1997 VOLKSWAGEN PASSAT wheel

Downloaded from www.Manualslib.com manuals search engine 40-61
Note:
The 6 balls of each joint belong to one tolerance
group. Check stub axle, hub, cage and balls for
indentations (pitting) and signs of seizure. Excessive
backlash in joint will be noticed as a knock during
load changes. In such cases the joint must be
replaced. Polished areas and ball track marks are not
a reason for changing the joint.
Installing - Swing segment of hub into rectangular cage
window.
- Tilt hub out of cage. - Press half of the total amount of grease Page 40-46 or Page 42-46 into the joint housing. - Install cage with hub in the joint housing. - Press in the balls one after the other from opposite sides whereby the original position of the hub to
cage and joint housing must be restored.
- Install new circlip in the hub. - Distribute the remaining grease in the boot. Page 61 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 40-62

Inner constant velocity joint, checking
The joint should be disassembled to replace dirty
grease and when checking the balls and ball
tracks for wear and damage. Note:
The ball hub and joint are paired and must not be
interchanged. - Swivel ball hub and ball cage. - Press out ball cage in direction of arrow. - Press balls out of cage. - Tilt ball hub out of ball cage over ball track
(arrows).
- Check joint housing, ball hub, ball cage and balls
for indentations (pitting) and signs of seizure. Page 62 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:
Excessive backlash in joint will be noticed as a
knock during load changes. In such cases the
joint must be replaced. Polished areas and ball
track marks are not a reason for changing the
joint.

Installing Note: - Insert ball hub over both chamfers into the ball
cage. Any installed position is acceptable. Press
balls into the cage.
- Insert hub with cage and balls at right angle to the
joint. When inserting make sure that the wide spacing -
a- on joint housing is aligned with the narrow
spacing -b- on the hub after swivelling in. Chamfer on inner diameter of ball hub (splines)
must face larger diameter of joint housing. Page 63 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 40-64
- Swivel in ball hub, whereby the hub must be
swivelled out of the cage (arrows) far enough to
allow the balls to fit into the ball tracks. Checking operation of constant velocity joint:
The constant velocity joint is correctly assembled
when the ball hub can be moved by hand backward
and forward over its entire axial movement range. - Swivel in the hub with balls by applying firm
pressure on the cage (arrow). Page 64 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 40-65

Drive shaft with tripod
joint, repairing
1 - Outer constant velocity joint Replace complete Removing Fig. 1 Installing: Drive onto
the shaft with plastic
hammer until circlip
comes out Greasing Notes
Page 40-46 Checking Page 40-62 2 - Circlip Always replace Install in groove of
shaft
3 - Thrust ring
4 - Dished washer Larger diameter
(concave side)
contacts thrust ring Page 65 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 40-66

5 - Clamp Always replace Tightening, Fig. 2
and Fig. 3 6 - Boot for constant
velocity joint, 90 mm
dia. Check for cracks and
abrasion Before tightening the
small clamp, ventilate
boot briefly so
pressure is equalized,
Fig. 2 7 - Clamp Always replace Tightening, Fig. 2
and Fig. 4 8 - Drive shaft, left, with
inner tripod joint Repair of inner joint
and replacement of
boot not possible at
this time Replace if damaged Page 66 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 40-67

9 - Inner splined screw, 45 Nm (33 ft lb)
10 - Drive shaft, right, with
inner tripod joint Repair of inner joint
and replacement of
boot not possible at
this time Replace if damaged Page 67 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 40-68
Fig. 1 Constant velocity joint, outer, removing - Drive off from drive shaft with forceful blow using
an alloy hammer. The boot is pressed on forcefully when installing on
the joint body. This creates a vacuum in the boot that
makes a dent during driving (arrow). Briefly ventilate
the boot at the small diameter after installation to
provide equalize pressure. Fig. 2 Boot, ventilating Page 68 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