Removing and installing manual steering gear Tools

No.

Designation

Special tool

Order number

Explanation

1

Torque wrench Stahlwille 730 R/20 or Hazet 6292-1 CT

commercially available (refer to workshop manual)

2

Wrench socket

commercially available, e.g. Hazet or Stahlwille (24 mm across flats)

3

Tie-rod puller

commercially available, e.g. Nexus 168-1

-

Centering bolt

9116

000.721.911.60

Too Short Porssche 924 Tie Rod

No.

Designation

Removal

Installation

1

Self-locking hexagon nut

1

replace, tighten to 30 Nm (22 ftlb)

2

Hexagon head bolt

1

when fitting steering shaft, avoid putting the shaft under strain

3

Split pin

2

only present if castle nut is fitted

replace

4

Castle nut or lock ring

2

30 Nm (22 ftlb), turn to next split pin hole if required (max. torque 50 Nm (37 ftlb)). Tighten lock nut to 50 Nm. (37 ftlb)

5

Hexagon head bolt

4

if the steering or the tie-rod(s) are to be replaced, start by slackening the castle nut(s), item 9.

tighten to 23 Nm (17 ftlb)

6

Washer

4

7

Clamp

2

Fit with Contifix or Capella - Oil B Waxfree (supplied by Texaco). Note instructions for Capella assembly oil on page 48 - 010.

8

Steering tie rod assy.

2

undo only if the steering or the tie rod(s) have to be replaced.

when replacing, note references on page 48-011 (3 versions). Adjust with the steering rack blocked (page 48-011).

9

Lock nut

2

tighten to 50 Nm (37 ftlb) with the steering rack adjusted correctly.

Check adjustment again after having tightened the adjustment.

No.

Designation

Removal

Installation

10

Steering stop ring

2

install in correct position. Caution:

Never omit the stop ring when fitting the steering tie-rod to the steering gear since this may cause the tie-rod to retract fully into the steering gear housing (risk of damage to the steering)

11

Bellows, left-hand

1

check, replace if required

12

Clamp

1

replace, only fitted to RH side

13

Bellows, right-hand

1

check, replace if required

14

Rack-and-pinion steering gear

1

Never fit steering tie-rod (s) without stop ring, item 10. Coat fully extended tie-rod ends with VW steering gear grease AOF 063 000 04.

15

Rubber insert, right-hand (1 x) left-hand (1 x)

2

check, replace if required

16

Plug

1

center in centered position relative to steering gear, remove plug

replace if required

17

Ball joint

2

check, make sure correct version is fitted when parts are replaced (refer to spare parts catalog)

18

Hexagon nut

2

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