Removing and installing power steering box (LHD vehicles) — AUDI

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Opens: power steering fluid
• Special tools named: puller
• Renewed: bulkhead seal

Don't miss

• Always renew bulkhead seal if damaged.Make sure bulkhead seal is properly positioned in bulkhead.
• Servotronic connector is located above solenoid valve block for air suspension (2) on A-pillar.
• For illustration purposes, bolt (3) is shown from inside. It is located exactly behind banjo bolts (1) and (2) next to servotronic solenoid valve N119.
• Bolt (4) can only be removed when taking out steering box.
• Ensure that bulkhead seal is not damaged by steering box pinion.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Remove driver's storage compartment 68.
2. Use cable tie (A) to secure universal joint (2) at steering column.
3. Position vehicle on lifting platform .
4. Carefully pull engine cover panel off 4 mounting studs (arrows).
5. Remove turbocharger heat shield (arrows).

6. Remove nuts (1).
7. Remove centre heat shield (3).
8. Detach left heat shield (arrow 1) for steering box (arrow 2) and move clear to the bottom.
9. Remove catalytic converter 26.
10. Remove wheel trim; on light-alloy wheels, pull off trim cap (use puller in vehicle tool kit).
11. Remove front wheels.
12. Secure brake disc with one wheel bolt.
13. Remove wheel housing liners (front left and front right) 66.
14. Draw off hydraulic fluid from reservoir using oil extractorV.A.G 1358 A.
15. Remove screw plug (arrow) from steering box.
16. Set steering box to centre position
17. Remove trim in wheel housings (left and right) (arrows).
18. Move aside bulkhead seal (1).
19. Unscrew bolt (2) from universal joint (3). [Note: Always renew bulkhead seal if damaged.Make sure bulkhead seal is properly positioned in bulkhead.]
20. Detach electrical connector for servotronic solenoid valve N119(1). [Note: Servotronic connector is located above solenoid valve block for air suspension (2) on A-pillar.]
21. Place drip trayV.A.G 1306 underneath to catch hydraulic fluid.
22. Detach hose clip (4) from suction hose (3).
23. Disconnect suction hose (3) and move to one side.
24. Remove banjo bolt (2) for expansion hose (1).
25. Allow hydraulic fluid to drain.
26. Then close off connections at hydraulic pump, expansion hose and suction hose by fitting clean plugs.
27. Detach hose clip from suction hose (1).
28. Disconnect suction hose from power steering pump.
29. Unscrew pressure pipe (2) from power steering pump.
30. Allow hydraulic fluid to drain.
31. Then close off connections at hydraulic pump, expansion hose and suction hose by fitting clean plugs.
32. Unscrew bolt (4) and nut (5).
33. Pull or press track rod downwards out of steering arm.
34. Unscrew nut (1), take out bolt (2) and lift out both links (3). [Note: Do not apply chisel or similar between steering arm (1) and seal (2) on track rod ball joint to press out track rod, as this would damage seal.When pressing track rod out of steering arm, apply pressure only to end of track rod ball joint, or knock out end of joint using a wooden or rubber mallet.]
35. Remove encapsulation around track rod.
36. Turn wheel bearing housing to left side and secure in position.
37. Place a cloth underneath to catch hydraulic fluid.
38. Remove banjo bolt (1).
39. Remove banjo bolt (2) using offset ring spanner (e.g. Hazet 615).
40. Pull return pipe as far as possible towards right side in direction of bulkhead.
41. Remove bolt (3) from steering box. [Note: For illustration purposes, bolt (3) is shown from inside. It is located exactly behind banjo bolts (1) and (2) next to servotronic solenoid valve N119.]
42. Remove bolt (4) from steering box. [Note: Bolt (4) can only be removed when taking out steering box.]
43. Extract coolant from expansion tank using oil extractorV.A.G 1358 A. Detach hose leading to expansion tank.
44. Unscrew bolt (arrow).
45. Slide steering box slightly to right to permit removal of bolt (arrow) from steering box.
46. Guide steering box to left as far as possible and pivot 90° in anti-clockwise direction.
47. Then guide steering box to left as far as possible once again and pivot a further 90° in anti-clockwise direction. [Note: Ensure that bulkhead seal is not damaged by steering box pinion.]
48. Take out steering box towards the left side.
49. Unclip wire for servotronic solenoid valve N119 from transport retainers.
50. Insert steering box from left side and at the same time fit front left bolt in steering box.
51. Slide steering box towards right side until right bolt can be inserted in steering box.
52. Position steering box on plenum chamber (2nd mechanic required). [Note: Make sure threads and contact surfaces of bolts are free from oil and grease.]
53. Screw in but do not tighten bolts.
54. Start by tightening bolt (A).
55. Then tighten bolt (B).
56. Finally tighten bolt (C).
57. Use insert tool T40037 for tightening this bolt.
58. Set steering wheel to centre position and then attach universal joint to steering pinion.
59. Tighten banjo bolt (1).
60. Tighten banjo bolt (2) using offset ring spanner (e.g. Hazet 615) .

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