Assembly overview - power steering rack (ZF) — VW

Assembly overview - power steering rack (ZF)
In event of complaints, determine the cause with the help of the pressure test and leakage test, and
fault finding programme running gear No. 10
. If a fault is detected, the power assisted steering rack can be repaired.
Note
Always check steering system for leaks if fluid level in reservoir is low.
If leakage appears near pipe connections, first check lines and connections for leaks, tighten connections as necessary and wipe dry.
Power assisted steering rack can be repaired if leaks occur at steering pinion sealing ring or steering rack seal in steering gear housing.
To check steering rack seals, loosen hose clip on boot and push back boot.
Renew self-locking nuts and bolts.
Welding and straightening work on steering components is not permitted.
Use only
steering rack grease
A0F 063 000 04
for greasing steering rack.
Fluid type:
hydraulic fluid
G 002 000
Fluid capacity in system: 0.7…0.9 l.
Routing of suction and pressure line hoses
Chapter
.
Right track rod ball joint
Pressing off
Anchor
Checking:
Maintenance
Booklet
35
Modification
Modified track rod ball joint for Golf Variant
Chapter
50 Nm
Clamp
Boot
Unscrew track rod ball joint before removing.
Check for wear (slits, cracks); check sealing surfaces and sealing lips for dirt or damage.
Diameter of opening is greater than bellows of TRW power steering rack.
Must not be installed on a TRW power steering rack.
Clamp
Renew - open with pliers
Tightening
Chapter
Must not be installed on a TRW power steering rack.
Left track rod
Removing and installing
Chapter
Diameter of ball joint on seat for bellows ZF: 15 mm ∅ TRW: 12.7 mm ∅
Must not be installed on a TRW power steering rack.
Adjusting to length
Chapter
Clamp
Renew - open with pliers
Tightening
Chapter
Must not be installed on a TRW power steering rack.
Right track rod
Removing and installing
Chapter
Wheel alignment
Chapter
Diameter of ball joint on seat for bellows ZF: 15 mm ∅ TRW: 12.7 mm ∅
Must not be installed on a TRW power steering rack.
Left track rod ball joint
Pressing off
Anchor
Checking:
Maintenance
Booklet
35
Modification
Modified track rod ball joint for Golf Variant
Chapter
Self-locking hexagon nut, 30 Nm
Pressure equalising line
Self-locking hexagon nut, 30 Nm
Clamp
Rubber insert
Inner diameter ZF: 50 mm TRW: 44 mm
Power steering rack
Removing and installing
Chapter
Adjusting
Chapter
.
Checking steering torque
Fault finding programme, running gear No. 10
.
Steering rack with mobility aid, only permitted for vehicles up to 66 kW.
16V and VR6 vehicles have a higher steering torque of approx. 2 Nm
30 Nm
Lower universal joint
Cover washer
O-ring
Renew
Union nut, 30 Nm
Identification plate and manufactures initials