1997 VOLKSWAGEN PASSAT Gear

Downloaded from www.Manualslib.com manuals search engine 48-57

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

Downloaded from www.Manualslib.com manuals search engine 48-59

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

Downloaded from www.Manualslib.com manuals search engine 48-61

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

Downloaded from www.Manualslib.com manuals search engine 48-68

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

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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

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

Downloaded from www.Manualslib.com manuals search engine 48-77

Tie rods, removing and installing (power
steering gear - TRW and ZF)

Note:
Observe how tie rods are threaded into power
steering gear:

- Tie rods not secured with locking fluid
- Tie rods secured with locking fluid When exchanging secured version tie rods use
locking fluid D6 when installing.

Removing
The tie rods can only be removed/installed with
the steering gear removed. - Seal line connections on power steering gear. 1 - Plastic sealing plugs 2 - Plastic sealing plugs - Clean outside of power steering gear in vicinity of
the boot. Page 77 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1