Adjustment
The steering rack adjustment can be assessed during normal operation as follows:
- a) If the steering wheel is difficult to turn and the steering wheel does not return to its original position automatically, the rack is pressed too tightly.
- b) If there is vibration in the steering and the steering wheel turns too easily, the adjustment is too weak (make sure that the vibration is not caused by something else).
To adjust the steering mechanism, you will need a special key, shown in Figure L:7. You can make the key yourself from a regular 17 mm open-end wrench - to do this, you need to heat it at a distance of about 50 mm from the end and bend it at an angle of 25°.
Using this key, loosen the lock nut of the adjusting screw, which is located on the back of the housing (drawing L:8). Loosen the adjusting screw slightly, then tighten it until you feel the screw touch the rack stop washer. Lock the screw in this position by tightening the lock nut.
Check the steering operation. If the steering is stiff, loosen the adjusting screw slightly; if it is too light, tighten it slightly, and then check the steering wheel rotation again.
Replacing steering gear covers
Covers must be replaced if damaged in any way (cracks, abrasions, tears, etc.).
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The boots are secured with spring clips or clamps to the tie rods and steering gear housing. If the boots need to be replaced, remove the tie rod ends, then pull off the steering gear boots (see section "Steering rods and joints"). When installing new covers, lubricate the inside of the cover and the steering rod - this will make it easier to install the cover. Be careful not to damage the cover, since even small cracks will allow water and dirt to get into the steering mechanism.
Removal the steering gear
1. Loosen the wheel mounting bolts, lift and place the front of the vehicle on supports (see chapter "Basic rules for carrying out work"). Remove the front wheels.
2. Disconnect both steering rod joints from the steering knuckle arms using a ball joint puller.
3. Disconnect the gear shift drive from the bracket on the steering gear housing.
4 Remove the clamp bolt securing the lower steering shaft joint to the steering gear pinion shaft (4, figure L:1).
5. Unscrew three (or four) nuts (M13) for fastening the steering gear housing to the body brackets.
6. Remove the steering gear from the studs and carefully remove it through the opening of the left wheel arch.
Installation
Installation of the steering gear is generally carried out in the reverse order of removal. Please note the following:
- a) The rack, pinion and steering gear housing are not supplied as separate parts; in case of damage or wear, replace the steering gear assembly. VW branded exchange units are supplied without steering rods, in this case, transfer the rods to the new steering gear from the old one or install new steering rods (see above).
- b) Before installing the steering gear, set the rack to the middle position - the "C" dimension on both sides should be the same (drawing L:9).
- c) Screw the steering rods onto the rack on both sides, maintaining dimension "B" (drawing L:2) - see section "Technical data".
- d) On later production vehicles, the steering gear mount has been changed - the steering gear is secured with two brackets on rubber pads (drawing L:5). This type of steering gear cannot be installed on an earlier model vehicle (until August 1977). Before installing such a steering mechanism, check the condition of the rubber cushions and replace them if necessary.
- d) When installing a new steering gear on a vehicle with an automatic transmission, bend up the plate designed to secure the gearshift drive (A, figure L:1) - otherwise the plate will touch the exhaust pipe.
- e) Use new self-locking nuts to secure the steering gear to the studs.
- g) First insert the pinion shaft into the lower joint of the steering shaft, aligning the transverse groove of the shaft (A) with the hole of the joint (B) — figure L:11, and then install the steering gear onto the studs.
- h) Tighten all nuts and bolts to the torque specified in section "Technical data".
- i) Adjust the gearshift drive as described in Chapter "Clutch and manual transmission".
- k) Check the front wheel alignment as described above.
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