1996 VOLKSWAGEN PASSAT display

Downloaded from www.Manualslib.com manuals search engine 48-67
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.
Inner sealing ring for toothed rod, removing 1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Roller bearing 4 - Housing - Remove sealing ring for toothed rod from the
housing
- Disconnect hose line from valve body housing to
cylinder line
- Clean hose line, housing. Check threaded
connection for contamination (rubber residue,
chips) Page 67 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 - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and clean
thoroughly with compressed air and alcohol if
necessary
- Check cylinder race for scoring or other damage. If scoring can be felt, replace the complete steering
gear
- Clean toothed rod (remove old grease in tooth
pockets) Page 68 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 48-69

Checking toothed rod for scoring
If corroded areas or deep scratches are
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
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 sand paper 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 fine
grinding stone and/or sandpaper
1 - Toothed rod 2 - Sand paper (grain 350-600) Page 69 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 When the sealing rod is replaced it must be replaced
with a new one of the same color
Note the matching of the O-ring to the sealing ring - Press pliers together with slight pressure on the
sealing ring
- Pry out sealing ring and O-ring A - Needle nose pliers (standard commercial) O-ring 30.0 x 1.78/ white sealing ring O-ring 31.0 x 1.5/black sealing ring - Slide mounting sleeve 3315/19 onto toothed rod - Pull O-ring over the tool and insert in the groove of
the piston Page 70 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: 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

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When the groove -arrow- matches the edge -arrow -
A- of the housing, the sealing ring is properly seated. - Place support ring -1- and sealing ring -2- on tool - Drive sealing ring for toothed rod into housing to
stop Page 72 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 48-73
Toothed rod, installing in the housing
No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04
grease
- Slide protective tube over toothed rod to stop - Wipe away excess grease completely When sliding, make sure that the sealing ring is
pressed into the groove of the piston without
jamming - Coat piston of toothed rod and protective tube with
hydraulic oil
- Install installation sleeve 3315/21 into the housing - Slide toothed rod into the housing - Slowly introduce the toothed rod into the housing - Pull protective tube 3315/5 off the toothed rod Page 73 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 48-75
Make sure that the sealing ring in the housing is not
damaged by the teeth of the pinion. - Thread assembly mandrel 3315/17 onto valve
body.
- Lubricate valve body with hydraulic oil and
carefully install by hand into the valve body
housing (note position of toothed rod). - Tape the valve body with adhesive tape. Page 75 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1