48-41

Power steering gear (ZF)

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 power steering gear is malfunctioning determine cause

using pressure tests and leakage tests. If a malfunction
exists, then replace the steering gear.
 48-42

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.
To check rack seals, loosen the hose clip 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 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.)
Suction hose and pressure line routing page 48-48 .
 48-43

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
Remove tie rod end before removing
Check for wear (cuts, cracks), make sure sealing
surfaces and sealing lips are clean and undamaged
End diameters are larger than those of TRW power
steering gear
Not interchangeable with boot for TRW steering gear
5 - Clamp
Always replace
Tightening page 48-27
Not interchangeable with clamps for TRW steering
gear
 48-44

6 - Tie rod, left

Removing and installing page 48-26
Adjusting to length page 48-27
Not interchangeable with tie rod for TRW steering
gear
Seat dia. of boot - 4 - at tie rod:
ZF: 15 mm (0.59 in.)
TRW: 12.7 mm (0.50 in.)
7 - Clamp
Use pliers to remove
Tightening page 48-27
Not interchangeable with clamps for TRW steering
gear
8 - Tie rod, right
Removing and installing page 48-27
Wheel alignment page 44-1
Not interchangeable with tie rod for TRW steering
gear
Seat dia. of boot - 4 - at tie rod:
 ZF: 15 mm (0.59 in.)
TRW: 12.7 mm (0.50 in.)
9 - Tie rod end left
Separating page 48-22
Checking Repair Manual, Maintenance
Revised Cabrio tie rod end page 48-29
 48-45

10 - Self-locking hex nut

Always replace
30 Nm (22 ft lb)
11 - Pressure balancing line
12 - Self-locking hex nut
Always replace
30 Nm (22 ft lb)
13 - Clamp
14 - Rubber mounting
Inside diameter:
ZF: 50 mm (1.97 in.)
TRW: 44 mm (1.73 in.)
15 - Steering gear
Removing and installing page 48-21
Check turning torque
Turning torque on vehicles equipped with VR6
engine is approx. 2 Nm (18 in. lb) higher
Adjusting page 48-47
Steering gear with extra servo assistance only
 available on vehicles up to 66 kW (90 hp)
16 - 30 Nm (22 ft lb)
 48-46

17 - Lower universal joint

18 - Cover disc
19 - Sealing ring
Always replace
20 - Union nut
30 Nm (22 ft lb)
21 - Data plate and company initials
 48-47

Power steering gear (ZF), adjusting

Adjustment requirements:

Engine switched off

Vehicle raised on hoist

Wheels in straight ahead position

Note:

Two technicians are required for the adjustment.

Adjusting

- First technician: turn steering wheel back and forth (approx. 30 from center).
Knocking noise will be heard inside vehicle if there is excessive play
- Second technician: carefully turn adjusting bolt (arrow) into cover until knocking
noise can no longer be heard by first technician sitting inside vehicle.
- Road test vehicle.
Steering wheel must self center without sticking after cornering or
maneuvering.
- Re-adjust if necessary.