1990-94 Cabriolet, 1990-93 Fox, 1990-92 Golf and Jetta
ZF Steering Gear
- 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° with the engine not running.
- 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.
- Remove the steering gear from the vehicle.
- 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.
- Install the steering gear.
REMOVAL & INSTALLATION
- Disconnect the negative battery cable.
- 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.
- Remove the lower instrument panel trim.
- Remove the shaft clamp bolt. Pry off the clip, then drive the shaft toward the inside of the car with a brass drift.
- Disconnect the power steering hoses. Place a pan under the steering rack to catch any fluid.
- Remove the steering rack mounting bolts.
- Turn the wheels all the way to the right and remove the steering rack through the opening in the right wheel housing.
- Position the rack in the vehicle. Tighten the mounting bolts to 15 ft. lbs. (19 Nm).
- 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.
- Install the clip, then tighten the clamp bolt. Install the lower instrument panel trim.
- Connect the power steering lines, then refill the fluid reservoir.
- Connect the battery cable and properly bleed the power steering system as described in this section.
- Raise and safely support the vehicle on jack stands and remove the ignition key to lock the steering wheel.
- Place a catch pan under the power steering gear to catch the fluid.
- Disconnect the suction hose and the pressure lines and drain the fluid into the catch pan (discard the fluid).
- Remove the bolt from the steering shaft universal joint. Matchmark the universal joint to the pinion shaft.
- Disconnect the tie rod ends from the steering knuckles.
- Remove the mount nuts to remove the steering rack as an assembly.
- Fit the pinion shaft into the universal joint while fitting the steering gear into place on the body.
- Tighten the steering gear mount nuts and the universal joint bolt to 22 ft. lbs. (30 Nm).
- After inserting the tie rod ends into the steering knuckle, tighten the nut to 26 ft. lbs. (35 Nm) and tighten as required to install a new cotter pin.
- Connect the hydraulic lines, refill the fluid reservoir and bleed the system as described later.
- Raise and safely support the vehicle.
- Remove both front wheels and disengage both tie rod ends.
- Remove the low pressure (suction) hose from the pump and drain the system into a catch pan. Properly discard the fluid.
- At the steering column, remove the boot clamp, push the boot towards the body and remove the clamp bolt from the universal joint.
- On Cabrio models, remove the exhaust manifold and shift linkage bracket.
- Remove the rack mounting clamp nuts and remove the clamps.
- At this point on some vehicles, the rack cannot be removed from the body. Support the engine/transaxle and remove the subframe bolts to allow the rack to move towards the rear. On Cabrio models, remove the transaxle mount and bracket.
- Disconnect the power steering hydraulic lines and remove the rack toward the right.
- Be sure the mounting bushings are in good condition. Fit the rack assembly into place and tighten the clamp nuts to 22 ft. lbs. (32 Nm)
- Install any subframe bolts that were removed.
- Connect the hydraulic lines and install the steering column universal joint bolt.
- Fill the system with new fluid and run the engine to check for leaks and bleed the system.