1995 VOLKSWAGEN PASSAT steering

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Toothed rod, installing in housing No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04
grease
- Slide protective tube on to toothed rod to stop - Wipe excess grease off completely Page 45 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-46

- Coat piston of toothed rod and protective tube
with hydraulic oil When sliding, make sure that the sealing ring is
pressed into the groove of the piston without
jamming - Install installation sleeve 3315/22 into the housing - Slide toothed rod into the housing - Slowly introduce the toothed rod into the housing - Pull protective tube 3315/13 off the toothed rod Align teeth of toothed rod in such a way that they
point toward the teeth of the pinion
- Screw mounting sleeve 3315/18 on toothed rod
and coat with hydraulic oil
- Carefully slide toothed rod guide 1 over the
toothed rod into the housing to stop
- Slide toothed rod completely into the housing. Page 46 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-47
- Place lock washer in the housing and press in far
enough until the groove in the lock washer in the
slot of the housing is visible
- Install new safety wire in the hole of the lock
washer (arrow)
- Pull safety wire in by turning the lock washer. (after pulling in, turn the lock washer approx. 1/2
revolution further)
1 - Safety wire in repair kit is not formed as a ring,
but supplied as a straight wire
2 - Pliers (standard commercial) Valve body, installing
Ball bearing must not be tipped when driving in - Carefully drive lower ball bearing for valve body
into stop Page 47 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-48
Make sure that the sealing ring in the housing is not
damaged by the teeth of the pinion - Screw assembly mandrel 3315/17 on valve body - Lubricate valve body with hydraulic oil and
carefully install by hand into the valve body
housing (note position of toothed rod) - Tape teeth of valve body with adhesive tape to
protect the sealing ring. Avoid wrinkles.
- Install upper roller bearing for valve body
(inscription on roller bearing points upward)
A - Adhesive tape B - Valve body Page 48 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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- Drive sealing ring in far enough sot that the groove for circlip in the housing is visible
- Install circlip - Remove adhesive tape - Remove assembly mandrel 3315/17 - Install hex nut for valve body and tighten, 30 Nm
(22 ft lb) with torque wrench SW 14 2 Note: - Install locking screw - Grease pressure piece and spring in housing in old position
- Install lock nut together with adjusting screw After tightening, the marking made during removal (arrow) on the adjusting nut and lock nut must
match If the toothed rod was replaced, before installing
the tie rods the steering gear must be readjusted Page 49 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-50

Adhesive tape, applying - Fill slot with sealing compound AKL 450 005 05 - Tape slot with adhesive tape 1 - Adhesive surface must be dry and free from
grease Page 50 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-51

Power steering gear, adjusting with new
toothed rod If a new toothed rod was used, the steering play
should be adjusted according to the following
description.
- Drill a hole 5.1 mm in diameter in the center of the
adjusting screw (on the back side center)
- Thoroughly clean adjusting screw - Place toothed rod in center position (measure
toothed rod excess right and left)
- Install pressure piece and spring in housing if not
done yet
- Screw adjusting screw and lock nut far enough into the housing so that the markings match Page 51 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-52
- Install gauge and set to "O" with approx. 1 mm
pre-load (make sure that the key does not stick,
front of key must not be crowned)
1 - 3315/8 2 - 3315/9 3 - 3315/1 4 - VW 387 - Screw right rod onto toothed rod and tighten by
hand
- Turn toothed rod radially from stop to stop, during
this process observe pointer on gauge. Page 52 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1