Servicing TRW power-assisted steering — VW

Special tools and workshop equipment required

VW 439 Guide pin
V.A.G 1331 Torque wrench
V.A.G 1332 Torque wrench

This repair is restricted to replacing the seals and if necessary the rack. Steering boxes which have been damaged in an accident must always be replaced!

For problem-free and successful repairs the greatest possible consciousness, cleanliness, expertise and the correct tools in good condition are necessary.

Notes:

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.
Only place parts which have been removed on a clean surface. If the repair cannot be completed immediately, cover parts.
Do not use fluffy cloths.
Only unpack replacement parts immediately before fitting.
Only use genuine packed parts.
Corroded racks must not be reused.

Track rod
Repair information => Page
48-110
Removing => Page
48-85
Installing => Page
48-100

Bellows
Installing => Page
48-102
Installation position => Page
48-102

Hose clip
Open with pliers
Installation position => Page
48-103
Tensioning => Page
48-104
Renew

Circlip
Removing => Page
48-88
Installing => Page
48-97
Renew

Securing ring
Removing => Page
48-88
Installing => Page
48-97

Rack guide
Supplied as an assembly with oil seal in repair kit
Renew

Seal
Is fitted to the rack guide (item -
6
-) in repair kit

Pressure balancing pipe
Check for damage (dents, kinks)

Rack
Check for scoring => Page
48-93
After removing coat immediately with hydraulic oil (protection against corrosion)
Can be supplied as replacement part, allocation

=> Replacement parts catalogue

Plug
Is only required when the rack is replaced
To fit drill hose in the adjusting screw => Page
48-108
Is supplied in repair kit

Adjusting screw with lock nut, 60 Nm
Before unscrewing mark position of adjusting screw and lock nut in relation to housing => Page
48-85
Adjusting steering box => Page
48-107

Spring
Thrust piece
Removing => Page
48-86
Mark installation position

Housing
Check cylinder contact surface for scoring, if necessary renew steering box complete

Union bolt, 30 Nm
Seal
Renew
Is not included in repair kit

=> Replacement parts catalogue

Oil seal
Removing => Page
48-88
Installation position => Page
48-91
Installing => Page
48-91
Renew

Valve body
Removing => Page
48-88
Cannot be repaired
Is not available as replacement part, if damaged renew steering box

Support ring
If fitted must be refitted

Adhesive foil
Before sticking on thoroughly clean this area of the housing e.g. with thinners, bonding surface must be free of oil and grease
Renew

Roller bearing
Installation position: Lettering faces upwards

Oil seal
Renew

Circlip
Ball bearing
Drive out with VW 439 downwards from top
Grease with steering box grease AOF 063 000 04
Installing => Page
48-97

Self-locking hexagon nut, 30 Nm
Renew

Plug, 40 Nm
Removing and Installing =>Page
48-87
Renew

Pipe
Do not disconnect
Is not available as replacement part
Seal cannot be replaced

Seal
Is already fitted to new racks which are supplied as a replacement part

Seal
If scoring is visible or can be felt, renew => Page
48-94
Is already fitted to new racks which are supplied as replacement part

Seal
Is not available as replacement part

Oil seal
Renew
Removing => Page
48-90
Installation position => Page
48-92
Installing => Page
48-92