Kruger... Is it the pinch clamp on the end of the shaft that is moving.... If so then try cleaning the splines on the shaft with a wire brush. Then get a hacksaw blade and run that through the slot in the pinch clamp to widen up the gap. Then re clamp with new nylock nut and bolt. Check for movement after

Shaggy

No the pinch clamp is fine.  Its the lower side of the coupling disc - lower steering shaft coupling which attaches to the the worm shaft that runs through the box (hope I am getting the name right.... just checked in my workshop manual and I think I have )  Though looking at the workshop manual I guess the same thing would work as it has splines on the shaft.  Does the Lower steering shaft coupling have slots cut in to match up with the splines on the worm shaft???

If it helps ahve a look at this link and the diagram at the top - its item 4.  The worm shaft into this is moving so this is where I suspect the splines are damaged   http://www.vwheritage.com/vw_act_page.render_pageID_128_lang_EN_country_GB.htm?startRow=1&startPage=1&maxDisplayRows=15&dcCfcSortSelect=PopularitySort|asc&dcCfcBrandFilter=excluded&dcCfcOriginFilter=excluded&dcCfcPriceFilterLow=excluded&dcCfcPriceFilterHigh=excluded&searchText=&classicSearchText=&classicSearchType=

Yes that's the bit I'm on about. Usually a good clean up of the shaft and then running a hack saw through the gap in the pinch clamp helps to cure the problem  as this opens up the gap, when you tighten up the M8 pinch bolt you get a tighter grip on the shaft

Shaggy

Thanks...

So what is the easiest way to get to this ?  Take the worm shaft out ?  if so how do I do that.  I took the large nut off the end and I can see the adjuster but that appears to have a very very large star bolt (think thats what you call it) ... or am I best taking the box off ?

Just take the box off, as taking the steering box apart is something I don't recommend as it messes up back lash on the worm screw inside.

Kruger... Is it the pinch clamp on the end of the shaft that is moving.... If so then try cleaning the splines on the shaft with a wire brush. Then get a hacksaw blade and run that through the slot in the pinch clamp to widen up the gap. Then re clamp with new nylock nut and bolt. Check for movement after

WHS^^^ If necessary put two hacksaw blades in the frame together so as to widen the gap slightly, it should clamp up fine then.

Thanks Shaggy / David

If I get a chance this week I may try it one evening - if not it will have to be Saturday.  The white marker pen turned out to be a great tip.  Everything was tight and nothing obvious (and didnt do it all the time).

Dav... I will give this a try before I take you up on the kind offer of the box.  But will let you know depending on how I go on.

Kruger... Is it the pinch clamp on the end of the shaft that is moving.... If so then try cleaning the splines on the shaft with a wire brush. Then get a hacksaw blade and run that through the slot in the pinch clamp to widen up the gap. Then re clamp with new nylock nut and bolt. Check for movement after

WHS^^^ If necessary put two hacksaw blades in the frame together so as to widen the gap slightly, it should clamp up fine then.

Good call David, never thought to put two saw blades side by side to widen the slot. 

No problem, I'm away till Friday anyway. Hope the saw fixes it

Now I feel educated... thought the pinch bolt was the one that has the u clip thing with a bolt on above the upper steering shaft coupling   Thats the one that had some wear and the holes were slightly oval ... but managed to get that all tight.

Will let you all know how I progress

Bit of an update..... on Friday I had a day off and with all the good weather wanted to get the buggy working and safe.   So set about pulling the steering apart.

The things I found

1. The pinch bolt was Knackered.   Really chewed up.   I am not certain as it had no numbers on it but I am guessing it was not high tensile.  It was also a bit on the short side.

2. The splines were ok but full of dirt and stuff so gave them a good clean as suggested and ran a saw down them

3. I am now not happy about the way the steering has been mounted after spending some time looking at it.  I just happen to have a flatlands steering mount that I bought from Adam when he split his buggy .... so this will be going on soon.

Went to my local specialist bolt store and got a slightly longer high tensile bolt.  Fitted it and all now seems fine.

Had a good play on Friday and Saturday in the buggy... wow the weather was amazing and so much fun to be out in the buggy.  Hope it stays like this as I will be planning to use the buggy as much as I can 

Nice one bud.... Glad our collective advice paid off for you