VW Passat & Audi A4 1990-2000

Power Steering Rack

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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 necess