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

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9 - Inner splined screw, 45 Nm (33 ft lb)
10 - Drive shaft, right, with
inner tripod joint Repair of inner joint
and replacement of
boot not possible at
this time Replace if damaged Page 67 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 Constant velocity joint, outer, removing - Drive off from drive shaft with forceful blow using
an alloy hammer. The boot is pressed on forcefully when installing on
the joint body. This creates a vacuum in the boot that
makes a dent during driving (arrow). Briefly ventilate
the boot at the small diameter after installation to
provide equalize pressure. Fig. 2 Boot, ventilating Page 68 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: Fig. 3 Clamp, tightening on large diameter - Install pliers VAG 1682 as in illustration. Make sure that the blades of the pliers lie in the corners
(arrow -B-) of the clamp.
- Tighten clamp by turning the spindle with a torque
wrench (do not tilt pliers during this process). Because of the hard material (compared to
rubber) of the boot and the stainless steel hose
clamp that is necessary, only tighten the clamp
with pliers VAG 1682. Tightening torque: 25 Nm (18 ft lb) Use torque wrench with adjustment range: 5 - 50
Nm (e.g. VAG 1331) Make sure that threads of spindle on the pliers
are easy to move. If necessary lubricate with
MoS
2 grease. If difficult to move, e.g. dirt in the threads, the
required tightening force of the clamp is not
achieved with the specified torque. Fig. 4 Clamp, tightening on small diameter Page 69 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 axle with triple-rotor joint,
removing and installing

Removing right-side drive axle
The right drive axle removal instructions remain
unchanged from the current repair manual
procedure.

Removing left-side drive axle - Set up engine support bridge. Page 70 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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- Remove rear transmission mounting bolt (arrow). - Remove front engine mounting bolt (arrow). - Lift engine/transmission assembly - Loosen drive axle nut while vehicle is standing on
its wheels. Page 71 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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- Disconnect drive axle from transmission drive
flange. - Mark installation position of bolts (arrows) and
remove. Installing - Swing wheel outward (if necessary, place block of
wood or equivalent between strut and wheel
housing as shown).
- Push engine/transmission assembly toward front
and remove drive axle.
- Install in reverse order of removal. Page 72 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 axle with triple-rotor
joint, servicing
1 - Outer constant velocity (CV) joint Replace complete part
only Removing Fig. 1 Installing: drive onto
shaft with plastic
hammer until circlip
seats (springs into
groove) Greasing page 40-
12 2 - Circlip Always replace Insert in groove in
shaft
3 - Thrust ring
4 - Belleville spring Larger diameter
(concave side)
contacts with thrust
ring
5 - Clamp Always replace Tightening page 40-
7 6 - Boot Check for tears and
chafing
7 - Clamp
8 - Axle shaft Page 73 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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9 - Clamp For triple-rotor joint 10 - Boot
11 - Clamp For triple-rotor joint 12 - Cover Destroyed when
disassembling No longer required for
assembly; not
available as
replacement part
13 - Rectangular sealing
ring Included in repair kit;
not used in production
14 - O-ring Not required for
assembly
15 - Circlip
16 - Roller
17 - Triple-rotor star Chamfer -arrow- goes
onto axle shaft splines
first
18 - Multi-point socket-
head bolt M10 x 20 80 Nm (59 ft lb) 19 - Housing Page 74 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 Removing outer CV joint - Drive joint off axle shaft with firm blow from soft
mallet. Page 75 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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Make sure plier jaws seat in grooves of clamp (arrows
-B-)
Note: Fig. 2 Tightening outer CV joint boot clamp - Position VAG 1682 pliers or equivalent (e.g. Snap-
On YA 3080) as shown in illustration.
- Tension clamp by using torque wrench to turn
spindle (keep pliers at right angle to shaft).
Tightening torque: 20 Nm (15 ft lb) Due to the hardness of the boot material
(compared to rubber), it is necessary to use a
stainless steel clamp. The clamp can only be
properly tightened using VAG 1682 pliers. Use a torque wrench with 5-50Nm (4-37 ft lb)
range (e.g. VAG 1331 or equivalent). Make sure that the spindle threads of the pliers
are not tight. If necessary coat the threads with
MoS
2 grease to ensure smooth operation. If the spindle threads are tight (e.g. dirty) the force
necessary for correctly tightening the clamp will
not be achieved, despite correct torque readings. Fig. 3 Tightening small end clamp Page 76 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