1996 VOLKSWAGEN PASSAT washer

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2 - Cotter pin Always replace 3 - Locking ring
4 - Hex nut Adjusting wheel
bearing play Fig. 4 5 - Thrust washer
6 - Outer wheel bearing Drive out outer race
with copper drift Pressing in Fig. 6 7 - Hex socket head bolt,
10 Nm (7 ft lb)
8 - Speed sensor Only on vehicles with
ABS
9 - Stub axle Straightening
operations are not
permitted! Page 2 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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10 - Brake backing plate Bolt together with stub
axle onto rear axle
11 - Oil seal Fill between sealing
lips with multi-purpose
grease. Driving in Fig. 8 12 - Dished washer Larger contact surface
(concave side) to
brake backing plate
13 - Hex bolt, 60 Nm (44 ft
lb)
14 - Inner wheel bearing Drive out outer race
with copper drift Pressing in Fig. 7 15 - Speed sensor rotor Pressing on Fig. 9 Page 3 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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Note: Fig. 3 Grease cap, driving on Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of
moisture, therefore always use the illustrated tool. Note:
Using a screwdriver it must be possible to move the
thrust washer by finger pressure (without prying). Fig. 4 Wheel bearing play, adjusting - Secure with locking ring and new cotter pin. Page 6 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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17 - Grease cap Pressing off Fig. 1
and Fig. 2 Driving on Fig. 3 18 - Locking ring
19 - Thrust washer
20 - Wheel bolt, 110 Nm (81
ft lb)
21 - Brake disc Before installing fill
hub with multi-purpose grease
22 - Inner wheel bearing Drive out outer race
with copper drift Pressing in Fig. 7 23 - Oil seal Fill between sealing
lips with multi-purpose
grease Driving in Fig. 8 24 - Speed sensor rotor Only on vehicles with
ABS
25 - Hex bolt, 60 Nm (44 ft
lb) Page 13 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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26 - Dished washer Large contact surface
(concave side) to
backing plate
27 - Backing plate
28 - Axle beam Straightening work is
not permissible! Only
use stub axles with 6
mounting holes.
29 - Parking brake cable Adjusting parking
brake Page 46-36 30 - Spring clip Page 14 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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Note: Fig. 3 Grease cap, driving on Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of
moisture, therefore always use the illustrated tool. Note:
Using a screwdriver it must be possible to move the
thrust washer by finger pressure (without prying). Fig. 4 Wheel bearing play, adjusting - Secure with locking ring and new cotter pin. Page 16 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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1 - Circlip Always replace Remove and install
with VW161 a
2 - Inner constant velocity
joint, 81 mm diameter Only replace complete Pressing off Page 40-54 Pressing on Page 40-55 Greasing Notes
Page 42-46 Checking Page 40-62 3 - Dished washer Inner diameter splined Installation position:
outer diameter
(concave side)
contacts constant
velocity joint Page 2 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