Dismantling, assembling and adjusting roller steering — VW

Special tools and workshop equipment required

VW 227
VW 277

VW 278b

VW 279

VW 280

VW 423

VW 758/1
Screwdriver
Feeler gauge of 0.05 mm
Rattle

Secure steering box on upper anchor

Fig.1
Fixture for steering box

Secure steering box on upper fixture tube, so that the fixture cut out for the different models (left-hand and right-hand drive vehicles) shows to the left side and the corresponding arrow forwards.
13 = for VW 1600

Dismantling, assembling and adjusting steering gearbox

Dismantling

Fig.2
Screw steering box into assembly and tester tool VW 280

The exact position is determined by the stop in the mounting tube.

A -
VW280

Fig.3
Take steering box housing cover off

Unscrew securing bolt lock nut and cover securing bolts first.

Fig. 4
Removing adjustment rod

To do this centre steering shaft. Remove grease and take securing bolt off steering roller shaft bolt.
Take adjustment bolt together with shim off.

Fig. 5
Removing steering shaft

Unscrew adjustment bolt lock nut.

A -
VW 277

Fig. 6
Removing steering shaft

Take adjustment screw off. Press out steering shaft together with angular contact ball bearing (use rubber headed hammer).

A -
VW 278b

Fig.7
Take seal ring off steering shaft, disk and upper angular contact ball bearing

A -
VW 423

Assembling

Fig.8
Install steering shaft together with upper angular contact ball bearing and disk

Install disk with a diameter of (0.35 mm) first. The definitive disk is determined with the tools VW 279 and VW 280 => Page
48-31
Install lower angular contact ball bearing.

Fig.9
Fit adjustment bolt

Use sealant. Tighten bolt lightly so that the lower angular contact ball bearings fit into their installation position.

A -
VW 278b

Fig.10
Adjust steering shaft moment of friccion

Unscrew adjustment bolt and tighten again until the steering shaft does no longer turn. When doing this use torque wrench with the following tightening torque:
0.15 -0.25 Nm.
Tighten adjustment bolt.

A -
VW758/1

Fig. 11
Assembling adjustment rod

a.- Check axial clearance of the steering roller. The clearance must not be greater than 0.04mm.
The clearance is measured with a feeler gauge of 0.05 mm between the roller and the disk. If the gauge enters between both parts the steering shaft must be renewed.

b.- Check adjustment bolt. If the thread or the contact surface are damaged, renew bolt.

A -
Feeler gauge 0.05 mm.

Fig.12
Install adjustment screw together with the disk and the adjustment rod

Select a disk with an appropriate diameter so that the adjustment disk can still be moved in its support with the index finger and the thumb without noticable clearance (disks of 2.0 ... 2.25 mm are available, with a diameter difference of 0.05 mm).

Fig. 13
Assembling adjustment rod and steering box

Screw onto limit stop

Fig.14
Adapt complete steering roller shaft

Install protective sleeve for sealing ring. Install steering roller shaft so that the roller stands at right angles to the spindle.

A -
VW 649

Note:

Fill gearbox grease in after performing the adjustments.

Fig.15
Fit steering box housing cover

Press cover off spindle in direction of arrow until it fits tightly in the housing.

A -
Commercially available rattle

Fig.16
Secure steering lever (only to adjust steering box)

Steering lever of the corresponding model. Check function of steering box by moving the steering lever to and fro.

Adjusting

Fig.17
Secure probe of testing and fitting tool

Probe sender must lie at the steering shaft.

Fig.18
Adjustment of perforated disk

Move disk until the corresponding steering lever number is under the marking.

Fig.19
Bring steering lever in steering central position

a.- Install steering lever so that its right hole can be seen under the corresponding hole of the disk.

b.- Insert testing shaft in the mentioned hole of the perforated disk.

c.- Move steering lever to and fro and move the disk so long, until the shaft is centred in the steering lever hole.

Insert the scale of the tool W 279 in the lever cut-out and secure.

Fig.20
Adjust tool handle

Place display of tool VW 279 to the raised mark of the steering box and set to "0".

A -
VW 279

Take testing shaft out.

Fig.21
Adjust steering box

d.- Turn steering lever 11° to the right or to the left.

Warning:
The value 11
Screw adjustment bolt of steering roller shaft into until no play is perceptible anymore. When doing this move steering lever to and fro by hand and hold steering shaft with the other hand. To secure use a two-armed flange - underside-, which has to be fixed onto the steering shaft.

Install adjustment bolt lock nut.

When turning in opposite direction observe that there is no play.

After passing the central position the steering shaft must be able to be turned (pressure of 9 to 12 kgcm). The steering shaft must not have any perceptible play at 11°± 2°. If there is still a play perceptible at 11°± 2° the steering box must be dismantled again and the steering shaft/steering roller adjustment corrected by installing a new shim.

a.- Alignment of steering without play to the left side of the scale, greater than 11°± 2°:
Install shimsof greater thickness.

a.- Alignment of steering without play to the left side of the scale, smaller than 11°± 2°:
Install a shimof smaller thickness.

Adjustment work must so long be repeated until the required measure is reached. Shims are available from 0.20 to 0.50 mm (grading of 0.05).

After the adjustment work, drive steering shaft seal ring in with VW 423.

Unscrew adjustment bolt lock nut from adjustment rod.

Unscrew steering box housing cover and take off steering column by turning the adjustment bolt.

Fill steering box up with approx. 160 cm3 gearbox grease (according to gear oil specifications).

When filling up pump lightly with the adjustment rod so that air comes out and the required grease quantity can enter the steering box.

Fill the adjustment bolt hole in the adjustment rod with grease up to top.

Insert new plastic plug in the steering box housing cover, if necessary.

Insert cover again with seal. Fit cover bolts. Raise the cover from the steering shaft and tighten hexagon bolt.

Adjust adjustment rod as described previously.

Mark steering central position with a new marking ring for steering shaft. Finally secure the ring with paintwork.

Check steering and adjust again (steering installed)

A - Checking (steering installed)

To check the roller steering it is not necessary to raise the vehicle.

1 -
Bring front wheels to straight-ahead position
2 -
Move steering wheel spoke lightly to and fro until resistance is perceptible. The area around the central position is determined by the steering box adjustment and the transmission parts (steering coupling and joint washer). In the area of the steering the play must not be more than max. 15 mm.

B - Readjust

If there is excessive play around the central position this could have three causes, which are to be checked in the indicated sequence:

a.- Check axial clearance of the steering shaft.

b.- Check clearance between steering roller and steering shaft.

c.- Check axial clearance of steering roller.

Fig.22
Steering box - Checking points

Warning:
Before adjusting the steering box ensure tight seat of securing bolts for the steering box housing cover and check steering box on front axle beam. Loosened bolts must be tightened to the prescribed tightening torque and finally the steering box can be adjusted.
Adjusting roller steering gear

a.- Check axial clearance of steering shaft

The steering shaft axial clearance can be determined by moving the steering shaft on the joint washer to and fro. To do this the vehicle must be raised. If there is play detected, rectify as follows:

Fig.23
Check axial clearance of the steering shaft

Fig.24
Loosen lock nut for adjusting screw

To do this turn steering to the right or the left on full lock.

A -
VW 227

Fig.25
Tighten adjustment bolt

Move steering shaft on steering coupling to and fro. When doing this tighten adjustment bolt until no play is perceptible.

A -
VW 278b

Fig.26
Hold adjustment bolt and tighten lock nut

Turn steering shaft from stop to stop. When doing this no strong stuck must be perceptible in the bearings. When having strong stucks the adjustment bolt is tightened too strong and the adjustment must then be corrected.

1 -
VW 278b
2 -
VW 277

b.- Check clearance between steering roller and steering shaft.

If the steering still has inadmissible play, repeat adjustment of steering roller to steering shaft The steering roller must be placed free of play in the steering shaft - steering in central position -. The adjustment steering roller/steering shaft can be done with raised vehicle. Only when the vehicle must be checked it must stand on its wheels again.

Procedure Bring steering in central position and then turn the steering wheel 90° to the left or to the right.

Loosen lock nut of the adjustment bolt for steering roller shaft and loosen adjustment bolt approx. one turn.

The adjustment bolt is accessible via the handhole cover of the luggage compartment.

Fig.27
Adjustment bolt for roller steering

Screw adjustment bolt into until the steering roller lies at the steering shaft. Hold adjustment bolt and tighten lock nut with a special wrench. Check clearance by turning the steering wheel for 90° in both directions. When doing this the vehicle is standing on its wheels. The measured clearance on the steering wheel must not exceed approx. 15 mm. If there is a bigger play on one of both sides, check adjustment of steering roller to steering shaft again by locking the steering wheel 90° towards this side.
Check tracking, readjust if necessary.

If necessary carry out road test. If the steering does not turn automatically again in the central position (approx. 45°) after passing a curve at a speed of 15 to 20 km/h, it could be that steering roller is adjusted too taut. In this case the adjustment must be corrected to avoid damage of steering shaft and steering roller.

c.- Axial clearance of steering roller

If the described adjustments do not result in a correct steering adjustment, the steering box must be dismantled again and the axial clearance checked, which must not exceed 0.04 mm. The clearance is measured with a feeler gauge of 0.05 mm between the roller and the disk. If the gauge enters between both parts the steering shaft must be renewed.

Fig.28
Check axial clearance of the steering roller

A -
Feeler gauge 0.05 mm.