Volkswagen Cars 2000-05

Removal & Installation

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Click image to see an enlarged view

Fig. Use a tie rod end removal tool to pop it loose from the knuckle.


NOTE
This procedure may throw the vehicles wheel alignment (specifically the toe angle) out of specification. A wheel alignment is recommended upon completion of the following steps.

  1. Engage the parking brake.
  2.  
  3. Raise and safely support the vehicle on jack stands and center the steering wheel.
  4.  


NOTE
Do not lift the suspension.

  1. Remove the front wheel(s).
  2.  
  3. Hold the tie-rod end and loosen the jam nut a half turn.
  4.  
  5. Loosen and remove the nut from the tie rod end that attaches it to the steering knuckle.
  6.  
  7. Use a ball joint / tie-rod end separator to pull the tie-rod end from the steering knuckle.
  8.  
  9. Count and record the number of turns that are required to remove the tie-rod end from the rod itself. This will allow you to position the new tie-rod end close to the original mark, thus keeping the vehicles alignment close to specification.
  10.  

To install:


NOTE
A new tie-rod end retaining nut is required any time the nut has been removed.

  1. Clean the tie-rod end threads as well as those on the tie-rod.
  2.  
  3. Install a new tie-rod end onto the tie-rod and thread it to the correct number of threads.
  4.  
  5. Tighten the jam nut to 26 ft. lbs. (35 Nm).
  6.  
  7. Install the tie-rod end into the spindle.
  8.  
  9. Install the lock-nut and tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the tire and wheel assembly. Tighten the lug nuts to 81 ft. lbs. (110 Nm).
  12.  
  13. Lower the vehicle and test the steering.
  14.  
  15. Check to ensure all components have been reinstalled and tightened to the proper setting.
  16.  
  17. Have the vehicles alignment checked by and authorized repair facility.
  18.  

Inner Steering Rods



  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. On models with the 5-valve engine, remove the air cleaner and intake pipe.
  8.  
  9. If removing the left tie rod on models equipped with the 1.8L engine, remove the heat shield.
  10.  
  11. Remove the tie rod cover by prying out the clips and removing the nut.
  12.  
  13. Open the steering rack boot clamps.
  14.  
  15. Remove the cap bolt from the top of the tie rod end, counting the number of revolutions needed for removal, then loosen and remove the pinch bolt and self locking nut.
  16.  
  17. Separate the outer tie rod end from the bearing housing (knuckle) using an appropriate tie rod end removal tool.
  18.  
  19. Slide the steering boot outward as far as possible and using a suitable size crow's foot and extension, loosen and remove the inner steering rod.
  20.  
  21. If replacing the inner steering rod and reusing the tie rod end;
  22.  
    1. Matchmark the steering rod to tie rod end lock nut and tie rod end.
    2.  
    3. Counter hold the steering rod.
    4.  
    5. Loosen the lock nut one turn.
    6.  
    7. Move the steering rod back and forth to make sure it is free. If necessary spray a penetrating lubricant onto the threads to loosen it.
    8.  
    9. Counter hold the steering rod and counting the number of revolutions for removal, remove the outer tie rod end.
    10.  


To install:

  1. Install the inner steering rod and torque to:
  2.  


    Inner steering rod-to-steering rack: 74 ft. lbs. (100 Nm)
     

  3. Inspect the steering boots and replace as necessary. Make sure the boots are not twisted during assembly. Apply a light coating of grease between the boot and the steering rod to help prevent the boot from twisting during an alignment procedure.
  4.  
  5. If tie rod end was removed;
  6.  
    1. Thread the jam nut and outer tie rod end onto the steering rod the same number of turns as the previously removed part. Make sure there is a sufficient length of the steering rod installed into the tie rod end.
    2.  

  7. Install the spindle of the outer tie rod end into the bearing housing (knuckle) and install the cap bolt the same number of revolutions counted during removal.
  8.  
  9. Install the pinch bolt and self locking nut and tighten to specification, the tighten the cap bolt as follows:
  10.  

Tie rod end-to-bearing housing (knuckle):



Pinch bolt and nut (replace nut): 33 ft. lbs. (45 Nm)
 
Cap bolt: 62 inch lbs. (7 Nm)
 

  1. Counter hold the steering rod and thread the jam nut until it contacts the tie rod end, then counter hold the tie rod end and tighten the jam nut to:
  2.  


    Steering rod-to-tie rod end nut: 30 ft. lbs. (40 Nm).
     

  3. The balance of the installation is in reverse order of removal noting the following:
  4.  
  5. Check and adjust the wheel alignment as necessary.
  6.  

Tie Rod




NOTE
This procedure requires the following special tools, or their equivalents:



Holding Fixture VW 313
 
Hose Clamp Pliers V.A.G 1275
 
Torque Wrench 40-200Nm V.A.G 1332
 
Open jaw insert, 34 mm V.A.G 1332/5
 
Transmission support T10108
 


NOTE
The tie rods can only be removed/installed once the steering gear is removed.

  1. Remove the steering gear, as outlined in this section.
  2.  
  3. Plug or cap the fluid line connections on power steering gear if not already done.
  4.  
  5. Clean outside of power steering gear in the area of the boot.
  6.  
  7. Open clamp and slide boot back.
    NOTE
    Use only hole "5" and the allocated upper hole from transmission support to tighten power steering gear.

  8.  
  9. Tighten the power steering gear on transmission support T10108, then unscrew tie rod from connecting rod.

    Click image to see an enlarged view

    Fig. Tighten the power steering gear on transmission support T10108, then unscrew tie rod from connecting rod

  10.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Tighten the tie rod to power steering gear to 55 ft. lbs. (75 Nm)
    2.  
    3. Inspect boot for wear (cuts, tears) and check that sealing surfaces for boot are clean.
    4.  
    5. When installing the boot, turn the tie rod so that the tie rod ball joint shank is in the installation position.
      NOTE
      Use only genuine VW OEM clamps.



      Click image to see an enlarged view

      Fig. When installing the boot, turn the tie rod so that the tie rod ball joint shank is in the installation position

    6.  
    7. Tighten the clamp with Hose Clamp Pliers V.A.G 1275 .
    8.  
    9. Install the steering gear, as outlined in this section.
    10.  

  2.  

Tie Rod Ends




WARNING
The following procedures will require the vehicle's alignment to be checked and if necessary, adjusted. This should be done by a professional with proper resources and equipment. Failure to recheck the alignment could cause poor handling and loss of control resulting in vehicle damage and bodily injury.

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Matchmark the steering rod to tie rod end lock nut and tie rod end.
  8.  
  9. Counter hold the steering rod.
  10.  
  11. Loosen the lock nut one turn.
  12.  
  13. Move the steering rod back and forth to make sure it is free. If necessary spray a penetrating lubricant onto the threads to loosen it.
  14.  
  15. Matchmark the tie rod end spindle height-to-bearing housing. (Note: this adjustment affects the raised toe)
  16.  
  17. Remove the cap bolt from the top of the tie rod end, counting the number of revolutions needed for removal, then loosen and remove the pinch bolt and self-locking nut.
  18.  
  19. Separate the outer tie rod end from the bearing housing (knuckle) using an appropriate tie rod end removal tool.
  20.  
  21. Counter hold the steering rod and counting the number of revolutions for removal, remove the outer tie rod end.
  22.  

To install:

  1. Clean the threads on the inner tie rod spindle (front wheel spindle connecting rod).
  2.  
  3. If identical, thread the replacement outer tie rod end onto the steering rod the same number of turns as the previously removed part. If the replacement part is not identical, thread it onto the steering rod until it bottoms against the jam nut, then back off one turn. Make sure there is a sufficient length of the steering rod installed into the tie rod end.
  4.  
  5. Install the spindle of the outer tie rod end into the bearing housing (knuckle) and install the cap bolt the same number of revolutions counted during removal.
  6.  
  7. Install the pinch bolt and self locking nut and tighten to specification, the tighten the cap bolt as follows:
  8.  

Tie rod end-to-bearing housing (knuckle):



Pinch bolt and nut (replace nut): 33 ft. lbs. (45 Nm)
 
Cap bolt: 62 inch lbs. (7 Nm)
 

  1. Counter hold the steering rod and thread the jam nut until it contacts the tie rod end, then counter hold the tie rod end and tighten the jam nut to:
  2.  


    Steering rod-to-tie rod end nut: 30 ft. lbs. (40 Nm).
     

  3. Reinstall the wheel and tire assembly. Torque the lug bolts in a three step crisscross patter to:
  4.  

Lug bolts:



M14 x 1.5: 89 ft. lbs. (120 Nm)
 

  1. Reconnect the negative battery cable.
  2.  
  3. Check the alignment and set the toe and toe raised adjustment as necessary.
  4.  



Click image to see an enlarged view

Fig. Use a suitable tie rod end removal tool to release the tapered shaft from the bearing housing/knuckle assembly



Click image to see an enlarged view

Fig. When reinstalling a tie rod end, locking pliers can be used to keep the tapered spindle seated and prevent it from spinning freely

 
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