Volkswagen Type II Transporter 1200 Series Shop Manual page 155

to a torque of 70 ft/lb. Insert the split pin to secure the
nut.
(4) Connect the steering connecting rod with the
pitman arm, fit castellated nut and tighten to a torque of
20ft/lb. Insert the split pin to secure the nut.
(5) Position front wheels straight ahead and instal the
steering column on the steering worm. Position a new lock
plate on the coupling flange and lock the bolts with the
ends of the lock plate.
(6) Check condition of steering column bearing but
greasing is not required as it is pre-lubricated with special
grease. Insert the spring support ring with the shoulder
facing the top.
Steering-9
(7) Position the steering wheel allowing a gap of .012"
between the wheel hub and the trafficator switch. Fit the
securing nut and tighten to a torque of 20 ft/lb.
(8) Ensuring that the steering column is correctly
positioned within the column tube, instal the steering
column cover plate and secure with two screws.
(9) Checking that the front wheels are in the straight
ahead position, the steering wheel spokes should be
horizontal. Check trafficator switch operation.
DIRECTION
INDICATOR
SWITCH~
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1
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a
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I
STEERING COLUMN TUBE
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CIRCLIP
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II
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STEERING LOCK -
~-
-~-.~l?J-'.- KEY
6~~7{3
_ ) SHEAR BOLTS
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WIRE
SWITCH HANDLE
t
STEERING SHAFT
SPRING
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J-CIRCLIP
Exploded View of Steering Column and Shaft Components (1500-1600 model shown).
12. INTERMEDIATE SWING LEVER AN'D SHAFT
TO REMOVE (Early Models)
(I) Disconnect the steering damper from the
intermediate swing lever.
(2) Disconnect the steering connecting rod and tie-rod
ends from the swing lever.
(3) Remove the swing lever pinch bolt after bending
back the lock plate tabs.
(4) Remove grease nipples.
(5) Using a special tool press down the intermediate
swing lever shaft from the top and remove the lever and
shaft.
TO INSTAL (Early Models)
Installation 'iS a reversal of the removal procedure
while observing the following points:
(1) Check the diametrical clearance of the intermediate
swing lever shaft and, if necessary' replace bushes.
(2) Check the condition of the lever shaft for wear or
damage and renew, if necessary.
(3) Before fmally assembling the intermediate swing
lever and shaft it is essential to give sufficient pre-load to
avoid rattling when the vehicle is being driven. The lever,
155
when installed, should compress the spring washer at least
.024" -.031 ". The spring washer compressed to this limit
should exert a force of 260-300 lb which will not allow
rattling to occur.
To check the condition of the spring washer for
obtaining the correct pre-load, in the first instance, instal
the lever and shaft with all components except the spring ,
washer and in this case the clearance between the thrust
washer and the swing lever should be a= b-e; while b is the
free length of the spring washer and is equal to .189"
±
.028" and cis the pre-load and is equal to .024" -.031".
If the measured clearance exceeds the value calculated
for a, correct by inserting a further thrust washer .020"
thick between the dust seal and spring washer. Replace a ,
weak spring washer.
(4) Dismantle the swing lever and shaft and re-assemble
with the spring washer after checking the condition of the
lever shaft for wear or damage and renew, if necessary.
(5) Position the lower thrust washer on the swing lever
shaft, instal the shaft in the mounting bushes. From the top
end of the shaft slip the following components onto the
lever shaft in this order; spring washer, dust seal and plastic
seal.