1996 VOLKSWAGEN PASSAT check engine

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Repair Manual, Engine
Mechanical, Repair Group 10 20 - Vibration damper Not installed on
vehicles with VR 6
engine
21 - Sub-frame Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 4 Remove sub-frame from below with control arm but without
steering gear using transmission jack VAG 1383 or equivalent.
After installing check
position of steering
wheel and align front
end. Aligning
engine/transmission
assembly
22 - Stabilizer bar mounting 23 - Stabilizer bar 24 mm diameter 24 - Cap nut Reworking in side
member Page 40-11 Page 30 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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1 - Circlip Always replace Remove and install
with VW161 a
2 - Gasket Always replace. Pull
off protective foil and
stick onto joint. (Only
on 100 mm diameter
constant velocity joints
3 - Inner constant velocity
joint 100 mm diameter Only replace complete Pressing off Fig. 3 Pressing on Fig. 4 Greasing Notes
Page 40-46 Checking Page 40-62 4 - Dished washer Inner diameter splined Installation position:
outer diameter
(concave side)
contacts constant
velocity joint Page 47 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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5 - Boot for 100 mm
diameter constant
velocity joint Rubber version With vent hole Check for tears and
chafing Installation position for
left drive shaft Fig. 5 Installation position for
right drive shaft Fig. 6 Coat inside of cap with D3 Drive off with drift 6 - Drive shaft Left shaft, solid bar
(not illustrated) Right shaft, tube 7 - Clamp Always replace Tensioning Fig. 7
and Fig. 8 Page 48 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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8 - Boot for 90 mm
diameter constant
velocity joint Polyester elastomer
version Check for tears and
chafing The balance pressure
briefly ventilate boot
before tensioning the
small clamp Fig. 7 Installation position for
left shaft, wheel end Fig. 10 and Fig. 11 Installation position for
right shaft, wheel end
Fig. 12 9 - Clamp Always replace Tensioning Fig. 7
and Fig. 8 Page 49 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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10 - Dished washer Outer diameter
(concave side)
contacts thrust washer
11 - Thrust washer
12 - Circlip Always replace Insert in shaft groove 13 - Outer constant velocity joint, 90 mm diameter Only replace complete Removing Fig. 2 Installing: drive onto
shaft with plastic
hammer until
compressed circlip
seats Greasing Notes
Page 40-46 Checking Page 40-60 Page 50 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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14 - Outer constant velocity joint, 90 mm diameter For vehicles with 16V
and VR6 Wedge splines, larger
diameter Only replace complete Removing Fig. 2 Installing: drive onto
shaft with plastic
hammer until
compressed circlip
seats Greasing Notes
Page 40-46 Checking Page 40-60 15 - Vibration damper Removing and
installing Fig. 1 Installation position
Fig. 1 Available as spare part Is only installed on the
right drive shaft tube. Exception: On vehicles with 85 kW (115 hp)
and manual
transmission 02C only
installed on left solid
drive shaft Page 51 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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16 - Clamp Always replace 17 - Support rings On rubber type boot
only On transmission end
only See Parts catalog 18 - Boot for 100 mm
diameter constant
velocity joint Polyester elastomer
version Check for tears and
chafing To balance pressure
briefly ventilate boot
before tensioning the
small clamp Fig. 7 19 - Protective cap
20 - Hex bolt, 35 Nm (26 ft
lb) Page 52 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Outer constant velocity joint, checking
The joint should be disassembled to replace dirty
grease or for checking the balls and ball tracks
for wear and damage.

Removing - Before disassembling mark position of the ball hub
in relation to the ball cage and housing with an
electric scriber or oil stone.
- Swivel ball hub and ball cage. - Remove balls one after the other. - Turn cage until the two rectangular windows
(arrow) are aligned with the joint housing.
- Lift out cage together with hub. Page 60 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1