1996 VOLKSWAGEN PASSAT transmission

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Installing

- Remove remains of locking fluid from outer joint
and hub splines. (Splines must be free of oil and
grease). - Apply locking fluid D 185 400 A2 to splines as
shown in illustration. Bead cross section approx. 3
mm.
- Install drive shaft. - Connect ball joint to control arm. - Install drive shaft to transmission flange shaft and
secure. Note: - Install 12-point nut to drive shaft and tighten. To tighten 12-point nut we recommend the angle
measuring wrench VAG 1756 or equivalent. Only loosen and tighten with vehicle standing on
its wheels (danger of accident). Page 44 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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Tightening torques:
Drive shaft to flange shaft/transmission 45 Nm
(33 ft lb)
Drive shaft to wheel bearing 90 Nm (66 ft lb) and
housing turn 45 further (1
/
8 turn) Ball joint/control arm 35 Nm (26 ft lb) Page 45 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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Note:
Chamfer on inner diameter of ball hub (splines) must
face the contact shoulder on the drive shaft. Fig. 4 Inner constant velocity joint, pressing
on
- Press on joint up to stop. - Install circlip. Dimension "a" = 17 mm
Note:
Before assembling boot on drive shaft mark position,
dimension "a", with for example paint or adhesive
tape. Under no circumstances should paint surface
be damaged with a sharp tool. Fig. 5 Installation position of left drive shaft
transmission end joint boot - rubber
version Page 55 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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The large diameter of vent chamber -A- must fit on
the larger diameter. Fig. 6 Installation position of right drive shaft
transmission end joint boot
B - Vent hole Often the boot is pushed in when installing on the
joint body. This creates a vacuum inside the boot
which draws a fold in (arrow) while driving. After
installing, lift the boot at small diameter end to
equalize pressure. Fig. 7 Joint boot, ventilating Page 56 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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Cuff seating tolerance "a": 1
/
2 to 11
/
2 grooves visible
at end of cuff.
Note:
This installation position tolerance is also valid for the
left drive shaft transmission end boot (polyester
elastomer version). Fig. 10 Installation position of left drive shaft
wheel end joint boot, shaft diameter 27
mm Cuff installation position: Cuff butts against shaft
shoulder (arrow). Fig. 11 Installation position of left drive shaft,
wheel end, shaft diameter 22 mm Page 58 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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- Remove rear transmission mounting bolt (arrow). - Remove front engine mounting bolt (arrow). - Lift engine/transmission assembly - Loosen drive axle nut while vehicle is standing on
its wheels. Page 71 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