display VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Workshop Manual

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

Downloaded from www.Manualslib.com manuals search engine 48-60

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

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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

Downloaded from www.Manualslib.com manuals search engine 48-63
- 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

Downloaded from www.Manualslib.com manuals search engine 48-64
- Remove circlip for valve body with needle nose
pliers 1
- Drive valve body out from below with driver - Slide toothed rod all the way in the direction of the
valve body
- Turn circlip so that the pointed end of the circlip is
in the groove (arrow) of the housing Page 64 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 48-65
Center roller bearing for valve body, removing - First lift circlip with slotted screwdriver then pull out with pliers
- Before removing toothed rod, clean housing
opening with compressed air
- Remove dirt and any chips that may be present - Pull toothed rod out of the housing to the right with
toothed rod guide
A - Screwdriver B - Pliers (standard commercial) - Lubricate toothed rod When installing the puller A, make sure that the claws
(arrows on fig. N48-0058, page 45) engage
correctly under the sealing ring. The puller must not
be spread too wide because otherwise the seat for
the sealing ring and the housing will be damaged or
the sealing ring can jam in the housing. - Drive center roller bearing out toward the top A - Puller, e,g, Kukko 21/4 B - Driver Page 65 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 48-66
For easier installation of the puller, it is recommended
that a rubber band be placed around the jaws.
Illustration shows the housing in cross section for
better view.
Sealing ring for valve body, removing 1 - Puller e.g. Kukko 21/4 2 - Rubber band 3 - Sealing ring 4 - Housing When installing the puller A, make sure that the claws
(arrows on fig. N48-0058, page 46) engage
correctly under the sealing ring. The puller must not
be spread too wide because otherwise the seat for
the sealing ring and the housing will be damaged or
the sealing ring can jam in the housing. - Drive sealing ring out toward the top A - Puller, e.g. Kukko 21/4 B - Driver - Drive out lower ball bearing with VW 439 Page 66 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 48-67
For easier installation of the puller, it is recommended
that a rubber band be placed around the jaws.
Illustration shows the housing in cross section for
better view.
Inner sealing ring for toothed rod, removing 1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Roller bearing 4 - Housing - Remove sealing ring for toothed rod from the
housing
- Disconnect hose line from valve body housing to
cylinder line
- Clean hose line, housing. Check threaded
connection for contamination (rubber residue,
chips) Page 67 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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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