48-21

Power steering, servicing

Power steering gear, removing and
installing

CAUTION!

Pay special attention to the following rules of

cleanliness when working on the power
steering.

Thoroughly clean all connections and adjacent

areas before disconnecting.

Place parts that have been removed on a clean

surface and cover.

Do not use fluffy cloths.

Carefully cover or seal opened components if

the repairs cannot be completed immediately.

Only install clean components.

Only unpack replacement parts immediately

prior to installation.
Do not use parts which have been stored loose
(e.g. in tool box).

When the system is open do not work with

compressed air or move the vehicle if it can be
avoided.
 48-22

Removing

- Separate tie rod ends from steering arms.

A - Ball joint separator (commercial type) e.g. Kukko 128/2

- Remove universal joint shaft bolts (arrows).

- Using oil extractor, remove and discard hydraulic oil from reservoir.
Use suction device, e.g. Fluid Evacuators Co. Model EX-1, or equivalent
If no oil extractor is available, remove suction hose at power steering pump
and drain oil
 48-23

- Support engine/transmission assembly using engine support bridge 10-222A

and bracket 10-222A/1.
- Remove steering gear boot from its seat on steering gear.
- Remove subframe bolts.
- Lower engine/transmission assembly.
Two halves of universal joint will pull apart
- Disconnect hydraulic lines from steering gear and seal with plastic bags and
tape.
- Seal threaded holes on steering gear with plastic plugs.
Alternatively use plug, Part No. 113 301 229 A, banjo-bolt, Part No. N 904 674
01 and several 16 mm sealing washers
- Remove steering gear retaining nuts (bolts remain in subframe).
- Remove steering gear rearward.

CAUTION!

Part numbers are for reference only. Always check with your Parts
department for latest information.
 48-24

Installing

- Install in reverse order of removal.

- Align front end and check position of steering

wheel.

Notes:

When lifting the engine/transmission assembly the lower half -A- of the joint
shaft must be guided into the upper half -B- of the joint shaft (2nd technician
required).
Coat boot with lubricant, e.g. soft soap, before pulling onto the steering gear.

Tightening torques

Joint shaft halves 25 Nm (18 ft lb)

Steering gear 30 Nm (22 ft lb)
Tie rod end 35 Nm (26 ft lb)
Subframe front and rear 70 Nm (52 ft lb) plus additional 1/4-turn (90 )
Rear subframe bracket 65 Nm (48 ft lb)
 48-25

Changes to splines on steering gear

pinion and steering column universal
joint shaft

1 - Steering pinion shaft

Previous: 36 splines
New: 22 splines
2 - Lower universal joint fork
Previous: 36 splines
New: 22 splines
3 - Steering gear

Notes:
Steering gear with 36 splines on the steering pinion are not available as
replacement parts. If a 36 spline steering gear is being changed to a 22 spline
steering gear, then also install a new universal joint with 22 splines.
Mixed installation is not permissible; e.g. old pinion (36 splines) and new
universal joint (22 splines).
 48-26

Tie rods (TRW or ZF), removing and

installing

Removing

Note:

Only remove and install tie rods when the

steering gear has been removed page 48-21 .

- Seal hydraulic line connections on steering gear.

1 - Plastic plug
2 - Plastic plug
- Clean outside of steering gear in area of boot.
- Open clamp and push back boot.

- Hold steering gear by clamping rack in vise and remove tie rod.
If possible use open end wrench instead of vise
If using vise, remove contaminates such as metal filings etc. (if necessary)
 48-27

Installing

- Check tie rod length dimension -a- on left tie rod and adjust if necessary.
Dimension -a- = 406 1 mm (15.98 0.04 in.)
- Install tie rod and lock.
Tightening torque: 80 Nm (59 ft lb)

Notes:
Only adjust toe on the right tie rod.
If the left tie rod end must be removed, adjust to dimension -a- when
reinstalling.
New left tie rods must be checked for dimension -a- and, if necessary, adjusted
before installation.
- Check boots for wear (cuts, cracks) and check boot sealing surfaces for
cleanliness.
- Turn tie rod end to correct position and install boot.
- Insert pressure balancing line.

Notes:

Do not damage sticker -A- when pushing boot on (TRW steering gear only).
Make sure pressure balancing line and boots are correctly fitted.
Use only genuine replacement clamps -B-.
 48-28

- Tension clamps using pliers VAG 1275 or equivalent.

Note:

The boots must never be twisted (arrows) when installed.

 48-29

Revised tie rod end, Cabrio

From VIN 1ES 000 001, all Cabrio vehicles are
equipped with a revised tie rod end with a new
pin that is 3 mm (1/8 in.) longer than the previous
pin. Only these revised tie rod ends will be
supplied as replacement parts. Identifying
page 48-30 .

For vehicles up to VIN 1ER 030 000, if one tie

rod end is to be replaced with the newer revised
tie rod end then both tie rod ends must be
replaced.

CAUTION!

DO NOT install two different types of tie rod

end in the same vehicle!

For vehicles from VIN 1ER 030 000, equipped

with the revised tie rod end, individual tie rod
ends can be installed.
 48-30

Identifying tie rod ends

Up to VIN 1ER 030 000

1 - Manufacturer: TRW Vehicle Systems

Centered mark on pin (arrow -A-)
Manufacture's mark "ECO" on lower side
2 - Manufacturer: Lemfoerder Metallwaren
Conical recess on pin (arrow -B-)
Manufacture's mark "LMO" or "LME" on lower side

From VIN 1ES 000 001

1 - Manufacturer: TRW Vehicle Systems

Cylindrical recess and centered mark (arrow -A-) on pin
Manufacture's mark "ECO" on lower side