DIY Volkswagen Polo steering rack repair

In detail: DIY Volkswagen Polo steering rack repair from a real master for the site my.housecope.com.

Content

1 The device and operation of the steering rack "Volkswagen Polo" sedan, major malfunctions and do-it-yourself repairs
2 Volkswagen Polo Sedan: professional replacement of tie rod ends, repair of VW Polo steering rack and column in service station conditions

Road safety comes first. To avoid emergencies, you must constantly take care of your car, check the performance of all components.

Steering can cause major problems while driving. The correct operation of all elements of the steering mechanism is the key to safe driving, especially in urban conditions.

Volkswagen Polo sedan is a car designed by German craftsmen for Russian conditions. But no matter how strong the Wolfsburg sedan may seem, even it requires careful maintenance.

Steering Polo is one of the main topics raised by motorists in the endless forums on the Internet. Many people start to have strange noises when driving. A complication can occur in any part of the device: from the steering wheel to the tie rod ends. To avoid costly repairs, it is important to diagnose in time and figure out what the difficulty is.

The general scheme of the steering of the Volkswagen Polo sedan consists of three main components: the steering column, the electric booster and the "gear-rack". Most often, the last part is exposed to wear - the steering rack.

The reiki structure looks like this. Two steering rods are attached to the shaft gear. At the ends there are tips, which, thanks to ball joints, interact with the steering knuckles of the car's suspension. The protective function is performed by special covers that protect the surface of the mechanism from moisture and dirt.

Video (click to play).

The rack pinion is one of the oldest mechanisms used in early automobiles in the early 20th century. Over time, the design faded into the background, being replaced by more complex worm gears. However, in recent decades, global manufacturers have returned to basics using steering rack technology in the automotive industry. This decision was largely due to the appearance on the market of the independent MacPherson suspension. The simplified design of the new type of suspension required an unpretentious steering mechanism.

The Volkswagen Polo sedan, which is an example of modernity, is equipped with the same MacPherson strut with a standard steering rack. The only difference between the mechanism and the analogue of a century ago is the presence of electronic auxiliary control systems, which are installed on most models today.

The main positive side of the steering rack is the simplicity of the mechanism. The structure uses a small number of rods and hinges, which reduces the frequency of breakdowns. In addition, if you perform a high-quality repair of the rack and pinion mechanism, then you can forget for a long time about trips to the car service or the endless waste of invaluable time in the garage. The advantages can also include the insignificant weight of the device. Like the rest of the suspension system, the rack is made of lightweight materials, which are great cost savings for manufacturers.

Thanks to the excellent stiffness of the rack, it guarantees high precision of car control, and the electric power steering smoothly returns the steering wheel to the standard position.

Unfortunately, the rigidity also conveys disadvantages, which are felt in the form of countless "irregularities" of Russian roads.A negative feature is the occurrence of unpleasant vibrations and noises in the rail, which appear on sedans with low mileage. This is a headache for many modern cars equipped with the MacPherson system.

Sooner or later, the mechanism wears out, and similar "sound" problems emerge, resulting in expensive repairs. It all depends on the build quality and manner of operation.

The main breakdowns of the device are associated with an increase in the free wheeling of the steering wheel, which becomes difficult to rotate, and incomprehensible knocks appear in the column. Increased travel is commonly associated with loose ball link mountings or increased rail-to-bolt clearance. The same reasons can be caused by extraneous noise in the operation of the device.

Depending on the degree of damage to the rail, you can repair individual elements of the system, or completely change the mechanism.

The easiest way, of course, is to install a new unit in place of the old one. The procedure will require the following tools: two keys "13" and "18" with sockets of the same dimensions, a hexagon "6" and a special removable device for hinges. The keys for "19" and "21" are also useful for removing the tips of the steering rods. To dismantle the front suspension cross member, you will need to look for a key on "16" in the amount of two pieces and a head on "14", as well as a hydraulic stand and a jack.

The sequence of actions is as follows:

First you need to remove the cover located under the dashboard. There is a built-in small piston that can be easily removed.

We find the main mechanism - the steering rack, which is connected to the intermediate shaft using a tightening bolt.

We unscrew the bolt and dismantle the intermediate shaft from the gear.

Then we remove the steering rods from the steering knuckles.

We remove the cross member together with the rail and stabilizer bars.

Disconnect the steering gear from the cross member by screwing in two mounting bolts.

We take out the rail, change it to a new copy and assemble all the parts in the reverse order.

In conclusion, it is worth going to the maintenance station so that the specialists use their equipment to adjust the alignment angles of the front wheels.

Prices for a complete set of Volkswagen Polo steering gear are not small. Therefore, if the funds do not allow you to purchase a new sample, and the external condition of the device quite satisfies you, then you can disassemble the mechanism and repair the internal parts.

The most common cause of unpleasant knocking on the rail is a small plastic sleeve inside the metal "tube".

To get to the hated element, you need to disassemble the device:

First, remove the boot from the rail.

Unscrew the nut and take out the steering "worm", under which the needle bearing is located.

The left steering rod can be removed with a gas wrench.

Using a puller, we take out the sleeve from the device.

In the image and likeness of the old model, we make a new sleeve from a special plastic blank: we cut out small cuts with a hacksaw so that the air circulates perfectly through the "tube".

Image - DIY Volkswagen Polo steering rack repair

We insert a new copy into place, apply a special lubricant to the elements to improve the interaction of parts and assemble the installation in the reverse order.

This completes the repair. After such a procedure, peace and quiet in the salon of the Polo sedan is guaranteed.

The Volkswagen Polo steering rack solves the problem of transferring power from the steering wheel to the traction of the car. This model is famous for its reliability, but the car part has its drawbacks and weaknesses. On the market there are slats from various manufacturers, original and analogs.

The steering on the Volkswagen Polo is distinguished by comfort, good stability and light feedback. The steering rack of this model allows you to easily cope with maneuvering in difficult road conditions. This is especially noticeable when cornering.This Volkswagen Polo assembly includes the following main parts:

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anthers and tie rod socket;
gear rack, O-rings;
center seal, booster cylinder;
hydraulic tubes;
end seal;
input shaft gear;
cylindrical spools.

Driving accuracy is 90% dependent on the correct operation of the steering rack. Therefore, it is important to periodically evaluate the condition of the part. This will avoid an emergency. The very mechanism of the device of this component of the car is complex.

Therefore, in the absence of the necessary equipment, experience and knowledge, it is simply impossible to carry out repairs on your own. The way out of the situation will be an appeal to specialists.

The electromechanical amplifier deserves special attention. The drive gears drive the wheel steering components.

A number of steering rack faults can be eliminated. But in some cases, repairs are simply not advisable. In this case, a replacement should be carried out. The price of a steering rack for a Volkswagen Polo depends on a number of factors. Moreover, this detail does not differ on bodies of various types - sedan, hatchback. Price:

There are a number of weak, problem areas - typical for a given vehicle unit. Problems do not arise often, but they occur due to difficult roads throughout the Russian Federation. In fact, the steering section is one of the most stressed systems in a car. Immediately after the undercarriage. The greatest production is present at the point of engagement of the gear and the gear base. That is why problems most often arise in just this pair of details.

The cause of a node malfunction may be:

wear of the toothed part;
mechanical destruction.

In the first case, the problem can be solved by simply adjusting the steering rack. If there is significant wear, which cannot be eliminated in this way, or there is mechanical destruction, then the parts should be replaced. The adjustment is carried out with a special nut. It controls the stop, its position determines the distance between the rack teeth.

The replacement process includes standard steps:

it is necessary to lift the car on a lift, otherwise and remove the front wheels (the steering wheel must be fixed straight);

then, using a head 18, it is enough to unscrew 4 bolts - the subframe will be disconnected along with the stabilizers (and the subframe itself will remain hanging on the muffler);
the steering rack must be pulled out carefully through the muffler - the latter does not need to be removed for this.

If it is necessary to carry out only a replacement, then the installation is carried out in the reverse order. Most often, an anther revision is required. It is enough to remove the plastic gland, after which you can see the 36 mm head under it. After unscrewing, it is necessary to unscrew the rail to the left position and remove the steering worm. The needle bearing is located at the bottom.

If necessary, the small plastic sleeve can be pulled out during the disassembly process. Assembly is carried out upside-down. It is very important to carry out all operations carefully. Especially when it comes to plastic components. Otherwise, the destruction of the part is possible. In the process of removing and installing the rack, it will be possible to replace the steering tips. Since the dismantling process involves their removal.

After replacing the rail, tips, you need to make the alignment. And also to adjust the rail itself with a special nut. In the absence of experience, it is better to entrust this business to professionals, so mistakes can be avoided.

The device and operation of the steering rack "Volkswagen Polo" sedan, major malfunctions and do-it-yourself repairs

Good steering is the key to safe driving in any car, including the Volkswagen Polo sedan. A malfunctioning steering rack is the cause of many road traffic accidents (RTA), therefore, automakers pay a lot of attention to the reliability of this unit. Volkswagen Polo, developed by the German concern VAG, is produced in Russia, on the territory of the Kaluga Automobile Plant. The car enjoys a well-deserved popularity among Russian motorists.

The main unit of the system that controls the car is the rack that regulates the rotation of the front wheels. It is located on a subframe in the area of the front axle suspension. The end part of the steering shaft of the column, on which the steering wheel is mounted, goes into the salon. The steering column also includes: an ignition switch and a lever handle that adjusts its position relative to the driver. The column is covered by a cover located below the dashboard in the cabin.

The assembly that controls the car includes the following main components:

steering column with steering wheel;
a driveshaft through which the column is connected to the rail;
steering rack that controls the rotation of the wheels;
electric amplifier with control unit.

The torque from the steering wheel is transmitted to the rack-pinion that controls the rotation of the wheels

The steering column transfers the rotational force from the driver's steering wheel to the intermediate shaft, with cardan shafts at the ends. This part of the control system consists of the following parts:

Upper and lower intermediate shaft driveshafts.
Intermediate shaft.
The bracket that secures the steering column to the body.
Handle of the lever that controls the position of the steering column.
Egnition lock.
The shaft to which the steering wheel is attached.
Electric motor with gear.
Electric power steering control unit (ECU).

The intermediate propeller shaft allows you to change the position of the steering wheel in the cabin

An electric motor with a gearbox generates additional torque for the shaft to which the steering wheel is attached. The electronic control unit analyzes the speed of the car, the angle of rotation of the steering wheel, as well as information from the torque sensor developed on the steering wheel. Based on these data, the ECU decides to turn on the electric motor, making it easier for the driver. The steering column contains energy-absorbing elements that increase the passive safety of the driver. There is also an anti-theft device that blocks the steering shaft.

The ECU plays a special role in the operation of the system. It not only determines the direction and amount of force to be added to the torque of the steering shaft, but also reports errors in the operation of the entire steering system. As soon as a malfunction is detected, the control unit memorizes its code and turns off the electric power steering. A fault message appears on the dashboard informing the driver.

The choice of the classic steering rack is due to the fact that the car manufacturer VAG uses a McPherson-type suspension for the front-wheel drive of the car. The mechanism is simple and has a minimum number of parts. This results in a relatively low weight of the rail. The steering gear consists of the following main components:

Traction tip of the left wheel.
Link steering the left wheel.
Anthers that protect against dirt.
Drive shaft with worm gear.
A housing that acts as a crankcase.
Right wheel control rod.
Traction tip of the right wheel.

The accuracy of turning the wheels directly depends on the operation of this device.

The device works as follows: the rack-pinion, located inside the housing (5), has fixed rods at the ends that control the wheels (2, 6). Rotation from the steering column is transmitted through the drive worm shaft (4). Carrying out a translational movement from the rotation of the worm gear, the rack moves the rods along its axis - to the left or to the right. At the ends of the rods, there are traction ends (1, 7), interacting through ball joints with the steering knuckles of the McPherson front suspension. To prevent dust and dirt from getting into the mechanism, the rods are covered with corrugated anthers (3). The steering rack housing (5) is attached to the front axle cross member.

The steering unit is designed for the entire period of operation of the Volkswagen Polo sedan. In the event of a malfunction or poor technical condition that does not meet safety requirements, its main components can be repaired or replaced.

Over time, any mechanism wears out. The steering is no exception. The degree of wear is influenced by the condition of the road surface in the region where the vehicle is used. In some cars, problems appear after the first 10 thousand kilometers. Others reach, without any problems in management, up to 100 thousand km. Below is a list of common Volkswagen Polo sedan malfunctions and their symptoms:

It is imperative to make cuts in the sleeve so that air gets inside the body

If there is a garage with a viewing hole, an overpass or a lift, you can fix the steering rack malfunction with your own hands. The knock and backlash of the pinion shaft is eliminated by installing a new bushing, the standard sizes of which are presented above. This is one of the most common Volkswagen Polo sedan steering faults. To carry out such a repair, it is necessary to grind the bushing and make cuts in it (see figure).

For dismantling and repair work, you will need a tool:

wrenches in sizes 13, 16 and 18, with socket heads of the same sizes;
hexagon size 6 and dodecagon M10;
keys for 19 and 21, as well as heads for 14 and 32;
self-made head for 36 (see figure below);
removable hinge device;
grease for the rail - you need to choose one so that it does not liquefy at high temperatures;
hammer;
rags.

The work is performed in the following sequence:

The car is installed on the inspection pit.
The plastic steering column cover is removed and the carpet is turned off. It is necessary to unscrew the plastic nut securing the carpet.
The propeller intermediate shaft is separated from the rack drive shaft. In order to unscrew the bolt, you need a key for 13 or a dodecahedron M10

The car is hung on both sides in order to remove the front wheels. For this, stops are installed under the body.

The wheels are removed so that you can pull out the steering rack

The head for removing the shaft must be made by yourself or ordered by a master. In this case, it should be remembered that the diameter of the drive shaft is 18 mm (the head must go through it), and the outer diameter of the head must not exceed 52 mm (it must pass freely into the housing bore).At the top of the head, you need to make cuts in order to use a gas wrench to unscrew.

The fixing nut is very hard to remove, so you need good cuts for the gas wrench and a lever

Marks are placed on the adjusting bolt to return it to its original position during assembly. The bolt is loosened and the pinion shaft is removed from the housing. Immediately after this, it is best to insert the drive shaft into the housing. This is done so that, with further movements of the housing, the needle bearing, which fixes the lower part of the shaft, does not fall apart.

In order to remove the pinion shaft, it is enough to unscrew the bolt 2 turns

From the side of the right link, you can see the retaining ring that fixes the spent sleeve, located immediately behind it.

To remove the bushing, you must first remove the retaining ring

To remove the retaining ring, take a bar, bend and sharpen at one end. Knocked out by tapping on the bar from the side of the left pull.

To prevent the ring from warping, it must be carefully displaced around the entire circumference, moving the bar

Following the retaining ring, the old bushing is removed. In its place, a new bushing and a retaining ring are pressed in.

A small chamfer is removed on the left side of the pinion shaft so that it can fit into the new bushing without problems.

The chamfer can be removed with a file and sanded with fine emery.

The pinion shaft is gently inserted into the hub. If it does not work out by hand screwing in, you can use a hammer by tapping it on the shaft through a block of wood.

Before inserting the shaft, the new bushing must be coated with grease.

All parts are generously lubricated and assembled in the reverse order.

After everything is assembled, you need to check the steering wheel for ease of rotation and return to its original position. Then you need to go to the service station and adjust the wheel alignment so that the car does not drift to the side on the road and the tires on the wheels do not wear out prematurely.

All configurations of these vehicles are equipped with an electric power steering. The column is height adjustable. The standard type of steering gear is rack and pinion. The operation of the EUR is controlled by a separate control unit - it is based on the readings of the torque sensor, the angle of rotation of the steering wheel and the speed of movement. The force applied to the steering wheel increases the geared motor, which works according to the scheme: lower speed - less effort, and vice versa.

That is, in addition to repairing elements directly included in the control mechanism (steering wheel, column, rods, tips, etc.), it includes an ECU, sensors, fuses, connectors, wires. On the one hand, electronics can also fail, forcing them to additionally look for replacement parts for it. On the other hand, it also detects malfunctions and warns about them with an indicator on the instrument panel.

The use of auxiliary devices made it possible to create a simplified type of steering rack. Experienced craftsmen call this an undoubted plus in its device. And after the repair of the steering mechanism in our car service, customers do not experience any control problems for years.

The increased rigidity of the rail is both an advantage (increased control accuracy) and, taking into account the state of Russian roads, a disadvantage (a broken road quickly puts it out of action). The problem can be solved by replacing some parts with analogs (for example, plastic ones with metal ones, they are not as light as the originals from Volkswagen, but more durable).

If you do not want to waste time and money on a more expensive and lengthy repair of the VW Polo steering rack, it is better to immediately pay attention to small, barely noticeable changes in the steering mechanism. The longer the visit to the car service is postponed, the more these signs will manifest themselves, and the details will become unusable.

There is a knock when driving on uneven roads. On a Volkswagen Polo, it usually comes from the bottom, on the right side of the rail.
The control is difficult, namely, the free wheeling of the steering wheel increases, you have to make great efforts when turning, the steering wheel sticks and it does not return to its original position, the steering wheel can rotate more freely in one direction than in the other.

The state of the mechanism is significantly influenced by:

Driving style and experience of the driver (starting with the steering wheel turned out, or holding it in this position for a long time will quickly disable the rail);
The condition of the roadway (driving on irregularities, with the intersection of pits and bumps also has a negative effect on units and parts);
Untimely maintenance (ignoring the signs of malfunctions increases the effect of wear);
Deterioration of parts (sooner or later they deplete their resource, regardless of the driver, road and care).

Knocking noise can be caused by loosening fasteners and increasing clearances. Driving can be difficult due to damage to the boot. Failure of the electronic control unit may also occur.

Not a single master will start repairing and will not even name its approximate cost until diagnostics are carried out.If the person you turned to for help promises to fix everything quickly and for free, without even knowing what the cause of the breakdown may be, it is difficult to call him a specialist in this area.

Both the repair time for the Polo Sedan rail, and its cost, including the price of new parts, entirely depend on the results of the diagnostics. In our car service, it is carried out in a comprehensive manner:

At the first stage, a thorough examination is carried out. Attention is paid to the condition of anthers, threaded connections, fasteners. The backlash angle of the rods and the joints of their ends is checked. The source of the knock or rattle is determined.
At the second stage, the performance of the steering rack is tested using a special test stand.
At the third stage, diagnostics are carried out already during the repair, after disassembling the mechanism, the condition of the parts is checked, the unusable ones are replaced.

Repairing a steering rack on a Polo Sedan can be simple or difficult.

Downtime is performed with the removal of the steering rack from the car, but without dismantling it. For example, if you need to replace the anthers. It may not be removed at all if only adjustment is required. It is imperative that after it tests are carried out in practice - that is, in the movement of the car. Sometimes this is enough to reduce backlash or get rid of knocking.
Complex repairs, as practice shows, are required in the overwhelming majority of cases.

The unit is removed from the car. Here you need to take into account the nuances of its location and observe the accuracy and sequence of removing the fasteners.
The steering rack is removable and completely disassembled.
The shaft is cleaned and polished on the machine.
After troubleshooting, the worn out parts are replaced (consumables must be replaced).
The rail is assembled and installed back.
The rack and camber / toe are adjusted.

Among other things, diagnostics allows you to determine the overall degree of wear of the assembly. If it exceeds 50%, you may not be offered a repair, but a complete replacement of the steering rack. It's up to you to decide - the price of replacing the entire mechanism, taking into account the options offered in our car service, will be approximately comparable to the cost of replacing most of its parts.

It also has its advantages:

The time for replacing the steering rack, as a rule, is less than the time for a complex repair;
A completely redesigned steering will last longer than a refurbished steering.

Our car service offers options that allow you to reduce the cost of the replacement procedure. For instance:

Install analog;
Replace the old one with the original reconditioned rail;

In both cases, the price will be significantly lower than the original, and in terms of quality they will not be inferior to it - this is guaranteed.

Our masters suggest considering other parts of the steering mechanism. One of the most important of these is the steering column.

Repair of the steering column of the Polo Sedan is required if:

Increased backlash of the cardan joint.
The terminal connection to the shaft is damaged.
The position adjustment mechanism is out of order.

Repair is carried out in stages:

Disconnects "minus" from the battery.
The steering wheel is removed.
The casing is detached.
The airbag contact ring is deactivated.
The steering column switches are removed.
The "mass" fastener is unscrewed and the wire is disconnected from the column.
The column is removed together with the ignition switch, intermediate shaft and EUR.

Next, diagnostics are performed. Worn parts are replaced. The assembly is done in mirror order.

If there is a knock when cornering, this may indicate a failure of the tips. Diagnostic results indicate the need to replace them, and the procedure itself is performed on a lift and it is also performed in stages:

The wheel is dismantled from the side of the tip to be replaced.
Measurements of the threaded part are made, which will come in handy later, while maintaining the wheel alignment angle.
Remove the ball pin fasteners to the steering knuckle arm.
The finger is pressed out using a special puller and removed from the fist.
The tie rod end is screwed on.
The new tie rod end is being installed in the reverse order.

Our technicians have many years of experience in repairing and replacing steering racks, columns, steering rod ends.
Thanks to both experience and the use of special equipment, all work is carried out in a short time.
Clients can count on an inexpensive and professional service.

Video (click to play).

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