1997 VOLKSWAGEN PASSAT Engine

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14 - Outer constant velocity joint, 90 mm diameter For vehicles with 16V
and VR6 Wedge splines, larger
diameter Only replace complete Removing Fig. 2 Installing: drive onto
shaft with plastic
hammer until
compressed circlip
seats Greasing Notes
Page 40-46 Checking Page 40-60 15 - Vibration damper Removing and
installing Fig. 1 Installation position
Fig. 1 Available as spare part Is only installed on the
right drive shaft tube. Exception: On vehicles with 85 kW (115 hp)
and manual
transmission 02C only
installed on left solid
drive shaft Page 51 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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16 - Clamp Always replace 17 - Support rings On rubber type boot
only On transmission end
only See Parts catalog 18 - Boot for 100 mm
diameter constant
velocity joint Polyester elastomer
version Check for tears and
chafing To balance pressure
briefly ventilate boot
before tensioning the
small clamp Fig. 7 19 - Protective cap
20 - Hex bolt, 35 Nm (26 ft
lb) Page 52 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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The damper consists of two halves. Both halves are
joined to one another by spring pins (arrow).
Installation position Fig. 1
Note:
Fig. 1 Vibration damper, removing and
installing Only replace vibration damper with drive shaft
removed Before driving in spring pin protect shaft paint
finish against damage. To prevent axial movement apply adhesive tape
or a suitable adhesive to internal diameter. When installing vibration damper -A- note correct
installation position. Ensure dimension "a" is
maintained.
Dim. "a" = 521 1 mm right shaft
264 1 mm left shaft (if installed) Fig. 1
1 Vibration damper, installation position Page 53 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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Fig. 2 Outer constant velocity joint, removing - Drive joint off drive shaft with a firm blow from an
aluminium hammer. Note: Fig. 3 Inner constant velocity joint, pressing
off First drive boot off with drift Support ball hub Page 54 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:
Chamfer on inner diameter of ball hub (splines) must
face the contact shoulder on the drive shaft. Fig. 4 Inner constant velocity joint, pressing
on
- Press on joint up to stop. - Install circlip. Dimension "a" = 17 mm
Note:
Before assembling boot on drive shaft mark position,
dimension "a", with for example paint or adhesive
tape. Under no circumstances should paint surface
be damaged with a sharp tool. Fig. 5 Installation position of left drive shaft
transmission end joint boot - rubber
version Page 55 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 40-56
The large diameter of vent chamber -A- must fit on
the larger diameter. Fig. 6 Installation position of right drive shaft
transmission end joint boot
B - Vent hole Often the boot is pushed in when installing on the
joint body. This creates a vacuum inside the boot
which draws a fold in (arrow) while driving. After
installing, lift the boot at small diameter end to
equalize pressure. Fig. 7 Joint boot, ventilating Page 56 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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Fig. 8 Larger clamp, tensioning - Use pliers VAG 1682 as shown in illustration.
Ensure that the jaws of the pliers seat in the -arrow -B- of the clamp.
- Tension clamp by turning the spindle with a torque
wrench (do not tilt pliers). Note: Fig. 9 Smaller clamp, tensioning 40 The clamp can only be tensioned with pliers
V.A.G 1682. Tightening torque: 25 Nm (18 ft Ib). Use torque wrench with 5 - 50 Nm range (e.g.
V.A.G 1331). Make sure the spindle thread is not tight. If
necessary lubricate with MOS 2 grease If the thread is tight, e.g. dirty, the required
tensioning force for the hose clamp will not be
achieved inspite of correct tightening torque
settings. Page 57 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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Cuff seating tolerance "a": 1
/
2 to 11
/
2 grooves visible
at end of cuff.
Note:
This installation position tolerance is also valid for the
left drive shaft transmission end boot (polyester
elastomer version). Fig. 10 Installation position of left drive shaft
wheel end joint boot, shaft diameter 27
mm Cuff installation position: Cuff butts against shaft
shoulder (arrow). Fig. 11 Installation position of left drive shaft,
wheel end, shaft diameter 22 mm Page 58 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