Front axle VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Suspension, Wheels, Brakes, Steering

00 - General, Technical data
Suspension, Wheels, Brakes, Steering
Technical data
Steering
Brakes
Wheels, tires
40 - Front suspension
Front Wheel Suspension, Shafts and Axle
Front suspension, servicing (Base suspension)
Sub-frame, stabilizer bar and control arm (Base suspension)
Ball joint, checking (Base and Plus suspension)
Reworking cap nut in side member (Base and Plus suspension)
Wheel bearing, suspension strut and drive shaft, removing and installing (Base
running gear)
Front suspension strut, servicing (Base and Plus suspension)
Front suspension, servicing (Plus suspension)
Sub-frame, stabilizer bar and control arm, removing and installing (Plus
suspension)
Ball joint, removing and installing (Plus running gear)
Wheel bearing and suspension strut, removing and installing (Plus suspension)
Drive shaft, removing and installing (Plus running gear)
Drive shaft, repairing
Outer constant velocity joint, checking
Inner constant velocity joint, checking
Drive shaft with tripod joint, repairing
Drive axle with triple-rotor joint, removing and installing
Drive axle with triple-rotor joint, servicing
Triple-rotor joint, disassembling
Triple-rotor joint, assembling
42 - Rear suspension
Rear Wheel Suspension, Shafts and Axle
Rear axle, servicing (vehicles with front wheel drive)
Reworking cap nut in side member (front wheel drive vehicles)
Suspension strut, disassembling and assembling (front wheel drive vehicles)
Wheel bearings, servicing
Drum brakes (front wheel drive vehicles), wheel bearings, servicing
Wheel bearings, servicing - disc brakes (front wheel drive vehicles)

Downloaded from www.Manualslib.com manuals search engine Rear axle, servicing (four wheel drive vehicles)
Rear drive shafts, servicing
Reworking cap nut in side member (four wheel drive vehicles)
Suspension strut, disassembling and assembling (four wheel drive
vehicles)
Wheel bearings, servicing - disc brakes (four wheel drive vehicles)
44 - Wheels, Tires, Wheel alignment
Vehicle alignment
Test requirements:
Vehicle alignment specifications (front wheel drive vehicles)
Vehicle alignment specifications (four wheel drive vehicles)
Front wheel camber, adjusting
Calculating the direction of travel:
45 - Anti-lock brake system
Anti-locking Brake System (ABS) and Anti-locking Brake System with
Electronic Differential Lock (ABS/EDL) Teves 04
Notes for repair work on ABS, ABS/EDL
Control module, removing and installing
Wheel speed sensor and rotor for speed sensor, removing and installing
Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock
(ABS/EDL), Teves 20 GI
Safety precautions
ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master
cylinder (Teves 20 GI), servicing
ABS hydraulic unit and ABS control module (Teves 20 GI), removing and
installing
Brake hydraulic system, bleeding and filling
Assembly overview - hydraulic unit, brake servo/brake master cylinder
Hydraulic unit, removing and installing
Brake Pedal Position Sensor, removing and installing
46 - Brakes - Mechanical components
Front brakes, servicing (Girling caliper)
Brake pads, removing and installing

Downloaded from www.Manualslib.com manuals search engine 40-1

Front Wheel
Suspension, Shafts
and Axle
Front suspension,
servicing (Base
suspension)
I - Removing and installing
subframe, stabilizer bar and
control arm (Base suspension)
Page 40-2
II - Removing and installing
wheel bearings, suspension
strut and drive shaft (Base
suspension) Page 40-14
The Base suspension is
installed in Passat 1995
vehicles up to 85 kW. Page 1 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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Sub-frame, stabilizer bar
and control arm (Base
suspension)
Note: If a vehicle has to be
moved after removing the
drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the
wheel bearing will be
damaged. Specifications for wheel
alignment Page 44-2 . Welding and straightening
operations are not
permitted on load bearing
suspension components or
those components which
locate the wheels. Always replace self-locking
nuts. Always replace corroded
nuts/bolts. Page 2 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 - Hex bolt, 35 Nm (26 ft
lb)
2 - Ball joint Checking Page 40-10 Check rubber boot for
damage and if necessary, replace ball joint Mark installation
position. If replaced
set to center of
elongated hole and
check toe Elongated holes are
not for camber
adjustment. Failure to observe this instruction may result in damage
to drive shafts!
3 - Captive lock nuts
4 - Air deflector plate Secured to control arm by clip
5 - Control arm Page 3 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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6 - Control arm rear
mounting Installation position
Fig. 3 Pressing out and in
Fig. 4 7 - Hex bolt M 12 x 1.5 x 82 50 Nm (37 ft lb) and
turn 90 further 8 - Hex bolt M 12 x 1.5 x 65 70 Nm (52 ft lb) and
turn 90further 9 - Hex bolt M 12 x 1.5 x 78 70 Nm (52 ft lb) and
turn 90further 10 - Control arm front
mounting Pressing out Fig. 1 Pressing in Fig. 2 11 - Connecting link With rubber mounting Page 4 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 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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16 - Hex bolt, 65 Nm (48 ft
lb)
17 - Stabilizer bar mounting 18 - Stabilizer bar
19 - Stabilizer bar clamp
20 - Hex bolt, 25 Nm (18 ft
lb) To secure stabilizer
bar
21 - Vibration damper Note installation
position, large part
must protrude from
sub-frame
22 - Self-locking hex nut, 25 Nm (18 ft lb)
23 - Cap nut Repairing in side
member Page 40-11 Page 6 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. 1 Front control arm mounting, pressing
out Note:
Before pressing in, coat with acid-free lubricant, e.g.
soft soap. Fig. 2 Front control arm mounting, pressing in Page 7 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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One of the embossed arrows points toward the
recess in the control arm and the kidney shaped
opening (arrow A) faces towards center of vehicle. Fig. 3 Control arm rear mounting, installation
position Note:
If bonded rubber bushing is tight because of
corrosion, cut rubber out, saw through steel casing
and drive bushing out. Fig. 4 Control arm rear mounting, pressing
out and in Page 8 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