VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Repair Manual

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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

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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