Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Power Steering Rack

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ADJUSTMENT



ZF Steering Rack

See Figure 1

  1. This job requires 2 people. With the vehicle on the ground and the wheels straight ahead, turn the steering wheel back and forth about 30 degrees with the engine not running.
  2.  
  3. If the steering feels loose or makes noise, have an assistant turn the adjusting bolt clockwise until the noise stops. The noise may not stop completely so do not continue tightening the adjustment.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Adjustment point on the ZF power steering rack

TRW Steering Rack

See Figure 2

  1. Remove the steering rack from the vehicle.
  2.  
  3. Loosen the lock nut and use the special pin wrench to turn the adjuster until the rack can be moved by hand without binding or excessive free play.
  4.  
  5. Install the steering rack.
  6.  



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Fig. Fig. 2: A special pin wrench is required to adjust the TRW rack

REMOVAL & INSTALLATION



See Figure 3

Dasher, Quantum and Fox
  1. Disconnect the negative battery cable.
  2.  
  3. Pry off the lock plate and remove both tie rod mounting bolts from the steering rack (inside the engine compartment). Carefully pry the tie rods out of the mounting pivot.
  4.  
  5. Remove the lower instrument panel trim.
  6.  
  7. Remove the shaft clamp bolt. Pry off the clip, then drive the shaft toward the inside of the car with a brass drift.
  8.  
  9. Disconnect the power steering hoses. Place a pan under the steering rack to catch any fluid.
  10.  
  11. Remove the steering rack mounting bolts.
  12.  
  13. Turn the wheels all the way to the right and remove the steering rack through the opening in the right wheel housing.
  14.  

To install:
  1. Position the rack in the vehicle. Tighten the mounting bolts to 15 ft. lbs. (19 Nm).
  2.  
  3. Temporarily install the tie rod mounting pivot to the rack with both mounting bolts. Remove one bolt, install the tie rod, and reinstall the bolt. Do the same on the other tie rod. Tighten the pivot bolts to 40 ft. lbs. (54 Nm). Make sure to install a new lock plate.
  4.  
  5. Install the clip, then tighten the clamp bolt. Install the lower instrument panel trim.
  6.  
  7. Connect the power steering lines, then refill the fluid reservoir.
  8.  
  9. Connect the battery cable and properly bleed the power steering system as described in this section.
  10.  



Click image to see an enlarged view

Fig. Fig. 3: Power steering rack assembly

Except Dasher, Fox and Quantum
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle on jackstands. Remove the ignition key to lock the steering wheel.
  4.  
  5. Place a catch pan under the power steering rack to catch the fluid.
  6.  
  7. Disconnect the suction hose and the pressure lines, then drain the fluid into the catch pan (properly discard the fluid).
  8.  
  9. Remove the bolt from the steering shaft universal joint. Matchmark the universal joint to the pinion shaft.
  10.  
  11. Disconnect the tie rod ends from the steering knuckles.
  12.  
  13. Remove the mount nuts to remove the steering rack as an assembly.
  14.  

To install:
  1. Fit the pinion shaft into the universal joint while fitting the steering rack into place on the body.
  2.  
  3. Torque the steering rack mount nuts and the universal joint bolt to 22 ft. lbs. (30 Nm).
  4.  
  5. After inserting the tie rod ends into the steering knuckle, torque the nut to 26 ft. lbs. (35 Nm) and tighten as required to install a new cotter pin.
  6.  
  7. Connect the power steering lines, then refill the fluid reservoir.
  8.  
  9. Connect the battery cable and properly bleed the power steering system as described in this section.
  10.  

 
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