Overview - Electromechanical Power Steering Gear

Fig 1: Electro-Mechanical Steering Gear Overview

Courtesy of AUDI OF AMERICA, LLC

1. Clamp
   • Always replace if removed
   • Use the CV Joint Boot Clamp Tool to tension the clamp, refer to Fig 3
     NOTE:

     Do not open or bend the new clamp.

   • For the correct version, refer to parts.
2. Tie rod
   • 100 Nm
   • Removing and installing, refer to TIE ROD, REMOVING AND INSTALLING .
   • Grease the joint with Power Steering Gear Grease
3. Electromechanical Steering Gear
   • Removing and installing, refer to ELECTROMECHANICAL POWER STEERING GEAR, REMOVING AND INSTALLING .
   • Grease the steering rack with Power Steering Gear Grease Note: there are different types of grease for the left and right. For allocation, refer to parts.
   • There are different versions, refer to parts.

     A removable heat shield mat was installed on the steering gear at start of production. Be sure to install this mat if installing the old steering gear again.

     A removable heat shield mat on the steering gear was replaced by a bonded heat shield mat as a running change. It is therefore not necessary to take the mat from the old steering gear and installing on a new steering gear.

     A replacement steering gear comes with the bonded heat shield mat.

4. Tie Rod End
   • Removing and installing, refer to TIE ROD END, REMOVING AND INSTALLING .
   • Check dust caps for damage and correct seating
   • Check dimension, refer to Fig 2
5. Nut
   • 80 Nm
   • Counterhold on the tie rod end when loosening or tightening
6. Spring Clamp
   • Always replace if removed
   • Spring Clamp, Installing, refer to Figure
7. Boot
   • Check for damage
   • Always replace if removed
   • Coat the inside of the joint boot seats all the way around and evenly with Power Steering Gear Grease before installing .
   • Check the boot seat on the steering gear housing for damage. The steering gear must be replaced if there is damage.
   • Must not be twisted when toe is being adjusted
   • Make sure it is installed correctly, refer to Figure.
   • Replacing, refer to BOOT, REPLACING .
8. Clamp
   • Always replace if removed
   • Use the CV Joint Boot Clamp Tool to tension the clamp, refer to Fig 3
     NOTE:

     Do not open or bend the new clamp.

   • For the correct version, refer to parts.
9. Tie Rod
   • 100 Nm
   • Removing and installing, refer to TIE ROD, REMOVING AND INSTALLING .
   • Grease the joint with Power Steering Gear Grease
10. Tie Rod End
    • Removing and installing, refer to TIE ROD END, REMOVING AND INSTALLING .
    • Check dust caps for damage and correct seating
    • Check dimension, refer to Fig 2
11. Locking Nut
    • 80 Nm
    • Counterhold on the tie rod end when loosening or tightening
12. Spring Clamp
    • Always replace if removed
    • Spring Clamp, Installing, refer to Figure
13. Boot
    • Check for damage
    • Always replace if removed
    • Coat the inside of the joint boot seats all the way around and evenly with Power Steering Gear Grease before installing .
    • Check the seat for the boot on the steering gear for damage before installing. If the steering gear housing is damaged, replace the steering gear.
    • Must not be twisted when toe is being adjusted
    • Make sure it is installed correctly, refer to Figure.
    • Replacing, refer to BOOT, REPLACING .

Fig 2: Tie Rod End Check Dimension

Courtesy of AUDI OF AMERICA, LLC

• Place a steel ruler -2- on the tie rod end and push it all the up to the edge -arrow- of the tie rod end -1-.
• Replace the complete steering gear with the tie rod and tie rod end if the check dimension -a- is less than 188 mm.

Fig 3: Tensioning Inner Clamp

Courtesy of AUDI OF AMERICA, LLC

-- Mount the CV Joint Boot Clamp Tool -1- as illustrated. Make sure that the jaws of the clamp tool are seated in the corners -arrows- of the clamp.

-- Tighten the clamp by turning the spindle using a torque wrench -2- (do not tilt the pliers).

• Use torque wrench -2- with 5 to 50 Nm range (for example, Torque Wrench 1331 5-50Nm VAG1331).
• Make sure the thread on the spindle -1- is easy to move. Lubricate with MoS₂ grease, if necessary.
• If the thread is tight, for example, dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Outer Boot Assembly

Fig 4: Identifying Outer Boot Assembly Dimension -A-

Courtesy of AUDI OF AMERICA, LLC

• Dimension -a- 2 mm.