1997 VOLKSWAGEN PASSAT AIR

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Repair Manual, Suspension, Wheels,Brakes, Steering, Repair Group 46 and47 10 - Wheel bearing Servicing Page 42-59 Servicing brakes 11 - Hex bolt, 85 Nm (63 ft
lb)
12 - Hex bolt for seat belt
strut, 25 Nm (18 ft lb) Page 4 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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Before installing, bring control arm into horizontal
position (unladen state). Removing and installing
suspension strut at body Page 42-4 .
Tightening torque -A-: 65 Nm (48 ft lb)
Note:
Support control arm otherwise damage may occur to
constant velocity joint as a result of over-stressing. Fig. 1 Suspension strut from control arm,
removing and installing Before removing propshaft, mark installation position.
If installed offset, imbalance will be excessive.
Tightening torque -A- and -B-: 45 Nm (33 ft lb)
Note:
Always support propshaft with wire otherwise
constant universal joint will be damaged. Fig. 2 Driveshaft and drive axle, removing and
installing at differential Page 5 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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Loosen and tighten only when vehicle is standing on
its wheels (danger of accident).
Tightening torque: 90 Nm (66 ft lb) and turn 45
further (1
/
8 turn)
Note:
Any paint residue and/or corrosion on the thread of
the outer joint must be removed before the nut is
installed. Fig. 3 Drive shaft, removing and installing Tightening torque -A- and -B-: 25 Nm (18 ft lb) Fig. 4 Stabilizer bar, removing and installing Page 6 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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Before installing coat with acid free lubricant, e.g. soft
soap.
Installation position: Shoulder on outer mounting to
outside, to inside on inner mounting (to center of
vehicle).
Note:
Deviations from the rear axle toe and camber
specifications can be corrected by using a bonded
rubber mounting with eccentric bushing Fig. 8 Fig. 7 Bonded rubber mounting, installing Page 8 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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The rubber mounting -A- is equipped with an
eccentric bushing which can change the position of
the control arm.
This rubber mounting may only be installed in the
control arm inner mounting. The camber and/or toe
can be changed according to installation position.
Note:
With this mounting the camber or toe can be altered
up to 18'. Fig. 8 Rubber mounting to correct camber/toe Installation position
Alteration
Eccentric upward Camber alteration negative
Eccentric downward Camber alteration pos.
Eccentric forward Toe alteration positive
Eccentric rearward Toe alteration negative Page 9 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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Removing and installing viscous coupling
Repair Manual, 5 Spd. Manual Transmission 02A; Repair Group 39
Tightening torque -A-: 45 Nm (33 ft lb) Fig. 9 Final drive, removing and installing
from axle beam Page 10 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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Connect segment corners of bonded rubber mounting
metal core with a line.
The continued line must pass through the center of
hole (arrow).
Note:
The kidney-shaped recess must be pointing in
direction of travel when viewed from the center of
vehicle. Fig. 10 Installation position, determining Place one half of the rubber bonded mounting in
correct position and pull in with tool 3128 and 3128/1.
Then place 2nd half in position and pull in. Fig. 11 Rubber bonded mounting, installing Page 11 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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Remove and install complete
When assembling mounting bracket and final drive
carrier away from the vehicle, make sure parts are
correctly located relative to each other.
It is essential that the bonded rubber mounting is
installed stress free in the vehicle. Fig. 12 Mounting bracket and final drive carrier, removing and installing
Tightening torque -A- 45 Nm (33 ft lb)
-B- 65 Nm (48 ft lb)
-C- 85 Nm (63 ft lb)
-D- 85 Nm (63 ft lb) No specific installation position
Insertion depth: flush with lower edge (arrow) Fig. 13 Final drive bonded rubber bushing,
pressing in and out Page 12 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