Manual Steering Gear Replace

Fig. 5 Centering Steering Gear:

1. Raise and support vehicle.
2. Remove wheels and press off tie rods with tool VW 266 H or an equivalent.
3. Remove steering gear universal joint bolt.
4. Remove steering rack retaining bolts.
5. Remove rack.
6. Center steering gear with tool 9116, Fig. 5.

NOTE: There are two types of steering tie rods. The new design is machined for a distance of .511 inch (13 mm) on the joint for the rubber stop ring. The old design was machined for a .236 inch (6 mm) distance. Only the new version is available for replacement.

Fig. 6 Tie Rod Ends Installation:

7. Screw tie rods on evenly. Measure from the ridge on the rubber stop ring to steering housing, Fig. 6. Distance ``a'' should equal 2.55 inches ± .0196 inch (65 mm ± 5 mm).
8. Torque tie rod locknuts to 31-41 ft.lbs. (43-57 N-m).
9. Torque rack to crossmember bolts to 14-17 ft.lbs. (20-24 N-m).
10. Torque tie rod to steering knuckle bolts to 22-36 ft.lbs. (30-50 N-m).

Fig. 7 Steering Rack Adjustment:

11. To adjust rack proceed as follows:
a. Tighten adjusting screw until it just touches the thrust washer, Fig. 7.
b. Hold adjusting screw with a suitable wrench, and rotate locknut with a second wrench.