locking VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Repair Manual

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Assembly overview: power assisted
steering box (TRW)
Determine cause of any malfunctions using
pressure and leak testing, Page 48-13 .
Note:
Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted.
To grease the rack only use steering gear
grease, Part No. AOF 063 000 04.
Type of oil: Hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 ltr. (0.74 - 0.95
qt)
Supply and pressure line routing from Page 48-85 . Page 19 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 - Self-locking nut 35 Nm
(26 ft lb)
2 - Self-locking 30 Nm (22
ft lb)
3 - Clamp
4 - Rubber mounting Internal diameter ZF:
50 mm TRW: 44 mm
5 - Right-hand tie rod 70 Nm (52 ft lb) Removing and
installing Page 48-77 Vehicle alignment
Page 44-1 Tie rod boot seat
diameter ZF: 15 mm
dia. TRW: 12.7 mm
dia. It must not be installed
on a ZF power
steering gear Page 20 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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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

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If very tightly seated, loosen locking screw with a
hammer and driver - Remove lower locking screw for valve body 1 - Ratchet (standard commercial) - Remove hex nut below valve body 1 - Ratchet (standard commercial) 2 - Open-end wrench (standard commercial) - Drive valve body upward from below with driver - Remove grease from teeth of valve body Page 35 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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- Drive sealing ring in far enough sot that the groove for circlip in the housing is visible
- Install circlip - Remove adhesive tape - Remove assembly mandrel 3315/17 - Install hex nut for valve body and tighten, 30 Nm
(22 ft lb) with torque wrench SW 14 2 Note: - Install locking screw - Grease pressure piece and spring in housing in old position
- Install lock nut together with adjusting screw After tightening, the marking made during removal (arrow) on the adjusting nut and lock nut must
match If the toothed rod was replaced, before installing
the tie rods the steering gear must be readjusted Page 49 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Assembly overview: power steering
gear (ZF)
It is not intended that repair work be carried out
on the power steering gear. If complaints are
received determine cause with the help of
pressure tests, leakage test and troubleshooting
programs. If a malfunction exists replace the
power steering gear.

Note:
Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted.
To grease the rack use only steering gear
grease, Part No. AOF 063 000 04.
Type of oil: Hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 Itr. (0.74 - 0.95
qt)
Supply and pressure line routing Page 48-85 . Page 54 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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- 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