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

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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

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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

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Cuff seating tolerance "a": From cuff position to
chamfer up to 1
/
2 a groove visible. Fig. 12 Installation position of right drive shaft,
wheel end joint boot Page 59 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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Outer constant velocity joint, checking
The joint should be disassembled to replace dirty
grease or for checking the balls and ball tracks
for wear and damage.

Removing - Before disassembling mark position of the ball hub
in relation to the ball cage and housing with an
electric scriber or oil stone.
- Swivel ball hub and ball cage. - Remove balls one after the other. - Turn cage until the two rectangular windows
(arrow) are aligned with the joint housing.
- Lift out cage together with hub. Page 60 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:
The 6 balls of each joint belong to one tolerance
group. Check stub axle, hub, cage and balls for
indentations (pitting) and signs of seizure. Excessive
backlash in joint will be noticed as a knock during
load changes. In such cases the joint must be
replaced. Polished areas and ball track marks are not
a reason for changing the joint.
Installing - Swing segment of hub into rectangular cage
window.
- Tilt hub out of cage. - Press half of the total amount of grease Page 40-46 or Page 42-46 into the joint housing. - Install cage with hub in the joint housing. - Press in the balls one after the other from opposite sides whereby the original position of the hub to
cage and joint housing must be restored.
- Install new circlip in the hub. - Distribute the remaining grease in the boot. Page 61 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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Inner constant velocity joint, checking
The joint should be disassembled to replace dirty
grease and when checking the balls and ball
tracks for wear and damage. Note:
The ball hub and joint are paired and must not be
interchanged. - Swivel ball hub and ball cage. - Press out ball cage in direction of arrow. - Press balls out of cage. - Tilt ball hub out of ball cage over ball track
(arrows).
- Check joint housing, ball hub, ball cage and balls
for indentations (pitting) and signs of seizure. Page 62 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