1997 VOLKSWAGEN PASSAT AIR

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3 - Boot Remove ball joint
before removing Check for wear (cuts,
cracks), ensure
sealing surfaces and
sealing lips are clean
and undamaged The end diameters are larger than the boot for TRW power steering
gears Must not be installed
on TRW power
steering gear
4 - Hose clip Always replace - use
pliers to open Tensioning Page 48-81 Must not be installed
on a TRW power
steering gear Page 56 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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5 - Right-hand tie rod Removing and
installing Page 48-77 Vehicle alignment
Page 44-1 Tie rod boot seat
diameter ZF: 15 mm
TRW: 12.7 mm Must not be installed
on a TRW power
steering gear
6 - Left-hand tie rod Removing and
installing Page 48-77 Tie rod boot seat
diameter ZF: 15 mm
TRW: 12.7 mm Must not be installed
on a TRW power
steering gear Adjusting length
Page 48-84 Page 57 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Repair Manual, Maintenance 7 - Lock nut, 50 Nm (37 ft
lb)
8 - Tie rod ball joint Splitting Page 48-16 Checking: 9 - Pressure balance pipe
10 - 30 Nm (22 ft lb)
11 - Clamp
12 - Rubber mounting Internal diameter ZF:
50 mm TRW: 44 mm
13 - Data plate and
company initials Page 58 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 (ZF)

Note:
Two mechanics are required when adjusting.
Adjust with engine switched off.

- Raise vehicle on hoist.
- Wheels in straight-ahead position.
- By turning the steering wheel to and fro (about
30 to center axis) a knocking noise will be
heard if there is excessive play. - The second mechanic carefully screws the
adjustment screw -arrow- into the cover until the
knocking noise can no longer be heard inside the
vehicle.
- Complete a road test ensuring that when
maneuvering or negotiating corners the steering
self-centers without sticking. Page 59 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 (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

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Power steering gear, disassembling Note:
Use jaw covers, check jaw covers for contamination;
e.g. metal chips or the like - Tie rods, removing - see tie rod, removing and
installing (TRW and ZF power steering), Page 48-34 - Close hose connections on power steering gear if
not already done
1 - Plastic locking screw 2 - Plastic locking screw - 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
- Remove cover Page 61 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Note: Do not change position of the adjusting screw
(arrow) Cover is stressed with slight spring pressure - Remove pressure piece 1 - Spreading pliers (standard commercial) Page 62 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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- Remove lower locking screw for valve body 1 - Locking screw - Remove Torx screw for valve body 1 - Open-end wrench (standard commercial SW 14) 2 - Torx insert (standard commercial E10) 3 - Ratchet (standard commercial 3/8") Page 63 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1