BBT Ball Bearing Steering Box for Beetle - Karmann Ghia - Type 3 - Thing

BBT Reset-Type Ball Bearing Steering Box Installation & Adjustments

Note:

The BBT steering gearbox is pre-adjusted to factory specifications and normally requires no additional adjustment. If inspection or fine adjustment is necessary, follow the procedures below.

Break-In Period

During the initial operation period the steering may feel slightly heavier than normal. This condition will gradually diminish as the steering gear completes its running-in period. After a short period of use, the steering response will become smoother and more precise.

Input Shaft Axial Clearance Adjustment - #3

• Completely loosen the lock nut #1 at the lower end of the input shaft.
• Rotate the large rear adjustment nut with four round holes #2 to adjust the worm shaft clearance.
• The shaft should rotate freely without any axial (up-and-down) movement.
• Tighten the lock nut #1 clockwise until all clearance is eliminated.
• The input shaft #3 should rotate smoothly by hand with slight resistance but without binding.

Important: If you are not familiar with steering gearbox adjustment procedures, it is strongly recommended that the work be carried out by a professional technician experienced in steering system calibration.

Steering Free Play Adjustment at the Center Position

• Rotate the input shaft #3 by hand fully to one side until it stops.
• Then rotate it to the opposite limit and record the total number of turns.
• Turn the shaft back exactly half of the total turns so that the steering gear remains at its center position.
• Use a wrench to loosen the lock nut #4 by turning it counter-clockwise.
• Using a flathead screwdriver, turn adjustment screw #5 clockwise until it bottoms out.
• Then rotate it back approximately 30 degrees counter-clockwise.
• Hold #5 in position with the screwdriver to prevent movement.
• While holding it, turn the input shaft #3 left and right by hand.
• It should rotate smoothly with slight resistance.
• Repeat the adjustment process until the input shaft #3, when positioned at the center of its rotation, moves smoothly left and right with slight resistance and without free play.
• After the correct clearance is achieved, hold #5 firmly with the screwdriver and tighten the lock nut #4 clockwise until securely locked.

Operational Check After Adjustment

• After installation and adjustment, the input shaft #3 should rotate smoothly.
• When positioned at the midpoint of its total rotation (steering center), the shaft should have slight resistance but no noticeable free play.
• After turning more than 90° away from the center position to either side, the torque required to rotate the shaft should gradually decrease compared with the center position.
• This design ensures improved directional stability when the vehicle is traveling in a straight line.

Wheel Alignment Requirement

The BBT reset-type ball bearing steering gearbox is more sensitive to wheel alignment than the original factory steering system. After installation, precise wheel alignment must be performed by a qualified automotive technician.

Lubrication

The steering gearbox is pre-filled with standard lubricating grease at the factory and is ready for A “plug and play” installation. If replacement grease is required, use No.3 lithium-based grease.