General Repair Information

The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful steering gear repairs. Understandably, general safety guidelines apply when performing repairs.

A series of applicable general notes for individual repair procedures - otherwise listed several times at many points has been collected here. They apply for this service information.

Steering Gear

Thoroughly clean connecting points and their surrounding areas before loosening.
When installing steering gear, make sure centering sleeves are correctly seated between bracket and steering gear.
Place removed parts on a clean surface and cover to prevent contamination. Use foils and paper. Do not use fluffy cloths!
Install clean parts only: remove the replacement part from its packaging just before installing it.
Use exclusively lubricants and sealants marked with part numbers.
Carefully cover over opened components or seal, if repairs are not carried out immediately.
Two different steering gear versions were implemented in MY 2004. Notes about difference. Refer to STEERING GEAR DIFFERENCES, GENERATION 1 AND 2, RABBIT .
As of MY 2009 steering gear generation 3 is being installed. Information on the differences between generation 2 and generation 3. Refer to STEERING GEAR, GENERATION 2 AND GENERATION 3 DIFFERENCES .

Gaskets and Seals

Always replace seals and gaskets.
After removing seals, inspect contact surface on housings and shafts for burrs and damage and repair if necessary.
Remove all residual sealant of fluid seals from sealing surfaces, no sealant residue must enter the steering gear housing when doing this.

Bolts and Nuts

Fig 1: Identifying Nut And Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Loosen and tighten the bolts and nuts of covers and housings in a diagonal sequence.
Loosen and tighten especially sensitive parts in diagonal manner in stages, for example servo motor with control module.
Tightening specifications for unoiled bolts and nuts are given.
Always replace self-locking nuts and bolts.

Electrical Components

Surely everyone has been shocked at one time or another when coming into contact with a metal object. The reason for this is the build-up of static electricity in the human body. This charge can lead to functional problems by touching the electrical components of steering gear.

Fig 2: Electrical Warning

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Touch a grounded object - for example a water pipe or a vehicle hoist - before working on electrical components. Do not make direct contact on connector terminals.

Guided Fault Finding, OBD and Test Instruments

Fig 3: Identifying VAS 5051

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Before performing repairs on electro-mechanical steering, the malfunction cause must be determined as exactly as possible using vehicle diagnostic, testing and information system VAS 5051 in operating modes guided fault finding, vehicle self-diagnosis and test instruments.