Generation 1
Generation 1
The generation 1 steering gear cannot be disassembled at this time.
=> [ Boot ]
=> [ Tie Rod ]
Boot
Special tools, testers and auxiliary items required
• Hose Clamp Pliers (V.A.G 1275)
• Torque wrench (V.A.G 1332)
• Tool Insert AF24 (V.A.G 1332/11)
• Locking Pliers (VAS 6199)
Removing
• If boot is faulty, moisture and dirt penetrates 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.
- Turn steering wheel into straight ahead position.
- Remove wheel.
- Clean outside of steering gear in area of bellows.
While doing this, no dirt must enter the steering gear through the faulty boot.
- Mark position of nut - 3 - on tie rod.
- Loosen nut - 3 -, counterhold on tie rod end - 2 - while doing this.
- Loosen spring clamp - 1 - using (V.A.G 1275 ) from boot and slide onto tie rod.
- Remove clamp and pull off boot from steering gear housing.
- Now twist tie rod out of tie rod end.
- Pull off boot with spring clamp from tie rod.
• If corrosion, damage, wear-out or first signs of contamination 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
CAUTION!
Do not lubricate the steering rack.
- Turn steering wheel into straight ahead position.
- Guide new clamp and boot onto tie rod.
- Install the tie rod up to the marking made during removal.
- Tighten lock nut - 3 - to tightening specification, counterhold on tie rod end - 2 - while doing this.
- Slightly grease the sealing surface of the bellow to the tie rod with grease (G 052 168 A1) (from the repair kit, from Fuchs Renolit JP1619).
- Slide boot - 2 - onto tie rod - 1 - as depicted in the illustration.
- Secure spring clamp on boot using (V.A.G 1275).
- Slightly grease the sealing surface of the bellow to the steering gear housing with grease (G 052 168 A1) (from the repair kit, from Fuchs Renolit JP1619).
- Push the boot all the way onto the steering gear housing.
- Tighten new clamp using (VAS 6199) to the extent depicted in the illustration.
Further installation is in the reverse sequence to removal.
- Install wheel and tighten. Refer to => [ Wheel Bolt Tightening Specification ] Specifications.
After the installation the vehicle must be measured.
- Perform vehicle alignment, refer to => [ Vehicle Alignment Procedure Overview ] Vehicle Alignment Procedure Overview.
- Perform basic setting for steering angle sensor ( G85) via => vehicle diagnosis, testing and information system (VAS 5051b), guided fault finding.
- Then perform basic setting of steering system via => vehicle diagnosis, testing and information system (VAS 5051B ) "Guided Fault Finding".
Tightening Specifications
Tie Rod
Special tools, testers and auxiliary items required
• Ball Joint Puller (3287 A)
• Hose Clamp Pliers (V.A.G 1275)
• Torque Wrench (V.A.G 1332)
• Open-Jaw Torque Wrench Insert (V.A.G 1923)
• Locking Pliers (VAS 6199)
Removing
- Turn steering wheel into straight ahead position.
- Clean outside of steering gear in area of boot.
Loosen nut - 3 -, counterhold on tie rod end - 2 - while doing this.
- Remove front wheel.
- Loosen the tie rod nut, but do not remove yet.
To protect thread, screw nut on pin a few turns.
- Press off tie rod ball joint from wheel bearing housing using (3287 A) and now remove nut.
- Loosen spring clamp (item - 1 - in illustration N44-10005 ) using (V.A.G 1275) from bellows and slide onto tie rod.
- Remove clamp and pull off boot from steering gear housing.
- Remove the tie rod from steering gear using (V.A.G 1923 ).
• If corrosion, damage, wear-out or first signs of contamination 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 tie rod
CAUTION!
Do not lubricate the steering rack.
- Turn steering wheel into straight ahead position.
- Guide new clamp and boot onto tie rod.
- Twist tie rod far enough into tie rod end until dimension - a - is obtained.
Dimension - a - = 371 ± 1 mm
- Rotate tie rod in steering rack and tighten.
- Slightly grease the sealing surface of the bellow to the tie rod with grease (G 052 168 A1) (from the repair kit, from Fuchs Renolit JP1619).
- Slide boot - 2 - onto tie rod - 1 -, pay attention to correct position when doing this.
- Secure spring clamp on boot using (V.A.G 1275).
- Slightly grease the sealing surface of the bellow to the steering gear housing with grease (G 052 168 A1) (from the repair kit, from Fuchs Renolit JP1619).
- Slide boot onto steering gear housing until it stops.
- Tighten new clamp using (VAS 6199) to the extent depicted in the illustration.
Further installation is in reverse sequence to removal.
- Install wheel and tighten. Refer to => [ Wheel Bolt Tightening Specification ] Specifications.
After the installation the vehicle must be measured.
- Perform vehicle alignment. Refer to => [ Vehicle Alignment Procedure Overview ] Vehicle Alignment Procedure Overview.
- Perform basic setting for steering angle sensor ( G85) via => vehicle diagnosis, testing and information system (VAS 5051B), guided fault finding.
- Then perform basic setting of steering system via => vehicle diagnosis, testing and information system (VAS 5051B ) guided fault finding.
Tightening Specifications
