1997 VOLKSWAGEN PASSAT Gear

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Repair Manual, Maintenance 9 - Steering gear Removing and
installing Page 48-15 Adjusting Page 48-24 10 - Tie rod end Separating Page 48-16 Checking: 11 - Hex nut 30 Nm (22 ft lb) 12 - Universal joint Page 22 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 (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

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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

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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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11 - Adjusting screw with
lock nut, 60 Nm (44 ft
lb) Before removing, mark position of adjusting
bolt and lock nut on
housing Steering gear,
adjusting Page 48-24 12 - Pressure spring
13 - Pressure piece Mark installation
position
14 - Housing Check cylinder race for scoring, if necessary
replace steering gear
complete
15 - Inverted tube nut, 30
Nm (22 ft lb)
16 - O-ring Always replace Is not included in
repair kit - see Parts
catalog Page 28 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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17 - Sealing ring Always replace 18 - Valve body Removing Page 48-32 Cannot be repaired Is not supplied as
replacement part, if
damaged replace
steering gear
19 - Support ring Eliminated starting
4/92 If present, it must be
reinstalled
20 - Adhesive film Thoroughly clean
housing in this area before sticking on, e.g. with thinner, adhesive surface must be free of oil and grease Always replace Page 29 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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21 - Roller bearing installation position:
inscription points up
22 - Sealing ring Always replace 23 - Circlip
24 - Ball bearing Drive from top
downward with VW
439 Grease with steering
gear grease AOF 063
000 04
25 - Self-locking hex nut, 30 Nm (22 ft lb) Always replace 26 - Locking screw, 40 Nm
(30 ft lb) Always replace Is already pre-
mounted on new
toothed rods that are
supplied as
replacement parts Page 30 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