Repairing ZF power assisted steering box — VW

Repairing ZF power assisted steering box
This repair is restricted to renewing the seals and if necessary the steering rack. Steering boxes which have been damaged in an accident must always be renewed!
For problem-free and successful repairs the greatest possible care, cleanliness, expertise and the correct tools in good condition are necessary.
Note
Thoroughly clean hose connections and their immediate vicinity before loosening.
Thoroughly clean work place (bench, vice) before commencing work and if necessary cover work surface e.g. with paper towels.
Place parts which have been removed on a clean surface. If the repair is not carried out immediately, cover parts.
Only use lint-free cloths.
Only unpack replacement parts immediately prior to fitting.
Only use genuine packed parts.
Corroded steering racks must not be reused.
Two different repair kits are available for ZF steering boxes. Refer to
Electronic parts catalogue
for allocation via part number of affected steering box.
Track rod
Boot
Hose clamp
Renew.
Retaining ring
Renew.
Steering rack guide
Version differs depending on steering box; allocated to relevant steering box via repair kit.
Renew.
O-ring
Is fitted to the steering rack guide (
Item
) in repair kit.
Pressure balancing pipe
Check for damage (dents, kinks).
Guide ring (slotted)
Renew if fitted.
Steering rack
Adjustment bolt
Hexagon bolt, 7 Nm
Cover
O-ring
Renew.
Spring
Washer
O-ring
Renew.
Thrust piece
Union nut, 30 Nm
O-ring
Renew.
Not contained in repair kit
Electronic parts catalogue
.
Oil seal
Renew.
Roller bearing
Valve body
Cannot be repaired.
Is not available as spare part, if damaged renew steering box.
Bush with roller bearing
Is supplied as assembly with oil seal and bearing in repair kit.
Renew.
O-ring
Pre-assembled on bush in repair kit
Item
.
Retaining ring
Renew.
Housing
Check cylinder contact surface for scoring, if necessary renew steering box complete.
Oil seal
Renew.
Support ring
Renew.
Ball bearing
Torx screw, 35 Nm
Renew.
Self-locking.
Screw plug, 30 Nm
O-ring
Not available as spare part.
Pipe
Must not be detached
Not available as spare part.
Oil seal
A white or black oil seal is used depending on steering box.
O-ring
Different O-rings are used depending on steering box.
O-ring/oil seal allocation
Item
.
30.0 x 1.78 - white oil seal.
31.0 x 1.5 - black oil seal.
Is already fitted to new steering racks supplied as spare parts.