a couple of turns on the pin to protect the threading.

- Use the (T40010 A) to force the tie rod end off of the wheel bearing housing. Next, remove the nut.






• Make sure that both lever arms on the puller are parallel to each other when you exert a great deal of force on them; adjust them so that they are parallel, if necessary.

- Mark the installed position of the nut - 2 - on the tie rod - 1 - for later.






- Loosen nut - 2 -, counterhold on tie rod end - 3 - while doing this.

- Open and remove the spring clip - 3 - using the (V.A.G 1921).






- Remove the clamping sleeve - 1 - and remove the boot - 3 - outward from the power steering gear.

- Remove the tie rod end - 3 - and nut - 2 - from the tie rod - 1 -.






- Pull off bellows with spring clamp from tie rod.

• If corrosion, damage, wear-out or first signs of soiling on steering rack can be seen, complete steering gear must be replaced.

• If no grease film is visible on steering rack, steering gear must also be replaced completely.

Installing

Install in reverse order of removal. Pay attention to the following:

Replace the boot each time it is removed.

Coat the inside of slits in the boot all the way around and evenly with power steering gear grease before installing.
Check the seat for the boot on the steering gear for damage before installing. If the steering gear housing is damaged, replace the steering gear.

Before installing, coat the steering rack with the grease supplied in the repair set.


Do not use other grease under any circumstances.

For this purpose, turn steering to stop toward both sides in succession.

For clearer illustration, steering gear has been removed in the illustration.

- Grease the steering rack on the toothed side - A - and on the thrust piece side with grease.






• To grease the rack, only use power steering gear grease. Keep in mind: There are different types of grease for the left and right.

- Set the wheels to the straight ahead position.

- Guide new clamp and bellows onto tie rod.

- Install the nut - 1 - and tie rod - 3 - up to the marking applied during removal.






- Tighten the nut - 2 - to the specification. Counterhold the tie rod end - 3 -.

The boot/power steering gear sealing surface must be free of grease when installing.

- Slide the boot onto the steering gear housing with a new clamp.

- Make sure the boot is seated correctly on the power steering gear.

- The boot must fit in the groove and on the contour of the power steering gear.

Clamping Sleeves, Installing






- Mount the (V.A.G 1682 A) - 1 - as illustrated. Make sure that the jaws of the clamp tool are seated in the corners - arrows - of the hose clamp.

- Tighten the clamp by turning the spindle using a torque wrench - 2 - (do not tilt the pliers).

• Tightening Specifications:

• Use torque wrench with 5 to 50 Nm range (e.g. (V.A.G 1331) ).

• Make sure the spindle thread on the (V.A.G 1682 A) - 1 - moves easily. Greases with MoS2 grease if necessary.

• If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

- Secure the spring clamp - 3 - on the boot - 2 - using the (V.A.G 1921).






Boot Assembling






• Dimension - a - = 2 mm

Further installation is in the reverse sequence to removal.

Tightening specifications, refer to => [ Electro-Mechanical Steering Gear Assembly Overview ] Removal and Replacement.

Tightening specifications, refer to => [ Electro-Mechanical Steering Gear With Tie Rods Assembly Overview ] Removal and Replacement.

- Axle alignment required; see table. Refer to => [ Wheel Alignment ] Wheel Alignment.

The axle alignment must be performed on a VW/Audi approved alignment stand.