1997 VOLKSWAGEN PASSAT Transmission

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Repair Manual, Engine
Mechanical, Repair Group 10 12 - Connecting link
mounting Conical side toward
control arm
13 - Washer Collar faces away from mounting
14 - Self-locking hex nut, 25 Nm (18 ft lb)
15 - Sub-frame Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 5 Remove sub-frame
from below with VAG
1383 (with control arm
but without steering
gear). After installing
check position of
steering wheel and
align front end. Aligning engine-
transmission assembly Page 5 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. 5 Supporting engine/transmission
assembly with 10-222 A and legs 10-222
A/1 Page 9 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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Reworking cap nut in side member
(Base and Plus suspension)
If the threads of the cap nut in the side member
are damaged, the thread must either be retapped
or the cap nut must be drilled out.
When drilling out proceed as follows.

- Support engine/transmission assembly with 10-
222 A and legs 10-222 A/1.

- Remove the sub-frame.
- Drill out the damaged side member cap nut with
a 10.2 mm diameter drill from underneath.

Note:
When drilling do not tilt the drill.

WARNING!

Wear protective goggles.

- Cut new M 12 x 1.5 thread in cap nut.
- Use a new bolt/washer assembly to secure sub-
frame Page 40-13 . Page 11 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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Repair Manual, Engine
Mechanical, Repair Group 10 20 - Vibration damper Not installed on
vehicles with VR 6
engine
21 - Sub-frame Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 4 Remove sub-frame from below with control arm but without
steering gear using transmission jack VAG 1383 or equivalent.
After installing check
position of steering
wheel and align front
end. Aligning
engine/transmission
assembly
22 - Stabilizer bar mounting 23 - Stabilizer bar 24 mm diameter 24 - Cap nut Reworking in side
member Page 40-11 Page 30 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. 3 Control arm rear mounting, pressing
out and in Fig. 4 Engine/transmission assembly,
supporting with 10-222 A and 10-222
A/3 Page 32 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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Ball joint, removing and installing (Plus
running gear)

Removing

- Loosen 12-point nut with vehicle standing on its
wheels.

- Disconnect drive shaft at transmission drive
flange.

- Remove bolts -arrow -A-.
- Loosen bolt -arrow -B-. - Separate connection between ball joint/control
arm. (First mark installation position). - Swing wheel and suspension strut outward and
support. Page 33 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:
Installing - Install ball joint splitter as shown in illustration and
press out ball joint.
1 - Splitter. Matra V 176 Place transmission jack VAG 1383/A, or
equivalent, underneath (danger of accident
through falling parts when pressing out the ball joint). Protect ball joint threads by threading nut on a
few turns.
- Install ball joint in wheel bearing housing. - Thread on new self-locking nut, and counterhold
with hex key (6 mm AF).
1 - Hex key (6 mm AF), shortened by approx. 10
mm.
2 - Crowfoot insert or slotted ring socket insert
Page 40-35 3 - VAG 1331 - Secure ball joint to control arm (align to old marks). Page 34 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 shaft, removing and installing
(Plus running gear)

Removing

- Loosen 12-point nut with vehicle standing on its
wheels.

- Disconnect drive shaft from transmission drive
flange. - Remove bolts (arrow -A-). - Loosen bolt (arrow -B-). - Separate connection between ball joint/control
arm. (First mark installation position). Note:
When pressing drive shaft out ensure sufficient
clearance is available. - Press drive shaft out. Install tool as shown in
illustration. Page 43 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