check engine VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service User Guide

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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

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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

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- Swivel in ball hub, whereby the hub must be
swivelled out of the cage (arrows) far enough to
allow the balls to fit into the ball tracks. Checking operation of constant velocity joint:
The constant velocity joint is correctly assembled
when the ball hub can be moved by hand backward
and forward over its entire axial movement range. - Swivel in the hub with balls by applying firm
pressure on the cage (arrow). Page 64 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 with tripod
joint, repairing
1 - Outer constant velocity joint Replace complete Removing Fig. 1 Installing: Drive onto
the shaft with plastic
hammer until circlip
comes out Greasing Notes
Page 40-46 Checking Page 40-62 2 - Circlip Always replace Install in groove of
shaft
3 - Thrust ring
4 - Dished washer Larger diameter
(concave side)
contacts thrust ring Page 65 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