1997 VOLKSWAGEN PASSAT boot

Downloaded from www.Manualslib.com manuals search engine 40-69
Note: Fig. 3 Clamp, tightening on large diameter - Install pliers VAG 1682 as in illustration. Make sure that the blades of the pliers lie in the corners
(arrow -B-) of the clamp.
- Tighten clamp by turning the spindle with a torque
wrench (do not tilt pliers during this process). Because of the hard material (compared to
rubber) of the boot and the stainless steel hose
clamp that is necessary, only tighten the clamp
with pliers VAG 1682. Tightening torque: 25 Nm (18 ft lb) Use torque wrench with adjustment range: 5 - 50
Nm (e.g. VAG 1331) Make sure that threads of spindle on the pliers
are easy to move. If necessary lubricate with
MoS
2 grease. If difficult to move, e.g. dirt in the threads, the
required tightening force of the clamp is not
achieved with the specified torque. Fig. 4 Clamp, tightening on small diameter Page 69 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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Drive axle with triple-rotor
joint, servicing
1 - Outer constant velocity (CV) joint Replace complete part
only Removing Fig. 1 Installing: drive onto
shaft with plastic
hammer until circlip
seats (springs into
groove) Greasing page 40-
12 2 - Circlip Always replace Insert in groove in
shaft
3 - Thrust ring
4 - Belleville spring Larger diameter
(concave side)
contacts with thrust
ring
5 - Clamp Always replace Tightening page 40-
7 6 - Boot Check for tears and
chafing
7 - Clamp
8 - Axle shaft Page 73 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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9 - Clamp For triple-rotor joint 10 - Boot
11 - Clamp For triple-rotor joint 12 - Cover Destroyed when
disassembling No longer required for
assembly; not
available as
replacement part
13 - Rectangular sealing
ring Included in repair kit;
not used in production
14 - O-ring Not required for
assembly
15 - Circlip
16 - Roller
17 - Triple-rotor star Chamfer -arrow- goes
onto axle shaft splines
first
18 - Multi-point socket-
head bolt M10 x 20 80 Nm (59 ft lb) 19 - Housing Page 74 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 40-76
Make sure plier jaws seat in grooves of clamp (arrows
-B-)
Note: Fig. 2 Tightening outer CV joint boot clamp - Position VAG 1682 pliers or equivalent (e.g. Snap-
On YA 3080) as shown in illustration.
- Tension clamp by using torque wrench to turn
spindle (keep pliers at right angle to shaft).
Tightening torque: 20 Nm (15 ft lb) Due to the hardness of the boot material
(compared to rubber), it is necessary to use a
stainless steel clamp. The clamp can only be
properly tightened using VAG 1682 pliers. Use a torque wrench with 5-50Nm (4-37 ft lb)
range (e.g. VAG 1331 or equivalent). Make sure that the spindle threads of the pliers
are not tight. If necessary coat the threads with
MoS
2 grease to ensure smooth operation. If the spindle threads are tight (e.g. dirty) the force
necessary for correctly tightening the clamp will
not be achieved, despite correct torque readings. Fig. 3 Tightening small end clamp Page 76 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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Triple-rotor joint, disassembling - Open hose clamp - Open clamp on shaft small end and push back
boot. Note: - Drive screwdriver or similar tool into cover and pry
open. If the cover will not pry open, insert screwdriver
and pry from the opposite side. The cover is destroyed in the removal process. It
does not need to be replaced. Page 77 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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Triple-rotor joint, assembling

- Slide small diameter boot clamp onto shaft.
- Slide triple-rotor joint boot onto shaft.
- Slide triple-rotor joint housing onto shaft.
Mounting triple-rotor star

Note: The side of the star with a chamfer (arrow) goes onto
the axle shaft splines first.
- Place triple-rotor star on axle shaft according to
previously marked position.
- Install circlip and make sure that it is correctly
seated.
- Install rollers according to previously marked
positions.
- Push triple-rotor joint housing over rollers and
secure (clamp housing in vise). Page 80 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:
A seal is formed directly between the triple-rotor joint
and the drive flange by the rectanular sealing ring.
The cover is no longer required. - Install rectangular sealing ring (arrow) from repair
kit. 90 grams into joint and 90 grams behind joint - Press 180 grams of axle shaft grease from repair
kit into triple-rotor joint .
- Install triple-rotor joint boot. - Install boot clamp. Page 81 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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Rear drive shafts, servicing
Removing and installing drive shafts Page 42-37
Note:
Grease quantity:
- - outer constant velocity joint 80 g G-6.3
- - inner constant velocity joint 80 9 G-6.3 Greasing outer joint: press half of the grease
into the joint, and the other half evenly into the
boot.
Greasing inner joint: press half of the grease
into the inner joint from both sides, the other
half evenly into the boot.
When replacing the boot, regrease joint if
required. Page 1 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4