Assembly overview: power assisted steering box (ZF) — 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 the power assisted steering box can be serviced.

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
Splitting =>Page
48-35
Checking:

=> Maintenance

Modification

Modified Golf estate ball joints => Page
48-45

50 Nm
Hose clip
Bellows
Remove ball joint before removing
Check for wear (cuts, cracks), ensure sealing surfaces and sealing lips are clean and undamaged
The end diameters are larger than the bellows for TRW power assisted steering boxes
Must not be installed on TRW power assisted steering box

Hose clip
Renew - use pliers to open
Tensioning => Page
48-49
Must not be installed on a TRW power assisted steering box

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

Hose clip
Renew - use pliers to open
Tensioning => Page
48-49
Must not be installed on a TRW power assisted steering box

Right-hand track rod
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
Must not be installed on a TRW power assisted steering box

Track rod ball joint, left
Splitting =>Page
48-35
Checking:

=> Maintenance

Modification

Modified Golf estate ball joints => Page
48-45

Self-locking hexagon nut, 30 Nm
Pressure balance pipe
Self-locking hexagon nut, 30 Nm
Clamp

Rubber mounting
Internal diameter
ZF: 50 mm
TRW: 44 mm

Power assisted steering box
Removing and installing => Page
48-34
Adjusting => Page
48-109
Checking steering moment

=> Fault finding, running gear No. 10

Steering box with extra servo assistance only available for vehicles up to 66 kW
Steering moment on 16 V and VR 6 vehicles is approx. 2 Nm higher

30 Nm
Lower universal joint
Cover disc
Sealing ring
Renew

Union nut, 30 Nm
Data plate and company initials