Assembly overview: power assisted steering box (TRW) — VW

If complaints are received determine cause with the help of pressure tests, leakage test and fault finding programme, running gear No. 10. If a fault exists then service assisted steering box.

Notes:

If reservoir fluid level is low then check steering system for leaks.
In the case of leaks at the pipe connections first tighten connections and wipe dry then recheck for leaks.
The steering box can be serviced if the pinion seal or the rack seals in steering box housing are leaking.
To check the rack seals loosen the hose clip on the bellows and push bellows to one side.
Renew self-locking nuts and bolts. Welding and straightening work on steering components is not permitted.
To grease the rack only use steering box grease Part No. AOF 063 000 04.

Type of oil: Hydraulic oil G 002 000
Oil system capacity: 0.7 ... 0.9 ltr.
Supply and pressure pipe routing
=> Page
48-110
.

Track rod ball joint, right

Modification

Modified Golf estate ball joints => Page
48-45
Splitting =>Page
48-35
Checking:

=> Maintenance

50 Nm
Hose clip
Bellows
Pull on and off over track rod
Must not be twisted after adjusting track
Must not be installed on a ZF power assisted steering box

Hose clip
Renew - open with pliers
Tensioning => Page
48-49

Left-hand track rod
70 Nm
Removing and installing
=> Page
48-47
Adjusting to length
=> Page
48-48
Track rod bellows seat diameter
ZF: 15 mm ø
TRW: 12.7 mm ø
Must not be installed on a ZF power assisted steering box

Hose clip
Renew - open with pliers
Tensioning => Page
48-49

Right-hand track rod
70 Nm
Removing and installing
=> Page
48-47
Vehicle alignment => Page
44-1
Track rod bellows seat diameter
ZF: 15 mm ø
TRW: 12.7 mm ø
It must not be installed on a ZF power assisted steering box

Track rod ball joint, left

Modification

Modified Golf estate ball joints => Page
48-45
Splitting =>Page
48-35
Checking:

=> Maintenance

Self-locking hexagon nut, 30 Nm
Pressure balancing pipe
Check for damage (dents, kinks)

Self-locking hexagon nut, 30 Nm
Clamp
Rubber mounting
Internal diameter
ZF: 50 mm
TRW: 44 mm

Steering box
Removing and installing
=> Page
48-34
Adjusting => Page
48-74
Checking steering moment

=> Fault finding, running gear No. 10

Steering box with extra servo assistance only available for vehicles up to 66 kW
Modified splines on vehicles from Chassis No. 1HN 002 450 => Page
48-44
Steering moment on16 V and VR 6 vehicles is approx. 2 Nm higher
Servicing => Page
48-50

30 Nm
Lower universal joint
From Chassis No.
1HN 002 450 modified splines => Page
48-8

Cover disc
Sealing ring
Renew

Union nut, 30 Nm