1996 VOLKSWAGEN PASSAT washer

Downloaded from www.Manualslib.com manuals search engine 48-4

19 - Lower steering column
bearing Pull in with VW 771
and large washer Drive out downward
with a tube
20 - Washer Tighten until head
shears off Drill out to remove 21 - Shear bolt
22 - Column tube
23 - Lower trim Page 4 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 48-5
Only use puller with leg clamp (e.g. Kukko 204/2
commercial type). Fig. 1 Splined adapter sleeve, removing Fig. 2 Splined adapter sleeve, installing - Place sleeve on steering column and press on with hex nut.
- Remove nut, place on washer and press sleeve
fully on with nut until sleeve is firmly seated. Page 5 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 48-11

Column tube for height
adjustable steering
wheel, removing and
installing
The column tube can be
adjusted in height by approx.
50 mm
1 - Operating lever
2 - Packing plate
3 - Column tube Square housing fits
over mounting bracket
4 - Rubber stop
5 - Return spring Hooked into mounting
bracket and column
tube
6 - Thrust washer
7 - Packing plate Page 11 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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8 - Clamping sleeve
9 - Mounting bracket Before assembling,
coat side sliding
surfaces with MoS
2
paste
10 - Bolt with left-hand
thread Tighten to 22 Nm (16 ft lb), After tightening install
locking plate
11 - Locking plate
12 - Locking plate nut, 8
Nm (70 in. Ib) Self-locking Always replace 13 - Washer
14 - Shear bolt Tighten until head
shears off Page 12 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

Downloaded from www.Manualslib.com manuals search engine 48-36

- Pull adhesive tape out of the housing Valve body sealing ring, removing - Pull toothed rod all the way to the left - Turn lock washer so that the opening of the circlip
(arrow) is in the groove of the housing
- Continue to turn the lock washer (direction of
rotation left or right) so that the circlip turns out of
the housing
- Pull toothed rod with toothed rod guide out of the
housing, pull off toothed rod guide and place
toothed rod so that toothed rod piston sealing ring
will not be damaged
1 - Needle nose pliers (standard commercial) - Lubricate toothed rod - Drive sealing ring upward A - Puller, e.g. Kukko 21/4 B - Driver When installing the puller -A- make sure that the
claws (arrow on illustration page 13) engage
properly under the sealing ring. The puller must not
be spread too wide because otherwise the seat for
the sealing ring and housing will be damaged or the
sealing ring can jam in the housing. Page 36 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 48-76
- Carefully slide bushing with roller bearing onto the
valve body.
- Drive bushing into the housing far enough so that
the groove for the circlip is visible.
- Install circlip. - Remove adhesive tape. - Remove installation mandrel 3315/17. - Install Torx screw into valve body and tighten to 35 Nm (26 ft lb). - Thread in locking screw, tighten to 30 Nm (22 ft lb)
and crimp at corner points.
- Grease pressure piece with AOF 063 000 04. - Install pressure piece, spring and washer in
housing.
- Install cover with adjusting screw. Adjust steering
gear after installation in vehicle. Page 76 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1