Checking Hydraulic Function of Steering Pressure Test Printed in Germany XXXIV 1994

REMOVING AND INSTALLING STEERING WHEEL

2. Mark position of steering wheel to steering shaft for reinstalling.

Installing

1. Install steering wheel with road wheels pointing straight ahead or according to disassembly mark in such a manner, that steering wheel spokes are horizontal.

2. Install hexagon nut with spring washer and tighten to specified torque.

3. Mount horn wires on impact pad and press impact pad on to retaining pins.

4. Check function of horns and direction indicator switch.

Removing

X. Pull impact pad off of steering wheel and take off horn wires.

3. Unscrew nut and remove steering wheel and washer.

TOOLS

No.

Description

Special Tool

Remarks

1

Circlip pliers

Standard tool

2

Mandrel

VW 295

3

Mandrel

VW 214 f/20

4

Pressure pad

VW 433

5

Sleeve

30-21

6

Locally made tool

Half of an approx. 4 mm thick washer welded on steering wheel mounting nut {M 18 x 1.5 hexagon nut)

No.

Description

Qty.

Note When: Removing Installing

Special Instructions

1

Self-locking nut

2

Replace, torque: 28 Nm (20 ftlb)

Watch installed position of universal joint no. 4, see page 48-23

2

Washer

2

Replace if necessary

3

Setscrew

2

4

Universal joint

1

Produce 8 mm gap for short version with tool 9208 (page 48 - 23). Check for damage

5

Pad

1

6

Nut M 18 x 1.5

50 Nm (36 ftlb)

7

Washer

1

Replace if necessary

8

Steering wheel

1

Steering wheel spokes horizontal with steering gear in center position (centered with tool 9132)

Remove tool 9132 immediately after installing steering wheel

9

Steering column switch

1

Unscrew mounting Align with cover bolt

10

Rubber cover

1

11

Spring

1

12

Circlip

1

13

Support

1

14

Screw

3

Different torque depending on type of screw (see point 6 of installing)

15

Spacer 2 mm thick

1

No.

Description

Qty.

Removing

Note When: Installing

Special Instructions

16

Washer

X

6 mm (one thick 4 mm and one thin 2 mm) for leather or 4 mm (one thick 4 mm) for leatherette

17

Steering tube with steering lock

1

18

Seal

1

Replace if necessary; position correctly

19

Steering shaft

1

Adjust axiaf play to 0.5 ... 1.0 mm

Washer Setscrew

1 1

Replace if necessary

Axial play of intermediate shaft will be changed as soon as steering shaft/intermediate shaft conn, is disconnected

23

Intermediate steering shaft

1

Changed from steel to forged aluminum to save weight

24

Shim

four 1.5 mm and one 0.5 mm thick shims

See repair manual for adjusting steering shaft axial play

25

Spring

1

26

Steering shaft mount, lower, with support

1

Install with sleeve 30-21

Steering shaft mount center

1 1 1

Deleted in 1981 models, no longer available as replacement, if necessary install old steering shaft without mount

No.

Description

Qty.

Installing

Special Instructions

30

Steering shaft mount, upper

1

Drive out with a suitable pipe

Drive in with VW 433

31

Ball

2

32

Spring

1

33

Self-locking nut

1

34

Washer

1

35

Adjusting lever

1

36

Bracket

1

37

Stud

1

38

Screw M 3.5 x 10

3

Same part as no. 40

39

Contact ring

1

Position correctly

40

Screw M 3.5 x 10

3

Same part as no. 38

41

Hub trim

1

42

Bolt

3

43

Insulator

3

Replace if necessary

REMOVING AND INSTALLING STEERING TUBE

2. If applicable, take off cover on steering intermediate shaft.

3. Disconnect battery ground wire at body. If car has electric seats, move them completely back to make assembly work easier.

4. Pull off impact pad on steering wheel and remove horn wires. Mark position of steering wheel on steering shaft. Unscrew hexagon nut and take off steering wheel with washer.

5. Unscrew cover underneath instrument cowl (not on older models) and cover underneath steering column switch.

Removing

1. Remove universal joint after unscrewing two hexagon head setscrews.

9. Remove 5 switches in instrument cowl by pulling off switch knobs, compressing both spring clips of each switch, pulling out switches and pulling off plugs. Remove rubber cover (ignition lock cover).

Unscrew mounting bolts for instrument cowl.

Unscrew mounting bolt for steering column switch.

9. Remove 5 switches in instrument cowl by pulling off switch knobs, compressing both spring clips of each switch, pulling out switches and pulling off plugs. Remove rubber cover (ignition lock cover).

Unscrew mounting bolts for instrument cowl.

Unscrew mounting bolt for steering column switch.

8. Remove steering column switch after disconnecting plug connector and pulling off plug. Lift instrument cowl for this purpose.

10. Pull plugs out of plug guides on back of instrument cowl (printed circuit) and lift off instrument cowl. Mark plugs for reinstallation.

11. Pull off plugs on ignition switch. Disconnect spring for steering wheel height control with a piece of suitable wire.

12. Remove circlip and support on steering shaft.

12. Remove circlip and support on steering shaft.

13. Unscrew mounting bolts on steering tube bracket.

14. Move up steering tube combined with steering and intermediate shafts. To prevent seizure of intermediate shaft on firewall while moving up, keep to the following procedures. Pull up steering tube slightly and then push down the now accessible steering and intermediate shafts in the steering tube against the stop on the steering shaft mount. Push down very carefully to prevent changing sit of mount.

Installing

1. Insert seal in firewall in correct position. Coat pertinent area and seal with tire assembly paste to make installation of steering tube easier.

2. Install steering tube with steering and intermediate shafts in car.

Preparations:

Circlip and support of steering shaft removed, steering shaft pushed down in steering tube, intermediate shaft pushed through firewall. Slide up steering shaft again before moving steering tube into firewall. Install support and steering wheel mounting nut temporarily instead of the circlip.

8. If applicable, mount cover on intermediate shaft.

Install universal joint between steering and intermediate shafts. First slide up universal joint on intermediate shaft fully (facilitates installation). Produce 8 mm gap between steering gear and universal joint with Special Tool 9208. Tighten universal joint mounting bolts to 28 Nm (20 ftlb).

For cars with a longer universal joint the gap will definitely be less than 8 mm after installing clamping bolt on the steering gear. In this case only make sure that there is a small gap between the steering gear and universal joint. The steering gear might have to be lowered to install the long universal joint.

4, Attach spring for steering wheel height control. Install circlip on steering shaft. Connect plugs on ignition switch.

5. Install steering column switch and instrument cowl. Tighten mounting bolts of cowl.

6. Align instrument cowl (horizontal position and equal distance to instrument panel on left and right sides). Then tighten 3 mounting bolts of steering tube to specified torque.

M 6 x 25 socket head bolt with 4 mm socket: 9.7 Nm (7 ftlb)

3. Mount steering tube with appropriate spacers, see pages 48 -17 and 18. Only tighten the socket head bolts finger tight.

7. Align steering column switch and tighten mounting bolt. Screw on cover(s). Connect battery ground wire.

9. Install steering wheel so that its spokes are horizontal when road wheels are pointing straight ahead or by mark made during removal operations.

Install mounting nut with washer and torque to 50 Nm (36 ftlb).

If necessary, correct position of steering wheel after test drive (not positioned horizontally before removal and slightly different universal joint position).

10. Check function of electrical system and pertinent parts.

REMOVING AND INSTALLING STEERING SHAFT/STEERING SHAFT BEARINGS ADJUSTING AXIAL PLAY OF STEERING SHAFT

Removing

1. Pull intermediate and steering shafts down out of steering tube quickly (circlip and support removed, steering wheel lock unlocked). This will also remove the lower steering shaft bearing.

2. Disconnect intermediate shaft on steering shaft after removing setscrew (arrow). Be careful not to damage the aluminum universal joint (use plastic hammer). Remove lower steering shaft bearing, spring and shims (if applicable) on steering shaft.

4. Drive upper steering shaft bearing out of outer tube with a suitable piece of pipe.

1. Drive or press in upper steering shaft bearing flush with Special Tool VW 433. Surface on bearing collar faces opening for steering column switch (arrow).

3. If steering shaft has three bearings (also refer to page 48-18), only remove the center bearing when damaged (must run easily) since replacement parts are no longer available. If necessary, install a steering shaft designed for three bearings without the center bearing.

4. Move steering shaft down out of steering tube partially (at most up to stop of shaft on lower bearing}. Install support, spring and shims (basic set: 4 X 1.5 mm and 1 x 0.5 mm) on steering shaft. Mount intermediate shaft on steering shaft. Before tightening the self-locking hexagon nut, push down (in direction of steering) intermediate shaft on steering shaft all the way against stop of setscrew on opening of steering shaft.

2. Move steering shaft into outer tube from below. If steering shaft still has three bearings, coat inside of outer tube as well as sleeve of center bearing with a multi-purpose grease for this operation.

3. Drive lower steering shaft bearing into steering protective tube against stop with Special Tool 30-21.

5. Clamp steering tube in a vise on the steering lock housing. Slide steering shaft into steering tube completely. Mount support and screw on locally made tool.

Adjusting value: 0.5 mm Nominal value: 0.5 — 1 mm

6. Check steering shaft axial play. Pull up steering shaft far enough so that spring is definitely against block (force approx. 30 kp/66 lb). In this state press support firmly against inner race of upper steering shaft bearing (with help of a tool if necessary). If necessary, center steering shaft slightly while support is being pushed down. The distance between edge of groove and support should be 0.5 mm (equals axial play). Check with help of a second mechanic and a 0.5 mm thick shim or a feeler gauge blade.

48-26 Repairing Steering and Intermediate Shafts Printed in Germany with Steering Tube

7. b) Axial Play (Distance) Excessive:

Move intermediate shaft on steering shaft in direction of steering wheel until the axial play is correct.

Torque hexagon nut to 28 Nm (20 ftlb). If the steering shaft opening is not sufficient for adjustment, use a larger shim set (6.5 mm basic set).

7. c) Insufficient or No Axial Play (Insufficient Distance or Support Positioned Above Edge

Use smaller shim set (6.5 mm basic set).

7. a) Axial Play (Distance) Correct:

Move intermediate and steering shafts out of steering tube far enough so that the setscrew is accessible.

Tighten self-locking hexagon nut to 28 Nm {20 ftlb).

8. After finishing adjustments always make sure that washer and nut still have a locking effect. Recheck axial play after tightening the self-locking hexagon nut to 28 Nm (20 ftlb).

9. Install support and circlip. Install steering wheel and check easy movement of steering shaft and locking effect of steering wheel lock.

DISASSEMBLING AND ASSEMBLING STEERING WHEEL HEIGHT CONTROL

Disassembling

Assembling

1. Move steering wheel height control lever to release position.

Remove balls and spring. Make sure that a cloth is held above the area of the balls (to prevent injury) and catch the first ball after turning the bracket.

2. Unscrew self-locking hexagon nut. Move out control lever with stud and take off bracket.

1. Screw stud in control lever. Threaded part must protrude slightly {arrow).

2. Mount bracket on steering tube. Give sliding surfaces a thin coat of Optimoly HT paste. Insert control lever with stud and screw in mounting nut. Only screw in mounting nut finger tight.

1. Move steering wheel height control lever to release position.

Remove balls and spring. Make sure that a cloth is held above the area of the balls (to prevent injury) and catch the first ball after turning the bracket.

3. Install balls and springs. First install one ball with spring. Then apply second ball with spring, using a suitable piece of pipe or a socket wrench, until the bracket can be turned on the balls. Balls must engage in one of the 5 holes in the bracket.

4. Tighten mounting nut of control lever so that the locking position is reached with a medium amount of force. When more force is applied, it should be possible to turn the control lever further in locking direction.

REPLACING UPPER STEERING SHAFT BEARING

1. Remove universal joint after unscrewing two hexagon head setscrews.

2, Disconnect battery ground wire at body. If car has electric seats, move them back completely to make work easier.

3. Pull off impact pad on steering wheel and remove horn wires. Mark position of steering wheel on steering shaft. Unscrew hexagon nut and remove steering wheel with washer.

4. Unscrew cover underneath instrument cowl (not on older models) and cover underneath steering column switch.

5. Unscrew mounting bolts for instrument cowl.

6. Unscrew mounting bolt for steering column switch.

7. Remove steering column switch after disconnecting plug connector and pulling off plugs, lifting instrument cowl for this.

8. Remove circlip and support on steering shaft.

9. Unlock steering lock and push steering shaft into steering protective tube far enough so that intermediate shaft in engine compartment rests on camshaft housing.

10. Apply a standard internal-claw puller, e. g. puller 62 - 020 from Schrem in Giengen, in upper steering shaft bearing. Spread puller enough so that bearing inner race is not pulled out of bearing outer race while driving out bearing (arrow}, since otherwise the balls would fall down into the steering tube.

11 Connect Special Tool VW 771 with internal-claw puller and drive out upper steering shaft bearing.

12. Drive in new steering shaft bearing flush with Special Tool VW 433. Surface on bearing collar must face up because of steering column switch guide tab.

14. Install steering column switch and covers. Connect battery ground wire.

15. Install universal joint between steering and intermediate shafts. If necessary, adjust 8 mm gap (see page 48 - 23).

16. Install steering wheel so that its spokes are horizontal when road wheels point straight ahead or according to mark made before removing.

Install mounting nut with washer and torque to 50 Nm (36 ftlb).

If necessary (not positioned horizontally before removing and slightly different universal joint position), correct steering wheel position after test drive.

13. Pull or push up steering shaft in steering tube. Check axial play of steering shaft, see page 48 - 25.

If there is no axial play, it must be adjusted since otherwise the new bearing could be destroyed in a short time. Install support and circlip.

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