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    VW Passat & Audi A4 1990-2000

    Power Steering Rack

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    Click image to see an enlarged view

    Fig. An exploded view of the power steering rack and related components-A4 2.8L model illustrated

    REMOVAL & INSTALLATION
    1990-97 Passat Models
    1. Note the radio security code and disconnect the negative battery cable.
    2.  
    3. Install an engine support cradle. For information on supporting the engine please refer to the following topic(s): Drive Train, Automatic Transaxle Removal, Manual Transaxle Removal
    4.  
    5. Raise and safely support the vehicle.
    6.  
    7. Remove the wheels.
    8.  
    9. Using a suitable tie rod end removal tool, remove the tie rod ends from the bearing housing.
    10.  
    11. Remove the lower dash trim to access the steering column u-joint and loosen the nut on the u-joint.
    12.  
    13. Extract the hydraulic fluid from the power steering reservoir using a siphon gun, or place a drain pan under the power steering pump and disconnect the supply hose and allow the fluid to drain.
    14.  
    15. Make sure the engine is properly supported by the support cradle.
    16.  
    17. Remove the steering gear to column protective boot.
    18.  
    19. Remove the subframe bolts, and then lower the engine assembly until the steering shaft u-joint is disconnected.
    20.  
    21. Disconnect the steering hoses and cover with a clean plastic bag and seal the holes in the steering rack with suitable plugs.
    22.  
    23. Remove the steering gear mounting nuts leaving the bolts in the subframe and remove the steering rack to the rear.
    24.  

    To install:

    1. Install the steering rack onto the subframe and tighten the fasteners to:
    2.  
    3. Steering rack-to-subframe: 22 ft. lbs. (30 Nm)
    4.  
    5. Carefully raise the engine assembly and with the help of an assistant, guide the coupling together at the u-joints and tighten to:
    6.  
    7. Steering rack coupling-to-steering column: 18 ft. lbs. (25 Nm)
    8.  
    9. Coat the coupling boot with soft soap to lubricate and slide in place.
    10.  
    11. Install the subframe mounts and rear bracket fasteners and tighten as follows:
    12.  

    Subframe mount-to-under body:



    Step 1: 52 ft. lbs. (70 Nm)
     
    Step 2: 90° ( 1 / 4 turn)
     
    Rear subframe bracket: 48 ft. lbs. (65 Nm)
     

    1. The balance of the installation is in reverse order of removal noting the following:
    2.  
    3. Top off the power steering fluid, using the recommended fluid type and amount. For additional information, please refer to the following topic(s): General Information and Maintenance, Fluids and Lubricants.
    4.  
    5. Make sure the ignition switch is in the OFF position before connecting the battery.
    6.  
    7. Properly bleed the pump as outlined in Power Steering Pump Bleeding.
    8.  
    9. Check the alignment and adjust as necessary.
    10.  

    A4 & 1998-00 Passat Models
    1. Note the radio security code and disconnect the negative battery cable.
    2.  
    3. Remove the battery.
    4.  
    5. Remove the driver's side stowage compartment.
    6.  
    7. Center the steering wheel and remove the ignition key.
    8.  
    9. Move steering wheel until the steering lock engages.
    10.  
    11. From under the dash, using mechanic's wire or tie wraps, route them through the hole in the column and secure the steering column to the hairpin spring eyes, to prevent the column from falling downward when the rack is removed.
    12.  


    WARNING
    Failure to support the steering column may damage the horn and air bag spool.

    1. Remove the nut on the steering column u-joint, then using a Torx® T50 socket, relieve the tension by turning the bolt clockwise and remove the bolt.
    2.  
    3. Pull the u-joint downward off the steering rack.
    4.  
    5. Using a hose clamping pliers, clamp off the suction and return lines.
    6.  
    7. Slightly loosen the wheel bolts, then raise and safely support the vehicle.
    8.  
    9. Remove the front wheels, and then disconnect the tie rod ends.
    10.  
    11. Remove the tie rod plastic body covers by prying off the clips and removing the nuts.
    12.  
    13. Place a suitable drain pan under the vehicle.
    14.  
    15. Using a 22mm ( 7 / 8 inch) socket, loosen, drain and remove the banjo bolts on the steering housing.
    16.  
    17. Using a 19mm ( 3 / 4 inch) socket, loosen, drain and remove the remaining banjo bolt on the steering housing.
    18.  
    19. Remove the steering rack mounting bolts and with the help of an assistant, remove the steering rack out through the left side wheel housing.
    20.  

    To install:

    1. Center the steering rack as follows;
    2.  
      1. Removing the hex or inverted Torx® bolt near the left boot and pinion gear case area on the front of the rack.
      2.  
      3. Move the rack until the dimple in the rack is visible through the threaded hole in the housing.
      4.  
      5. Install a bolt, such as Tool No. VAG 1907, with a tapered pointed end that is the same diameter and thread pitch as the remove bolt, to lock the rack centered in place.
      6.  

    3. Slide the rack through the left side of the vehicle and while holding in place, loosely install the top two bolts, then install the bottom bolt. Tighten the bolts to 48 ft. lbs. (65 Nm)
    4.  
    5. Install the large return hose using new sealing washers and tighten to 37 ft. lbs. (50 Nm)
    6.  
    7. Install the smaller pressure hose using new sealing washers and tighten to 30 ft. lbs. (40 Nm)
    8.  
    9. Remove the bolt used to center the rack and install the socket head bolt previously removed and torque to 13 ft. lbs. (18 Nm)
    10.  
    11. Install the steering shaft U-joint, remove the temporary support device and insert the Torx® T50 tensioning bolt turning it counterclockwise to tension, then install the lock nut and torque to 30 ft. lbs. (40 Nm)
    12.  
    13. The balance of the installation is in reverse order of removal noting the following:
    14.  
    15. Remove the hose clamping pliers and top off the power steering fluid using the recommended fluid type and amount. For additional information, please refer to the following topic(s): General Information and Maintenance, Fluids and Lubricants.
    16.  
    17. Make sure the ignition switch is in the OFF position before connecting the battery.
    18.  
    19. Properly bleed the pump as outlined in Power Steering Pump Bleeding.
    20.  
    21. Check the alignment and adjust as necessary.
    22.  

     
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