1996 VOLKSWAGEN PASSAT tow

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 48-60

Power steering gear, disassembling and
reassembling (ZF)
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.

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 60 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 48-65
Center roller bearing for valve body, removing - First lift circlip with slotted screwdriver then pull out with pliers
- Before removing toothed rod, clean housing
opening with compressed air
- Remove dirt and any chips that may be present - Pull toothed rod out of the housing to the right with
toothed rod guide
A - Screwdriver B - Pliers (standard commercial) - Lubricate toothed rod When installing the puller A, make sure that the claws
(arrows on fig. N48-0058, page 45) engage
correctly under the sealing ring. The puller must not
be spread too wide because otherwise the seat for
the sealing ring and the housing will be damaged or
the sealing ring can jam in the housing. - Drive center roller bearing out toward the top A - Puller, e,g, Kukko 21/4 B - Driver Page 65 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 48-66
For easier installation of the puller, it is recommended
that a rubber band be placed around the jaws.
Illustration shows the housing in cross section for
better view.
Sealing ring for valve body, removing 1 - Puller e.g. Kukko 21/4 2 - Rubber band 3 - Sealing ring 4 - Housing When installing the puller A, make sure that the claws
(arrows on fig. N48-0058, page 46) engage
correctly under the sealing ring. The puller must not
be spread too wide because otherwise the seat for
the sealing ring and the housing will be damaged or
the sealing ring can jam in the housing. - Drive sealing ring out toward the top A - Puller, e.g. Kukko 21/4 B - Driver - Drive out lower ball bearing with VW 439 Page 66 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 48-71

Power steering gear, assembling

Note: The sealing lip (arrow) of the sealing ring points
upward toward the teeth 1 on the valve body
For better viewing, the illustration shows the body
housing in cross section with installed valve body.
The valve body is shown slightly raised for better
viewing
Inner sealing rod for toothed rod, installing Lubricate the sealing rings with hydraulic oil
before installing
- Note correct installation position of the sealing ring - Place sealing ring for valve body on the tool and
drive in to stop. For installation position, see next
illustration
- Drive center roller bearing for valve body into stop The sealing lip (arrow) of sealing ring -3- points
toward cylinder -4-.
For better illustration, the drawing shows the housing
in cross section. 1 - Valve body 2 - Support ring 3 - Sealing ring 4 - Cylinder Page 71 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1