1995 VOLKSWAGEN PASSAT steering

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For easier installation of the puller, it is recommended
that a rubber band be placed around the claws.
Illustration shows the housing in cross section for
better view
1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Sealing ring 4 - Glide bearing do not remove Page 37 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Inner sealing ring for toothed rod,
pulling out

- Install puller for sealing ring far enough so that
the marking on the tool (arrow) matches the
housing edge (only then will the claws engage
behind the support ring)

- Spread claws -2- of the tool by turning the
spindle forcefully

Note: When introducing the tool, make sure that the
cylinder race is not damaged
1 - Support ring 2 - Claws 3 - Sealing ring 4 - Tool 3315/11 Page 38 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Parts, cleaning and checking - Install tool VW 771 in the puller - Pull out sealing ring - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and
thoroughly cleaned with compressed air and
alcohol
- Clean adhesive surface for adhesive tape in area
of the slot with solvent (e.g. L160 or alcohol)
- Check cylinder race for scoring or other damage. If scoring can be felt, replace entire steering gear
- Clean toothed rod (remove old grease in the tooth
pockets) Page 39 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Checking toothed rod for scoring If corroded areas or deep scratches are not
noticeable on the toothed rod, the toothed rod must
be replaced
An evaluation of whether the toothed rod was
damaged by force, e.g. by an accident, is not possible
with this visual inspection
If slight scoring (arrows) can be seen/felt on the
toothed rod that are only deep enough that they can
be ground off with sand paper (grain 350-600) the
toothed rod can still be used After sanding, lubricate toothed rod lightly
If the old toothed rod is used again, check the sealing
ring for scoring (visual inspection). If there is scoring
that can be seen or felt, the sealing ring and the O-
ring under it must be replaced. - Sand toothed rod with sandpaper in radial direction (this is only possible with slight scoring)
- Check chamfer on the front sides of the toothed
rod for damage, if necessary remove with a fine
grinding stone and/or sandpaper
1 - Toothed rod 2 - Sand paper (grain 350-600) 3 - Jaw covers Page 40 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Sealing ring on toothed rod, replacing - Press pliers together with slight pressure on the
sealing ring
- Pry out sealing ring and O-ring A - Needle nose pliers (standard commercial) 1 - Toothed rod with piston 2 - Sealing rod 3 - O-ring Page 41 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Sealing rings, installing on toothed rod
piston - Slide mounting sleeve on toothed rod - Pull O-ring over tool and install in groove of piston - Lubricate sealing ring with hydraulic oil, pull over
tool and install in groove of piston Page 42 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Power steering gear, assembling

Note;
All sealing rings should be lubricated with
hydraulic oil before installing. - Check whether the valve body housing -2- is
absolutely clean on the inside, otherwise clean
- Place sealing ring -1- on tool. The sealing lip -
arrow- points toward tool
- Drive sealing ring into stop 1 - Sealing ring 2 - Valve body housing - Make sure correct installation position of sealing
ring in valve body
- For better view, illustration shows valve tower in
cross section Page 43 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Inner sealing ring for toothed rod,
installing

- Place sealing ring on tool - Ensure correct installation position of sealing ring
for toothed rod
- Drive sealing ring -1- into the cylinder pipe far
enough so that the groove (arrow) on the tool
matches the edge (arrow A) of the housing
1 - Sealing ring A - Edge of housing For better view, illustration shows housing in cross
section
1 - Support ring 2 - Sealing ring 3 - Valve body housing Page 44 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1