Volkswagen Cars 2000-05

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:

    Front wheels and disengage both tie rod ends.
     
    Low pressure (suction) hose from the pump and drain the system into a catch pan.
     
    At the steering column, the boot clamp, push the boot towards the body and remove the clamp bolt from the universal joint.
     
    On Cabrio models, exhaust manifold and shift linkage bracket.
     
    Rack mounting clamp nuts and clamps.
     

  4.  
  5. At this point on some vehicles, the rack cannot be removed from the body. Support the engine/transaxle and remove the sub-frame bolts to allow the rack to move towards the rear. On Cabrio models, remove the transaxle mount and bracket.
  6.  
  7. Disconnect the power steering hydraulic lines and remove the rack toward the right.
  8.  

To install:

  1. Be sure the mounting bushings are in good condition. Fit the rack assembly into place and tighten the clamp nuts as follows:

    Except New Beetle: 22 ft. lbs. (32 Nm)
     
    New Beetle: 15 ft. lbs. (20 Nm) plus 90°
     

  2.  
  3. Install any sub-frame bolts that were removed.
  4.  
  5. Connect the hydraulic lines and install the steering column universal joint bolt.
  6.  
  7. Fill the system with new fluid and run the engine to check for leaks and bleed the system.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Battery, then the battery box.
     
    Bolt at the steering column U-joint.
     

  4.  
  5. Release the eccentric by turning the T50 Torx® bolt clockwise, then remove the bolt.
  6.  
  7. Before removing the steering column form 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.

  8.  
  9. 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.

  10.  
  11. Move the U-joint down and out of the way.
  12.  
  13. Using Hose Clamps 3094 or equivalent, pinch off the suction and return lines to the steering gear.
  14.  
  15. Remove or disconnect:
    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.

    Click image to see an enlarged view

    Fig. Exploded view of the steering gear mounting-Passat

     

  16.  

To install:

  1. Remove the screw plug to lock the steering gear in the center position with Locking tool VAG 1907 or equivalent, and tighten to 13 ft. lbs. (18 Nm).
  2.  
  3. Insert the steering gear into the vehicle through the left side wheel opening.
  4.  
  5. Hand-tighten mounting bolts 1 and 2.
  6.  
  7. Install bolt 3 and tighten to 48 ft. lbs. (65 Nm), then tighten bolts 1 and 2 to 48 ft. lbs. (65 Nm).
  8.  
  9. Using new sealing gaskets, install the return hose. Banjo bolt: 37 ft. lbs. (50 Nm). Suction hose banjo bolt: 30 ft. lbs. (40 Nm).
  10.  
  11. Connect the left and right tie rods. Mounting through-bolt: 33 ft. lbs. (45 Nm).
  12.  
  13. Install the tie rod opening cover.
  14.  
  15. Fit the J-joint to the steering gear, then insert the Torx® adjusting bolt by turning it clockwise.
  16.  
  17. Remove the Locking tool VAG 1907, then reinstall the screw plug and tighten to 13 ft. lbs. (18 Nm).
  18.  
  19. Tighten the adjusting bolt nut to 30 ft. lbs. (40 Nm).
  20.  
  21. Remove the steering wheel lock.
  22.  
  23. Remove the hose clamps 3094, and check the hydraulic fluid.
  24.  
  25. Install the battery tray, then connect the battery.
  26.  

 
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