Page 1. 48-31. Power steering gear (TRW). WARNING! If the power steering gear
is malfunctioning determine cause ... Type of oil: hydraulic oil, Part No. G 002 ... 3
- 3315/1. 4 - Dial gauge holder VW 387. - Install right side tie rod hand-tight.
48-31
Power steering gear (TRW) WARNING! Do not re-use fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection. If the power steering gear is malfunctioning determine cause using pressure tests and leakage tests. If a malfunction exists, then replace the steering gear.
48-32
Notes: If reservoir fluid is low check steering system for leaks. If leaks occur at line connections, tighten connections, wipe area dry and recheck for leaks. The steering gear can be serviced if the pinion seals or the rack seals in the steering gear are leaking. To check rack seals, loosen the hose clamp on the boot and push boot to one side. Always replace all self-locking nuts and bolts. Do not attempt to weld or straighten steering components. Use only steering gear grease, Part No. AOF 063 000 04, to grease the steering rack. Type of oil: hydraulic oil, Part No. G 002 000 System oil capacity: 0.7-0.9 liter (0.74-0.95 US qt.) Hose/line routing
page 48-48
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1 - Tie rod end, right Separating Checking
page 48-22 Repair Manual, Maintenance
Revised Cabrio tie rod end
page 48-29
2 - 50 Nm (37 ft lb) 3 - Hose clamp 4 - Boot Pull on and off over tie rod Must not be twisted after adjusting toe Not interchangeable with boot for ZF steering gear 5 - Clamp Always replace Tightening
page 48-27
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6 - Tie rod, right 70 Nm (52 ft lb) Removing and installing Adjusting to length
page 48-26
page 48-27
Not interchangeable with tie rod for ZF steering gear Seat dia. of boot - 4 - at tie rod: TRW: 12.7 mm (0.50 in.) ZF: 15 mm (0.59 in.) 7 - Clamp Always replace Tightening
page 48-27
8 - Tie rod, left 70 Nm (52 ft lb) Removing and installing Wheel alignment
page 48-26
page 44-1
Not interchangeable with tie rod for ZF steering gear Seat dia. of boot - 4 - at tie rod: TRW: 12.7 mm (0.50 in.)
ZF: 15 mm (0.59 in.)
48-35
9 - Tie rod end, left Separating Checking
page 48-22 Repair Manual, Maintenance
Revised Cabrio tie rod end
page 48-29
10 - Self-locking hex nut Always replace 30 Nm (22 ft lb) 11 - Pressure balancing line Check for damage (dents, kinks) 12 - Self-locking hex nut Always replace 30 Nm (22 ft lb) 13 - Clamp 14 - Rubber mounting Inside diameter: TRW: 44 mm (1.73 in.) ZF: 50 mm (1.97 in.)
48-36
15 - Steering gear Removing and installing Adjusting
page 48-21
page 48-37
Changes to splines on vehicles from VIN 1HN 002 450 page 48-25 Steering gear with extra servo assistance only available on vehicles up to 66 kW (90 hp) 16 - 30 Nm (22 ft lb) 17 - Lower universal joint Vehicles from VIN 1HN 002 450 18 - Cover disc 19 - Seal Always replace 20 - Union nut 30 Nm (22 ft lb)
page 48-25
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Power steering gear, adjusting when installed TRW Engine switched off Vehicle raised on hoist Wheels in straight ahead position Notes: Adjustment only required when steering play is not correct. Two technicians are required for the adjustment. Adjusting - First technician: turn steering wheel back and forth (approx. 30 from center). If play is excessive, knocking noise will be heard inside vehicle. - Second technician: loosen locking nut, counter hold using 3315/9 and carefully turn adjusting nut in until knocking noise can no longer be heard from vehicle
interior. - Tighten locking nut. - Road test vehicle. Steering wheel must self center without sticking after cornering or maneuvering
48-38
Power steering gear, adjusting with new rack TRW If a new rack has been installed then the steering play must be adjusted as follows: - Drill 5.1 mm diameter hole in center of adjusting screw (center on reverse side). - Thoroughly clean adjustment nut. - Center rack by measuring left and right-hand overhang. - Install thrust piece and spring in housing (if not already installed). - Turn adjusting screw and lock nut into housing until markings are covered.
48-39
- Attach dial indicator and set to "0" position with approx. 1 mm (0.039 in.) preload. Make sure that the dial indicator does not stick and its face is not damaged or deformed. 1 - 3315/8 2 - 3315/9 3 - 3315/1 4 - Dial gauge holder VW 387 - Install right side tie rod hand-tight. - Turn rack radially by hand (upper right section of illustration) and measure run out on dial indicator. Max. run out: 0.10 mm (0.0039 in.) - If the run out is greater than 0.10 mm (0.0039 in.), turn adjusting nut out of housing slightly. - Tighten lock nut. - Recheck run out and repeat adjustment if necessary. - Remove dial indicator.
48-40
Sealing hole in adjustment nut with plug from repair kit - Insert clip -2- with seal -1- into hole. - Place one drop of sealant in clip hole (arrow) and press plug -3- into clip. Sealant part number: AMV 188 001 02 - Install tie rods
page 48-26 .
