Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLKSWAGEN2002GOLF GLS, 2.0 K, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 10 (STEERING (A3 PLATFORM))POWER STEERING GEAR (TRW)NOTES
2002 Volkswagen Golf GLS, 2.0 K, Standard
Power steering gear (TRW): Notes
2002 Volkswagen Golf GLS, 2.0 K, StandardSECTION Notes
WARNING: This page does not describe the selected car, but rather 27 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.
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.
NOTE:
- 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, see POWER STEERING PUMP, RESERVOIR AND HYDRAULIC LINES, SERVICING
The following list pertains to Fig 1.
- Tie rod end, right
- Separating, see REMOVING
- Checking, see TIE ROD ENDS, CHECKING
- Revised Cabrio tie rod end, see REVISED TIE ROD END, CABRIO
- 50 N.m (37 ft lb)
- Hose clamp
- Boot
- Pull on and off over tie rod
- Must not be twisted after adjusting toe
- Not interchangeable with boot for ZF steering gear
- Clamp
- Always replace
- Tightening, see INSTALLING
- Tie rod, right
- 70 N.m (52 ft lb)
- Removing and installing, see TIE RODS (TRW OR ZF), REMOVING AND INSTALLING
- Adjusting to length, see INSTALLING
- 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.)
- Clamp
- Always replace
- Tightening, see INSTALLING
- Tie rod, left
- 70 N.m (52 ft lb)
- Removing and installing, see TIE RODS (TRW OR ZF), REMOVING AND INSTALLING
- Wheel alignment, see WHEEL ALIGNMENT, CHECKING
- 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.)
- Tie rod end, left
- Separating, see REMOVING
- Checking, see TIE ROD ENDS, CHECKING
- Revised Cabrio tie rod end, see REVISED TIE ROD END, CABRIO
- Self-locking hex nut
- Always replace
- 30 N.m (22 ft lb)
- Pressure balancing line
- Check for damage (dents, kinks)
- Self-locking hex nut
- Always replace
- 30 N.m (22 ft lb)
- Clamp
- Rubber mounting
Inside diameter:
- TRW: 44 mm (1.73 in.)
- ZF: 50 mm (1.97 in.)
- Steering gear
- Removing and installing, see POWER STEERING, SERVICING
- Adjusting, see POWER STEERING GEAR, ADJUSTING WHEN INSTALLED
- Changes to splines on vehicles from VIN 1HN 002 450, see CHANGES TO SPLINES ON STEERING GEAR PINION AND STEERING COLUMN UNIVERSAL JOINT SHAFT
- Steering gear with extra servo assistance only available on vehicles up to 66 kW (90 hp)
- 30 N.m (22 ft lb)
- Lower universal joint
- Vehicles from VIN 1HN 002 450, see CHANGES TO SPLINES ON STEERING GEAR PINION AND STEERING COLUMN UNIVERSAL JOINT SHAFT
- Cover disc
- Seal
- Always replace
- Union nut
- 30 N.m (22 ft lb)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.