boot VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Owner's Guide

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Instead of plastic sealing plugs a plug consisting of
Part No.113 301 229 A and banjo bolt, Part No. N
904 674 01 can be used. But when using these,
several 16 mm diameter sealing rings must be used
so that the holes in the banjo bolt are sealed. - Support engine/transmission assembly with 10-
222 A and 10-222 A/1 (support VR6 engine with
10-222A and 10-222A/3).
- Remove boot from seat on steering gear. - Remove subframe bolts. - Lower engine/transmission assembly; this will pull
the two halves of the universal joint apart.
- Disconnect hoses from steering gear and seal with plastic bag and adhesive tape.
- Seal power steering gear threaded holes with
plastic sealing plugs.
- Remove steering gear securing nuts (bolts remain
in subframe).
- Remove steering gear rearward. Page 17 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Installing
Install in reverse order.

- Check position of steering wheel and, if
necessary, align front end.

Note: Tightening torques: When lifting the engine/transmission assembly
guide the lower half of the universal joint shaft -A-
into the upper half -B- at the same time (second
mechanic necessary). Coat boot with lubricant, e.g. soft soap, before
pulling onto steering gear.
Universal joint shaft 25 Nm (18 ft lb) halves
Steering gear 30 Nm (22 ft lb)
Tie rod joint 35 Nm (26 ft lb)
Subframe front and rear
70 Nm (52 ft lb) and turn 90 further Rear subframe bracket 65 Nm (48 ft lb) Page 18 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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6 - Left-hand tie rod 70 Nm (52 ft lb) Removing and
installing Page 48-77 Adjusting to length
Page 48-84 Tie rod boot seat
diameter ZF: 15 mm
TRW: 12.7 mm Must not be installed
on a ZF power
steering gear
7 - Hex nut 50 Nm (37 ft lb) 8 - Boot Pull on and off over tie
rod Can be replaced with
steering gear installed Must not be twisted
after adjusting toe Must not be installed
on a ZF power
steering gear Page 21 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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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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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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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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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