display VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine 40-73

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

Downloaded from www.Manualslib.com manuals search engine 40-74

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 40-75
Fig. 1 Removing outer CV joint - Drive joint off axle shaft with firm blow from soft
mallet. Page 75 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

Downloaded from www.Manualslib.com manuals search engine 40-77

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

Downloaded from www.Manualslib.com manuals search engine 40-78
1 - Triple-rotor joint housing
2 - Triple-rotor star
3 - Axle shaft
Note:
CAUTION!
Do not let the rollers slide off the triple-rotor star
and fall to the floor. - Remove O-ring -arrow- from groove. - Mark installation positions of parts -1-, -2- and -3-. Noises while driving may result if the indicated
parts are not reassembled to their prior positions. Use a waterproof felt-tipped pen for marking
parts.
- Remove rubber gasket (arrow) from groove. - With triple-rotor joint housing clamped in vise, pull
axle shaft together with triple-rotor star upward out
of housing.
- Hold axle shaft in straight alignment to triple-rotor
joint and slowly push back triple-rotor joint housing
with other hand. - Mark installation position of rollers -1- on triple-
rotor star -2- using felt-tipped marker. Page 78 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 40-79

- Remove rollers and place on clean surface. -1- Pliers Commercially available - Remove circlip. - Press triple-rotor star off axle shaft. - Pull triple-rotor joint housing off axle shaft. - Clean shaft and triple-rotor joint housing. Page 79 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 40-80

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

Downloaded from www.Manualslib.com manuals search engine 40-81
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

Downloaded from www.Manualslib.com manuals search engine 40-82
- Tighten small diameter clamp with VAG 1275
pliers or equivalent (e.g. KD 474).
CAUTION! Secure the triple-rotor joint with tape so that
the housing is not inadvertently pushed back
when installing the axle shaft. Remove tape just prior to bolting to drive
flange. Page 82 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