1996 VOLKSWAGEN PASSAT front suspension

Downloaded from www.Manualslib.com manuals search engine Suspension, Wheels, Brakes, Steering

00 - General, Technical data
Suspension, Wheels, Brakes, Steering
Technical data
Steering
Brakes
Wheels, tires
40 - Front suspension
Front Wheel Suspension, Shafts and Axle
Front suspension, servicing (Base suspension)
Sub-frame, stabilizer bar and control arm (Base suspension)
Ball joint, checking (Base and Plus suspension)
Reworking cap nut in side member (Base and Plus suspension)
Wheel bearing, suspension strut and drive shaft, removing and installing (Base
running gear)
Front suspension strut, servicing (Base and Plus suspension)
Front suspension, servicing (Plus suspension)
Sub-frame, stabilizer bar and control arm, removing and installing (Plus
suspension)
Ball joint, removing and installing (Plus running gear)
Wheel bearing and suspension strut, removing and installing (Plus suspension)
Drive shaft, removing and installing (Plus running gear)
Drive shaft, repairing
Outer constant velocity joint, checking
Inner constant velocity joint, checking
Drive shaft with tripod joint, repairing
Drive axle with triple-rotor joint, removing and installing
Drive axle with triple-rotor joint, servicing
Triple-rotor joint, disassembling
Triple-rotor joint, assembling
42 - Rear suspension
Rear Wheel Suspension, Shafts and Axle
Rear axle, servicing (vehicles with front wheel drive)
Reworking cap nut in side member (front wheel drive vehicles)
Suspension strut, disassembling and assembling (front wheel drive vehicles)
Wheel bearings, servicing
Drum brakes (front wheel drive vehicles), wheel bearings, servicing
Wheel bearings, servicing - disc brakes (front wheel drive vehicles)

Downloaded from www.Manualslib.com manuals search engine Rear axle, servicing (four wheel drive vehicles)
Rear drive shafts, servicing
Reworking cap nut in side member (four wheel drive vehicles)
Suspension strut, disassembling and assembling (four wheel drive
vehicles)
Wheel bearings, servicing - disc brakes (four wheel drive vehicles)
44 - Wheels, Tires, Wheel alignment
Vehicle alignment
Test requirements:
Vehicle alignment specifications (front wheel drive vehicles)
Vehicle alignment specifications (four wheel drive vehicles)
Front wheel camber, adjusting
Calculating the direction of travel:
45 - Anti-lock brake system
Anti-locking Brake System (ABS) and Anti-locking Brake System with
Electronic Differential Lock (ABS/EDL) Teves 04
Notes for repair work on ABS, ABS/EDL
Control module, removing and installing
Wheel speed sensor and rotor for speed sensor, removing and installing
Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock
(ABS/EDL), Teves 20 GI
Safety precautions
ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master
cylinder (Teves 20 GI), servicing
ABS hydraulic unit and ABS control module (Teves 20 GI), removing and
installing
Brake hydraulic system, bleeding and filling
Assembly overview - hydraulic unit, brake servo/brake master cylinder
Hydraulic unit, removing and installing
Brake Pedal Position Sensor, removing and installing
46 - Brakes - Mechanical components
Front brakes, servicing (Girling caliper)
Brake pads, removing and installing

Downloaded from www.Manualslib.com manuals search engine 00-1

Suspension, Wheels, Brakes, Steering
Technical data Model

Sedan/Wagon and syncro Base
Suspension 1)
Sedan/Wagon and syncro Base
Suspension 2)

Wheelbase mm 2625 2625
Track, unladen mm 1479 front, wheel offset 38
1422 rear, wheel offset 38
1485 front, wheel offset 35
1428 rear, wheel offset 35
1489 front, wheel offset 33 3)

1432 rear, wheel offset 3)
1485 front, wheel offset 35
1441 rear, wheel offset 35
1489 front, wheel offset 33 3)

1445 rear, wheel offset 33 3)

Turning circle m 10.7 11.5
Steering roll radius
(negative) mm 0.5 with offset 35
3.5 with offset 38 12 with offset 35
15 with offset 38
Wheel lock angle inner
outer 42
36 3745'
34 30' 1)
Base Suspension, explanation Page 40-1 2)
Plus Suspension, explanation Page 40-26 3)
Syncro Page 1 of 8Suspension, Wheels, Brakes, Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

Downloaded from www.Manualslib.com manuals search engine 00-3
Brakes Model

Sedan/Wagon
Output kW (hp) 55 (75)
Brake master cylinder mm dia. 22.2 (Vehicles with ABS: 23.81)
Brake servo dia. in inches 10
Front brake caliper, piston diameter mm 54
Front brake disc mm dia. 256
Front brake disc, thickness mm 13
Pad thickness mm 14
Rear brake drum mm dia. 230
Wheel cylinder mm dia. 20.64
Lining thickness mm 5
Lining width mm 40 Page 3 of 8Suspension, Wheels, Brakes, Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

Downloaded from www.Manualslib.com manuals search engine 00-4
Model

Sedan/Wagon
Output kW (hp) 85 (115) 128 (172)
Brake master cylinder mm dia. 23.81
Brake servo dia. in inches 10
Front brake caliper dia. mm 54
Front brake disc mm dia. 256 288
Front brake thickness mm 20 13
Pad thickness mm 11 14
Rear brake caliper dia. mm 38
Rear brake disc mm dia. 226
Rear brake disc, thickness mm 10
Pad thickness mm 12 Page 4 of 8Suspension, Wheels, Brakes, Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

Downloaded from www.Manualslib.com manuals search engine 00-5
Model

Passat syncro
Output kW (hp) 85 (115) 128 (172)
Brake master cylinder mm dia. 23.81
Brake servo dia. in inches 10
Front brake caliper dia. mm 54
Front brake disc mm dia. 256 288
Front brake disc thickness mm 20 25
Pad thickness mm 11 14
Rear brake caliper dia. mm 38
Rear brake disc mm dia. 239
Rear brake disc, thickness mm 10
Pad thickness mm 12 Page 5 of 8Suspension, Wheels, Brakes, Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

Downloaded from www.Manualslib.com manuals search engine 40-1

Front Wheel
Suspension, Shafts
and Axle
Front suspension,
servicing (Base
suspension)
I - Removing and installing
subframe, stabilizer bar and
control arm (Base suspension)
Page 40-2
II - Removing and installing
wheel bearings, suspension
strut and drive shaft (Base
suspension) Page 40-14
The Base suspension is
installed in Passat 1995
vehicles up to 85 kW. Page 1 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

Downloaded from www.Manualslib.com manuals search engine 40-2

Sub-frame, stabilizer bar
and control arm (Base
suspension)
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. Specifications for wheel
alignment Page 44-2 . 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. Page 2 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