1996 VOLKSWAGEN PASSAT hose

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3 - Speed sensor Only on vehicles with
ABS Before installing
sensor, clean
mounting hole inner
surface and coat with
lubricating paste G
000 650
4 - Brake hose bracket
5 - Hex socket head bolt,
65 Nm (48 ft lb)
6 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace 7 - Guide pins
8 - Protective cap
9 - Pad retaining spring Replace when
changing pads Page 11 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

Downloaded from www.Manualslib.com manuals search engine 42-48

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

Downloaded from www.Manualslib.com manuals search engine 45-13
- Release retainer and disconnect ABS control
module connector (arrows).
- Connect bleeder hose and bleeder bottle to left-
front brake caliper bleeder screw, and open
bleeder screw.
- Depress brake pedal at least 60 mm (2-3/8 in.). - Install brake pedal loading device from special tool
VAG 1238B.
- Close left-front bleeder screw. - Remove heat shield from brake master cylinder. - Disconnect brake lines from brake master cylinder
and ABS hydraulic unit.
- Seal lines and threaded holes with plugs from
repair kit Page 45-11 . Page 5 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Front brakes,
servicing (Girling
caliper)
Note: After replacing brake pads,
depress brake pedal firmly
several times with vehicle
stationary so that the brake
pads are properly seated in
their normal operating
position. To remove brake fluid from
the reservoir, use a bleeder
bottle which is used only for
brake fluid. Brake fluid is
poisonous and must on not
be siphoned by mouth
using a hose! Wheel bolt tightening
torque: 110 Nm (81 ft lb) Page 1 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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10 - Wheel bearing housing 11 - Brake carrier with
guide pins and
protective caps Supplied as
replacement part
assembled with
sufficient amount of
grease on guide pins If protective caps are
damaged use repair kit Use grease packet
supplied to lubricate
guide pins
12 - Heat shield Install in piston 13 - Brake caliper housing Do not disconnect
brake hose when
changing brake pads Page 4 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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4 - Retaining spring Insert in both brake
caliper housing
drillings
5 - Brake carrier Supplied as
replacement part
assembled with
sufficient amount of
grease on guide pins If protective caps are
damaged use repair kit Use grease packet
supplied to lubricate
guide pins
6 - Brake caliper housing Do not disconnect
brake hose when
changing brake pads Removing and
installing Page 46-12 Page 2 of 7Front brakes, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2

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7 - Guide pins, 25 Nm (18
ft lb) Removing and
installing from
Page 46-12 8 - Protective cap
9 - Seal Always replace Pry out with suitable
tool
10 - Brake hose
11 - Banjo bolt, 30 Nm (22 ft lb)
12 - Ribbed bolt, 125 Nm
(92 ft lb)
13 - Wheel bearing housing 14 - Hex socket head bolt,
10 Nm (7 ft lb)
15 - Speed sensor Only on vehicles with
ABS Before inserting
sensor, clean
mounting hole inner
surface and coat with
lubricating paste, G
000 650 Page 3 of 7Front brakes, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2