1997 VOLKSWAGEN PASSAT four wheel drive

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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

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Mark mounting bracket installation position relative to
body longitudinal member, otherwise the rear axle
must be realigned on an axle alignment stand after
reinstalling. Fig. 14 Mounting bracket on body, removing
and installing
Tightening torque -A- 130 Nm (96 ft lb)
-B- 60 Nm (44 ft lb)
-C- 85 Nm (63 ft lb) Page 13 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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Reworking cap nut in side member (four
wheel drive vehicles)
If the threads of the cap nut in the side member
are damaged, it must either be retapped or the
cap nut must be drilled out.

- Remove control arm if necessary.
- Drill through damaged cap nut in the side
member using a 10.2 mm diameter drill from
underneath.

Note:
Do not tilt the drill when drilling.

WARNING!

Wear protective goggles. 1 - Cap nut 2 - Reinforcing plate 3 - Side member Page 6 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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Suspension strut,
disassembling and
assembling (four
wheel drive
vehicles)
1 - Cap Pry out with
screwdriver Pressing on Fig. 5 Installation position
Fig. 5 2 - Seal
3 - Self locking hex nut, 30 Nm (22 ft lb) Always replace 4 - Dished washer
5 - Upper rubber mounting 6 - Gasket (foam) Always replace Page 1 of 6Suspension strut, disassembling and assembling (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.5