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

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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

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Installing

- Remove remains of locking fluid from outer joint
and hub splines. (Splines must be free of oil and
grease). - Apply locking fluid D 185 400 A2 to splines as
shown in illustration. Bead cross section approx. 3
mm.
- Install drive shaft. - Connect ball joint to control arm. - Install drive shaft to transmission flange shaft and
secure. Note: - Install 12-point nut to drive shaft and tighten. To tighten 12-point nut we recommend the angle
measuring wrench VAG 1756 or equivalent. Only loosen and tighten with vehicle standing on
its wheels (danger of accident). Page 44 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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Tightening torques:
Drive shaft to flange shaft/transmission 45 Nm
(33 ft lb)
Drive shaft to wheel bearing 90 Nm (66 ft lb) and
housing turn 45 further (1
/
8 turn) Ball joint/control arm 35 Nm (26 ft lb) Page 45 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, repairing
Drive shafts on vehicles with Plus suspension
have shorter and finer splines on the outer joint.
The wheel bearing is secured by a 12-point nut.
The splines of the outer joint and the hub on Plus
suspensions are secured with locking fluid D 185
400 A2.
Drive shaft, removing and installing
Vehicles with Base suspension Page 40-14 Vehicles with Plus suspension Page 40-43
Note:
Grease quantity:
- - Outer constant velocity joint 100 g of G-6.3
grease

- - Inner constant velocity joint 110 g of G-6.3
grease
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 grease joint as
required. Page 46 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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1 - Circlip Always replace Remove and install
with VW161 a
2 - Gasket Always replace. Pull
off protective foil and
stick onto joint. (Only
on 100 mm diameter
constant velocity joints
3 - Inner constant velocity
joint 100 mm diameter Only replace complete Pressing off Fig. 3 Pressing on Fig. 4 Greasing Notes
Page 40-46 Checking Page 40-62 4 - Dished washer Inner diameter splined Installation position:
outer diameter
(concave side)
contacts constant
velocity joint Page 47 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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5 - Boot for 100 mm
diameter constant
velocity joint Rubber version With vent hole Check for tears and
chafing Installation position for
left drive shaft Fig. 5 Installation position for
right drive shaft Fig. 6 Coat inside of cap with D3 Drive off with drift 6 - Drive shaft Left shaft, solid bar
(not illustrated) Right shaft, tube 7 - Clamp Always replace Tensioning Fig. 7
and Fig. 8 Page 48 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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8 - Boot for 90 mm
diameter constant
velocity joint Polyester elastomer
version Check for tears and
chafing The balance pressure
briefly ventilate boot
before tensioning the
small clamp Fig. 7 Installation position for
left shaft, wheel end Fig. 10 and Fig. 11 Installation position for
right shaft, wheel end
Fig. 12 9 - Clamp Always replace Tensioning Fig. 7
and Fig. 8 Page 49 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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10 - Dished washer Outer diameter
(concave side)
contacts thrust washer
11 - Thrust washer
12 - Circlip Always replace Insert in shaft groove 13 - Outer constant velocity joint, 90 mm 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 Page 50 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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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