1996 VOLKSWAGEN PASSAT power steering

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Power steering gear, adjusting (TRW)

Note:
Two Mechanics are required when adjusting.
Adjust with engine switched off Adjusting steering box
By turning the steering wheel back and forth (about
30 to center axis) a knocking noise will be heard if
there is excessive play. - Raise vehicle on hoist. - Wheels in straight-ahead position. - Loosen locking nut (counter-hold with 3315/9). - Carefully turn adjustment screw (arrow) into cover
until knocking noise can no longer be heard inside
vehicle.
- Tighten locking nut. - Complete a road test ensuring that when
maneuvring or negotiating corners the steering
self-centers without binding. Page 24 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 48-25

Power steering gear, disassembling and
reassembling (TRW)
This repair is limited to replacing the sealing
rings and, if necessary, the toothed rod. Steering
gears that are damaged by an accident must be
replaced.
For a satisfactory and successful repair, the
greatest care, safety and proper tools are
required. The special tool set 3315 that is
pictured is also a part of this.

Note:
Clean hose connections and their surroundings
thoroughly before opening.
Thoroughly clean work place (workbench, vise)
before starting work if necessary place paper
towels on the working surface.
Place parts that have been removed on a clean
surface. If the repair will not be carried out
immediately, cover parts.
Do not use cloths with lint. All the replacement parts that are needed are
contained in the repair kit.
Only take replacement parts out of the package
right before installing. Use only parts in original
packaging.
Always install all of the parts in the repair kit Page 25 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 48-26

1 - Tie rod For removing, see tie
rod, removing and installing (TRW and ZF power steering gear)
Page 48-77 2 - Boot Installing, see tie rod, removing and installing (TRW and ZF) power
steering), Page 48-77 3 - Hose clamp Open with nipper pliers Installation position
and tightening, see tie
rod, removing and installing (TRW and ZF power steering),
Page 48-77 Always replace 4 - Circlip Always replace 5 - Lock washer
6 - Toothed rod guide Supplied in repair kit
as assembly with
sealing ring Always replace Page 26 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, disassembling

- Tie rods, removing - see tie rod, removing and
installing (TRW and ZF power steering), Page 48-77
- Close hose connections on power steering gear
if not already done

1 - Plastic locking screw
2 - Plastic locking screw Note:
Use jaw covers and check jaw covers for
contamination; e.g. metal chips or the like - Clean outside of power steering gear - Open hose clamp and push back boot - Clamp steering gear with toothed rod in vise and
remove tie rod - Remove tie rod - Take steering gear out of vise, screw on bracket
3315/1 and tighten bracket in vise Page 32 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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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 48-54

Assembly overview: power steering
gear (ZF)
It is not intended that repair work be carried out
on the power steering gear. If complaints are
received determine cause with the help of
pressure tests, leakage test and troubleshooting
programs. If a malfunction exists replace the
power steering gear.

Note:
Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted.
To grease the rack use only steering gear
grease, Part No. AOF 063 000 04.
Type of oil: Hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 Itr. (0.74 - 0.95
qt)
Supply and pressure line routing Page 48-85 . Page 54 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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1 - Power steering gear Removing and
installing Page 48-15 Adjusting Page 48-59 Checking steering
moment Steering gear with
reduced steering
moment only
permissible for
vehicles up to 85 kW Steering moment on
16 V and VR 6
vehicles is approx. 2
Nm higher
2 - Hose clip Always replace- use
pliers to open Tensioning Page 48-81 Page 55 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1