1996 VOLKSWAGEN PASSAT display

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4 - Boot for 94 mm
diameter constant
velocity joint Rubber version Check for tears and
chafing Installation position: At
cuff 1 to 1-1/2 grooves
visible Coat inside of cap with D3 Drive off with drift 5 - Drive axle Different drive axle
lengths - short shaft
right
6 - Hose clamp Always replace Tensioning Page 40-57 Page 3 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

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7 - Boot for 81 mm
diameter constant
velocity joint Polyester elastomer
version Check for tears and
chafing Installation position: At
cuff 1 to 1-1/2 grooves
visible To balance pressure
briefly ventilate boot
before tensioning the
small clamp
8 - Hose clamp Always replace Tensioning Page 40-57 9 - Dished washer Outer diameter
(concave side)
contacts thrust washer
10 - Thrust washer Page 4 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

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11 - Circlip Always replace Insert in shaft groove 12 - Outer constant velocity joint: 81 mm diameter Only replace complete Removing Page 40-54 Installing: drive onto
shaft with plastic
hammer until
compressed circlip
seats Greasing Notes
Page 42-46 Checking Page 40-60 13 - Inner support rings Prevents boot inflating Only installed on left
drive shaft
transmission end Page 5 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

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Reworking cap nut in side member (four
wheel drive vehicles)
If the threads of the cap nut in the side member
are damaged, it must either be retapped or the
cap nut must be drilled out.

- Remove control arm if necessary.
- Drill through damaged cap nut in the side
member using a 10.2 mm diameter drill from
underneath.

Note:
Do not tilt the drill when drilling.

WARNING!

Wear protective goggles. 1 - Cap nut 2 - Reinforcing plate 3 - Side member Page 6 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

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- Cut new thread in the cap nut, M 12 x 1.5.
- Use new bolts, Part No. N 010 137.1 and
washer, Part No. N 011 531.7 to secure the rear
axle.
Tightening torque: 65 Nm (48 ft lb)

Note:
The procedure described here must only be
performed on one cap nut on each side of the
vehicle. Page 7 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

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Suspension strut,
disassembling and
assembling (four
wheel drive
vehicles)
1 - Cap Pry out with
screwdriver Pressing on Fig. 5 Installation position
Fig. 5 2 - Seal
3 - Self locking hex nut, 30 Nm (22 ft lb) Always replace 4 - Dished washer
5 - Upper rubber mounting 6 - Gasket (foam) Always replace Page 1 of 6Suspension strut, disassembling and assembling (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.5

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7 - Suspension strut
mounting Welded nuts must be
located in the spring
seat recesses Installation position to
spring seat Fig. 3 8 - Spring seat
9 - Spacer tube
10 - Lower rubber
mounting
11 - Stop buffer mounting
12 - Washer
13 - Stop buffer
14 - Ring (Aluminium)
15 - Boot
16 - Protective cap Page 2 of 6Suspension strut, disassembling and assembling (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.5

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17 - Coil spring Removing and
installing Page 42-13 Allocation Parts
catalog 18 - Packing
19 - Circlip
20 - Lower spring plate Installation position
Fig. 1 21 - Shock absorber Can be replaced
individually Removing and
installing Page 42-4
and Page 42-37 Check shock absorber
for leaks and noises Application see Parts
catalog Page 3 of 6Suspension strut, disassembling and assembling (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.5