Removing and installing mechanical (manual) steering box: VW Polo 9N

🧭 Before you start

Fits: VW Polo 9N (2001–2009)

Don't miss

• Mark positions of bolts securing swivel joint to suspension link.

📋 Procedure

1. First check if radio is a coded unit. If it is, ask for anti-theft security code.
2. Disconnect earth strap of battery with ignition switched off Electrical system27Battery; Removing and installing battery.
3. Lift vehicle far enough to take weight off front wheels.
4. Undo 12-point drive shaft nut using 36 mm socket T10125.
5. Remove front wheels.

6. Mark positions of bolts securing swivel joint to suspension link.
7. Remove bolts (arrows).
8. Pull wheel bearing housing with swivel joint out of suspension link.
9. Pivot suspension strut outwards and hold in place with a wooden block or similar (1); at the same time pull drive shaft out of wheel bearing.
10. Secure drive shaft to body with wire.
11. Remove front wheels.
12. Remove nuts (arrows).
13. Pull wheel bearing housing with swivel joint out of suspension link.
14. Remove cover (2) - to do this remove plastic nuts (1).
15. Unscrew bolt (1) from universal joint and pull off universal joint in (direction of arrow).
16. Remove nut (1) from track rod.
17. Press track rod ball joint (2) off steering arm.
18. Remove steering box bolts (1) from subframe.
19. Fix position of subframe .
20. Lower subframe using engine and gearbox jackV.A.G 1383 A.
21. Remove steering box to rear.
22. Secure subframe .
23. Remove any locking fluid residue from the teeth/splines on the drive shaft/wheel hub and from the thread of the drive shaft.
24. Apply locking fluid D 185 400 A2 to the teeth/splines (1) (bead diameter 2mm) and the thread (2) (all around) as shown in the picture.
25. Fit drive shaft into wheel bearing.
26. Secure ball joint to suspension link: use new bolts (arrows) on old marks.
27. Bolt swivel joint to suspension link with new nuts (arrows).
28. Bolt steering box to subframe.
29. Bolt track rod to steering arm.
30. Install wheels and tighten bolts or nuts .
31. Tighten 12-point nut using 36 mm socket T10125.
32. Fit universal joint onto steering box pinion.
33. Insert hexagon bolt through lower part and tighten.
34. Fit cover (2) and screw on plastic nuts (1).
35. Encode radioRadio, telephone and navigation system91Radio systems.
36. Connect earth strap of battery Electrical system27Battery; Removing and installing battery.
37. Check toe adjustment .

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