Audi Cars 1999-05

Removal & Installation

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  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.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery
     
    Driver-s side storage compartment
     
    Set wheels straight ahead
     
    Nut and bolt at universal joint at lower end of steering column
     

  4.  
  5. Pull the steering column from the steering column.
  6.  
  7. With the steering wheel centered, remove the ignition key.
  8.  
  9. Pinch off the intake and return power steering hoses.
  10.  
  11. Remove the front wheels.
  12.  
  13. Remove the tie rod end from the steering knuckle connection.
  14.  
  15. Remove the steering column opening cover from the dash panel.
  16.  
  17. If necessary, remove the left exhaust pipe.
  18.  
  19. Drain the power steering fluid by removing the banjo bolts from the steering gear.
  20.  
  21. Remove the steering gear mounting bolts from the cross member and remove the steering gear through the left wheel housing.
  22.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the steering rack assembly-A6

  1. Steering gear into the vehicle. Temporarily install mounting bolts from above, but do not tighten.
  2.  
  3. Install the single mounting bolt from below and tighten.
  4.  
  5. Install the return hose and tighten the banjo bolt to 37 ft. lbs. (50 Nm).
  6.  
  7. Screw of the pressure hose and tighten the banjo fitting to 30 ft. lbs. (40 Nm).
  8.  
  9. Install the ignition key and release the steering lock.
  10.  
  11. Center the steering wheel, then install the universal joint to the steering gear pinion.
  12.  
  13. Install the eccentric bolt and tighten in a counterclockwise direction.
  14.  
  15. Install and tighten a new self-locking nut on the eccentric bolt. Torque the nut to 22 ft. lbs. (30 Nm).
  16.  
  17. Install the driver-s side storage compartment.
  18.  
  19. Install the dash panel cover.
  20.  
  21. Fully tighten steering gear mounting bolts in cross member.
  22.  
  23. Remove the power steering hose pinchers.
  24.  
  25. Install the front wheels and battery.
  26.  
  27. Refill the power steering fluid.
  28.  
  29. Start the engine, cycle the steering wheel from lock to lock. Turn the engine off and check and top up the power steering fluid.
  30.  



Click image to see an enlarged view

Fig. Exploded view of the steering gear mounting-A4 models

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery
     
    Battery box
     
    Steering column U-joint bolt
     

  4.  
  5. Release the eccentric by turning the Torx® T50 bolt clockwise, then remove the bolt.
    NOTE
    Before removing the steering column from the steering gear, secure the steering column with safety wire.


    WARNING
    Be sure to lock the steering wheel, otherwise the air bag unit coil spring may be damaged.

  6.  
  7. Lock the steering wheel in the center position and do not move during the repairs.
    NOTE
    The splines between the top and bottom part of the steering column must not be separated.

  8.  
  9. Move the U-joint down and out of the way.
  10.  
  11. Using hose clamps tool 3094, pinch off the suction and return lines to the steering gear.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Place a drip tray under the vehicle to catch any residual power steering fluid.



    Front wheels
     
    Left and right tie rods
     
    Tie rod opening cover
     



    Banjo bolts for the steering gear suction and return hydraulic hoses
     
    Steering gear mounting bolts
     
    Steering gear through the left side wheel opening
     

  14.  

To install:

  1. Remove the screw plug to lock the steering gear in the center position with locking tool VAG 1907 and torque to 13 ft. lbs. (18 Nm)
  2.  
  3. Install or connect the following:

    Steering gear through the left side wheel opening. Torque bolt No. 3 to 48 ft. lbs. (65 Nm) and bolts No. 1 and 2 to 48 ft. lbs. (65 Nm).
     
    Power steering gear hoses using new sealing gaskets. Torque the return hose banjo bolt to 37 ft. lbs. (50 Nm) and the suction hose banjo bolt to 30 ft. lbs. (40 Nm).
     
    Left and right tie rods. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Tie rod opening cover
     
    U-joint to the steering gear and the Torx® adjusting bolt by turning it clockwise
     

  4.  
  5. Remove the locking tool VAG 1907.
  6.  
  7. Install or connect the following:

    Screw plug. Torque it to 13 ft. lbs. (18 Nm)
     
    Adjusting bolt. Torque the nut to 30 ft. lbs. (40 Nm)
     

  8.  
  9. Remove the steering wheel lock
  10.  
  11. Remove the Hose Clamp tools 3094 and check the hydraulic fluid
  12.  
  13. Install or connect the following:
    WARNING
    If the hydraulic fluid requires being topped of, use only an approved fluid, otherwise internal damage may occur.



    Battery tray
     
    Battery
     

  14.  
  15. Start the vehicle and check for leaks.
  16.  
  17. Check and/or adjust the wheel alignment.
  18.  



Click image to see an enlarged view

Fig. Exploded view of the steering gear mounting-A4 models

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Secure the front wheel in a straight ahead position.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Place a drip tray under the vehicle to catch any residual power steering fluid.



    Cover in back of brake pedal
     
    Steering column U-joint bolt
     
    Engine undercover
     
    Hydraulic hose bracket on left subframe
     
    Servo reservoir suction hose
     
    Servo reservoir return line
     
    Front wheels
     
    Left and right tie rods
     



    Banjo bolts for the steering gear suction and return hydraulic hoses
     
    Sway brace support on transaxle side
     

  6.  
  7. Place a suitable jack under steering gear subframe.
  8.  
  9. Remove the bolts and screws from subframe.
  10.  
  11. Pry off subframe using a tire iron and carefully lower it.
  12.  
  13. Unbolt steering gear return line from clamp and rotary slide valve housing.

    Steering gear mounting bolts
     
    Steering gear through the left side wheel opening
     

  14.  

To install:

  1. Remove the screw plug to lock the steering gear in the center position with locking tool VAG 1907 and torque to 13 ft. lbs. (18 Nm)
  2.  
  3. Install or connect the following:

    Steering gear with guide sleeve into subframe and hand-tighten the bolts.
     
    Return line to clamp on steering gear
     
    Return line with new gaskets to rotary slide valve housing
     

  4.  
  5. Check sealing cuff at the steering pinion for proper seating.
  6.  
  7. Raise the subframe and insert steering pinion into hole on underside of vehicle. Bolt on subframe with old bolts. Torque subframe bolts to: 74 ft. lbs. (100 Nm) plus90°. Torque steering gear bolts to 15 ft. lbs. (20 Nm).
    NOTE
    Replace old bolts of subframe when aligning the vehicle.

  8.  
  9. Install or connect the following:

    Expansion hose with new gaskets to rotary slide valve housing
     
    Sway brace support and exhaust system bracket. Torque sway brace side bolts: 15 ft. lbs. (20 Nm) plus 90°, sway brace bottom bolts: 30 ft. lbs. (40 Nm) plus 90°
     
    Tie rods in steering knuckle and bolt on. If joint bolt also turns when tightening, counterhold with internal Torx screw (T40). Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Return line to servo fluid reservoir
     
    Engine undercover.
     

  10.  
  11. Slide universal joint onto steering pinion and secure with new bolts. Torque the bolts to: 22 ft. lbs. (30 Nm).
  12.  
  13. Install cover behind brake pedal.
    WARNING
    If the hydraulic fluid requires being topped of, use only an approved fluid, otherwise internal damage may occur.

  14.  
  15. Start the vehicle and check for leaks.
  16.  
  17. Check and/or adjust the wheel alignment.
  18.  

 
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