48-31

Power steering gear (TRW)

WARNING!

Do not re-use fasteners that are worn or deformed in

normal use.
Some fasteners are designed to be used only once,
and are unreliable and may fail if used a second time.
This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow
recommendations in this manual-replace these
fasteners with new parts where indicated, and any
other time it is deemed necessary by inspection.

If the power steering gear is malfunctioning determine cause

using pressure tests and leakage tests. If a malfunction
exists, then replace the steering gear.
 48-32

Notes:
If reservoir fluid is low check steering system for leaks.
If leaks occur at line connections, tighten connections,
wipe area dry and recheck for leaks.
The steering gear can be serviced if the pinion seals or
the rack seals in the steering gear are leaking.
To check rack seals, loosen the hose clamp on the boot
and push boot to one side.
Always replace all self-locking nuts and bolts.
Do not attempt to weld or straighten steering
components.
Use only steering gear grease, Part No. AOF 063 000 04,
to grease the steering rack.
Type of oil: hydraulic oil, Part No. G 002 000
System oil capacity: 0.7-0.9 liter (0.74-0.95 US qt.)
Hose/line routing page 48-48
 48-33

1 - Tie rod end, right

Separating page 48-22
Checking Repair Manual, Maintenance
Revised Cabrio tie rod end page 48-29
2 - 50 Nm (37 ft lb)
3 - Hose clamp
4 - Boot
Pull on and off over tie rod
Must not be twisted after adjusting toe
Not interchangeable with boot for ZF steering gear
5 - Clamp
Always replace
Tightening page 48-27
 48-34

6 - Tie rod, right

70 Nm (52 ft lb)
Removing and installing page 48-26
Adjusting to length page 48-27
Not interchangeable with tie rod for ZF steering gear
Seat dia. of boot - 4 - at tie rod:
TRW: 12.7 mm (0.50 in.)
ZF: 15 mm (0.59 in.)
7 - Clamp
Always replace
Tightening page 48-27
8 - Tie rod, left
70 Nm (52 ft lb)
Removing and installing page 48-26
Wheel alignment page 44-1
Not interchangeable with tie rod for ZF steering gear
Seat dia. of boot - 4 - at tie rod:
TRW: 12.7 mm (0.50 in.)
ZF: 15 mm (0.59 in.)
 48-35

9 - Tie rod end, left

Separating page 48-22
Checking Repair Manual, Maintenance
Revised Cabrio tie rod end page 48-29
10 - Self-locking hex nut
Always replace
30 Nm (22 ft lb)
11 - Pressure balancing line
Check for damage (dents, kinks)
12 - Self-locking hex nut
Always replace
30 Nm (22 ft lb)
13 - Clamp
14 - Rubber mounting
Inside diameter:
TRW: 44 mm (1.73 in.)
ZF: 50 mm (1.97 in.)
 48-36

15 - Steering gear
Removing and installing page 48-21
Adjusting page 48-37
Changes to splines on vehicles from VIN 1HN 002
450 page 48-25
Steering gear with extra servo assistance only
available on vehicles up to 66 kW (90 hp)
16 - 30 Nm (22 ft lb)
17 - Lower universal joint
Vehicles from VIN 1HN 002 450 page 48-25
18 - Cover disc
19 - Seal
Always replace
20 - Union nut
30 Nm (22 ft lb)
 48-37

Power steering gear, adjusting when

installed

TRW

Engine switched off

Vehicle raised on hoist

Wheels in straight ahead position

Notes:

Adjustment only required when steering play is

not correct.

Two technicians are required for the

adjustment.

Adjusting

- First technician: turn steering wheel back and forth (approx. 30 from center).
If play is excessive, knocking noise will be heard inside vehicle.
- Second technician: loosen locking nut, counter hold using 3315/9 and carefully
turn adjusting nut in until knocking noise can no longer be heard from vehicle
 interior.
- Tighten locking nut.
- Road test vehicle.
Steering wheel must self center without sticking after cornering or maneuvering
 48-38

Power steering gear, adjusting with new

rack

TRW

If a new rack has been installed then the steering

play must be adjusted as follows:

- Drill 5.1 mm diameter hole in center of adjusting screw (center on reverse side).
- Thoroughly clean adjustment nut.
- Center rack by measuring left and right-hand overhang.
- Install thrust piece and spring in housing (if not already installed).
- Turn adjusting screw and lock nut into housing until markings are covered.
 48-39

- Attach dial indicator and set to "0" position with approx. 1 mm (0.039 in.)
preload.
Make sure that the dial indicator does not stick and its face is not damaged or
deformed.
1 - 3315/8
2 - 3315/9
3 - 3315/1
4 - Dial gauge holder VW 387
- Install right side tie rod hand-tight.
- Turn rack radially by hand (upper right section of illustration) and measure run
out on dial indicator.
Max. run out: 0.10 mm (0.0039 in.)
- If the run out is greater than 0.10 mm (0.0039 in.), turn adjusting nut out of
housing slightly.
- Tighten lock nut.
- Recheck run out and repeat adjustment if necessary.
- Remove dial indicator.
 48-40

Sealing hole in adjustment nut with plug from repair kit

- Insert clip -2- with seal -1- into hole.

- Place one drop of sealant in clip hole (arrow) and press plug -3- into clip.
Sealant part number: AMV 188 001 02
- Install tie rods page 48-26 .