1996 VOLKSWAGEN PASSAT display

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Fig. 5 Supporting engine/transmission
assembly with 10-222 A and legs 10-222
A/1 Page 9 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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Ball joint, checking (Base and Plus
suspension)

Checking axial clearance Checking radial play - Forcibly pull ball joint down and press up again. Note: - Press lower part of wheel outward and inward. There must be no perceptible or visual "play"
during either test. Observe ball joint during checks. Take into account possible existing wheel bearing
play or "play" in upper suspension strut mounting. Page 10 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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Reworking cap nut in side member
(Base and Plus suspension)
If the threads of the cap nut in the side member
are damaged, the thread must either be retapped
or the cap nut must be drilled out.
When drilling out proceed as follows.

- Support engine/transmission assembly with 10-
222 A and legs 10-222 A/1.

- Remove the sub-frame.
- Drill out the damaged side member cap nut with
a 10.2 mm diameter drill from underneath.

Note:
When drilling do not tilt the drill.

WARNING!

Wear protective goggles.

- Cut new M 12 x 1.5 thread in cap nut.
- Use a new bolt/washer assembly to secure sub-
frame Page 40-13 . Page 11 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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Bolt/washer assemblies for sub-frame Securing point
Thread
Bolt
Part No.
Front sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9
N 101 612.01 1)

Rear sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01
Sub-frame bracket M10 M10 x 38 10.9 N 019 541.1
Engine front cross-member to side member M10 M10 x 75 10.9
N 904 078.01 1)
1)
These bolts are not listed in the parts catalog. They must be specially ordered. Page 12 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: Tightening torque remains unchanged.
1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm Page 13 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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Wheel bearing,
suspension strut and
drive shaft, removing and
installing (Base running
gear)
Note: If a vehicle has to be
moved after removing the
drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the
wheel bearing will be
damaged. Welding and straightening
operations are not
permitted on load bearing
suspension components or
those components which
locate the wheels. Always replace self-locking
nuts. Always replace corroded
nuts/bolts. Wheel bolt tightening
torque: 110 Nm (81 ft lb). Page 14 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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Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 00 1 - Self-locking nut, 265
Nm (195 ft lb) Only loosen and tighten with the vehicle standing on its wheels
(danger of accident) Any paint residue
and/or corrosion on
the thread of the outer
joint must be removed
before the nut is
installed
2 - Washer
3 - Brake disc Application 4 - Brake caliper Do not loosen brake
hose when working on
front suspension Hang up with wire or
similar
5 - Hub Pressing out Fig. 3 Pressing in Fig. 8 Pulling off bearing
inner race Fig. 5 Page 15 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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6 - Speed sensor rotor Only on vehicles with
ABS
7 - Hex bolt, 10 Nm (7 ft lb) 8 - Splash plate
9 - Circlip Ensure correctly
seated
10 - Wheel bearing Pressing out Fig. 6 Replace, as it is
destroyed during
pressing out Pressing in Fig. 7 11 - Self-locking hex nut, 35 Nm (26 ft lb)
12 - Wheel bearing housing 13 - Self-locking hex nut, 50 Nm (37 ft lb)
14 - Hex bolt Clamping bolt for ball
joint Page 16 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