Servicing power-assisted steering — AUDI

Attention
Keep workplace and components spotlessly clean
Notes:

The power-assisted steering uses hydraulic fluid, part no. G 002 000.
All parts marked with an asterisk are contained in the repair set and are to be replaced when servicing.
Moisten all sealing elements with hydraulic fluid before installing.
Welding and straightening repairs are not permitted on the steering components.
Screw clamps can also be used in place of wing hose clamps.

Steering box
Removing and installing =>Page
48-1
Adjust toe after removing and installing
Adjusting toe => Page
44-15
Vehicles with 169 kW engine do not feature Servotronic

Rack seal *
Always replace
Extracting =>Figs.
1
and
2

Circlip
Can only be removed and fitted after taking out rack.

Retaining ring
Slip onto rack as far as it will go.
Insert bellows in annular groove.

Bellows
Can be replaced without removing steering box
Adjust toe after replacement
Adjusting toe => Page
44-15

Wing hose clamp
Use screw clamps when performing repairs
Screw connection faces bulkhead

O-ring *
Always replace

Adjusting screw
Adjusting steering play =>Fig.
5

Hexagon bolt, 20 Nm
Cover
Screw onto steering box
The two adjacent holes must face forwards when viewed in direction of travel.

Sealing ring 35 x 2 mm *
Always replace
Insert in annular groove in steering box

Sealing ring 27 x 2,5 mm *
Always replace
Insert in annular groove in gasket holder

Gasket holder
Disassembling => Fig.
3

Spring
Insert in thrust piece

Thrust piece
Washer
Cheese-head bolt, 20 Nm

Valve housing
Seal *
Replacing =>Page
48-40

Backing ring
Straight pin 2.5 x 6 mm *
Always replace
Pull out with universal pliers before removing valve housing

Rotary valve/steering pinion
Knocking out of steering box => Fig.
4

Sealing ring 60 x 2 mm *
Always replace

Sealing ring 9 x 2 mm *
Always replace

Cap, 50 Nm
Secure with two centre punch marks offset by 180o

Thrust ring *
Always replace
Attach to cap.
Installation position =>Fig.
6

Sealing ring 44 x 2.5 mm *
Always replace
Attach to cap.
Installation position =>Fig.
6

Rack
Unscrew cap and push rack to left out of steering box.
Watch for scoring around rack seal
Fitting =>Page
48-42

Fig.1
Pulling out rack seal

Insert commercially available internal extractor (e.g. KUKKO 21/4) in sealing lip

Fig.2
Screwing multi-purpose tool to internal extractor

Clamp steering box in vice using soft jaws.
Screw -VW 771- with -VW 771/15- to internal extractor and knock out rack seal

Fig.3
Disassembling gasket holder

Pull out using commercially available external circlip pliers

Fig.4
Driving out steering pinion

Hold steering pinion by hand and knock out by hammering on steering box with commercially available rubber hammer.

Fig.5
Adjusting steering play

Note:

Two mechanics are required to perform adjustment. Adjustment work is to be performed with the engine switched off and the vehicle standing on its wheels. For ease of illustration the steering box is shown removed.

Move wheels to straight-ahead position.
Turning the steering wheel back and forth (roughly 30oabout centre axis) produces a rattling and cracking noise.
The second mechanic carefully screws in adjusting screw (arrow) into the cover until rattling and cracking noises can no longer be heard inside the vehicle.
Perform test drive and correct adjustment of necessary.

Fig.6
Installation position of thrust ring

1 -
Screw cap
2 -
Thrust ring
3 -
O-ring