1996 VOLKSWAGEN PASSAT wheel bolts

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Suspension strut is attached to the body by 4
retaining lugs in addition to the bolts. To remove, turn
suspension strut until retaining lugs are positioned
above the cut-outs. Fig. 3 Suspension strut, removing and
installing Angle of inclination to axle beam 13 30' 1. Fig. 4 Bolting mounting bracket to axle beam Page 5 of 14Rear Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1

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Reworking cap nut in side member
(front 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. When drilling out
proceed as follows:

- Remove rear axle.
- 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.

- Cut new thread in the cap nut, M 12 x 1.5.
- Use new bolts, Part No. N 010.127.4 (M 12 x 1.5 x 30), and washer, Part No. N 011.531.7, to
secure the rear axle.
Tightening torque: 70 Nm (52 ft lb)

Note:
The procedure described here must only be
performed on one cap nut on each side of the
vehicle. Page 8 of 14Rear Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1

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Rear axle,
servicing (four
wheel drive
vehicles)
Note: When removing and
installing the rear axle, it is
recommended to remove
axle and differential
together and to separate
away from the vehicle. If
only the axle beam is to be
removed and installed, the
wishbones can remain
attached to the shock
absorber. In both cases,
disconnect vacuum lines
and wiring before lowering
the assembly. Always replace self-locking
nuts and bolts. Always replace corroded
nuts and bolts. The ABS speed sensor
wiring connections are
located under the rear seat. Page 1 of 13Rear axle, servicing (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.3

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Front wheel camber, adjusting Note: - Install special tool as shown in illustration and
slightly pre-tension.
- Loosen suspension strut/wheel bearing housing
connection.
- Adjust camber by turning the spindle to specified
setting.
- Tighten suspension strut/wheel bearing housing
connection.
- Check camber and if necessary, repeat
adjustment. Slight cant of tool is permitted. Do not move steering with tool in place! Before adjusting camber, it is essential to
examine all suspension components for damage
(visual inspection) and to replace any damaged
parts. Because bolts with a shank diameter of 11 mm
diameter have been installed as standard it is no
longer necessary to replace bolts to correct
camber. Page 6 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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19 - ABS Hydraulic unit Connections (arrow)
show pipe work from
tandem master
cylinder to ABS
hydraulic unit Removing and
installing Page 45-23 20 - ABS/EDL Hydraulic
unit Removing and
installing Page 45-23 21 - Brake line connection Hydraulic unit to front
right brake caliper Thread connection:
M10 x 1, 15 Nm (11 ft
lb)
22 - Torx bolts (T 25)
23 - Brake line connection Hydraulic unit to rear
left wheel cylinder Thread connection:
M10 x 1, 15Nm (11 ft
lb) Page 4 of 10Assembly overview - hydraulic unit, brake servo/brake master cylinder12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.4

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Brake pads, removing and installing

Note:
Mark brake pads when removing if they are to be
reused. Re-install in their original position to
prevent uneven braking!

Removing

- Remove wheels. - Remove parking brake cable from brake caliper
(arrow).
- Remove securing bolts from brake caliper housing; counter-hold on guide pins. - Remove brake pads. Page 7 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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- Secure brake caliper housing with new self-
locking bolts. Note: - Attach parking brake cable (arrow) to brake caliper housing. After each brake pad change firmly depress brake
pedal several times with vehicle stationary, so
that the brake pads are properly seated in their
normal operating position. After changing brake pads check brake fluid level. Page 9 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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Steering

Assembly overview: steering column,
column tube, steering wheel and airbag
steering wheel

Airbag system functional check and
interrogating Diagnostic Trouble Code (DTC)
Memory.
Repair Manual, Body Exterior, Interior, Repair Group 68; General body repairs
Safety precautions when working on airbag
Repair Manual, Body Exterior, Interior, Repair Group 68, General body repairs
Note:
All parts marked with a "1)
" can be pre-
assembled outside of the vehicle
Pre-assembling steering column Page 48-6 Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted. Page 1 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1