Drum VOLKSWAGEN PASSAT 1996 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 Front brakes, servicing (Teves/Ate)
Brake pads, removing and installing
Rear wheel brakes, servicing (drum brakes)
Brake shoe adjustment, releasing
Rear wheel brakes, servicing
Brake shoes, removing and installing
Parking brake, adjusting (drum brakes)
Rear wheel brakes, servicing (disc brakes)
Girling rear wheel disc brakes (front and four wheel drive vehicles)
Brake pads, removing and installing
Parking brake, adjusting (disc brakes)
Parking brake lever assembly overview
Brake pedal/brake servo, removing and installing
Brake pedal, removing and installing
Brake Light Switch, adjusting
47 - Brakes - Hydraulic components
Assembly overview: brake master cylinder/brake servo
Girling front brake caliper, servicing
Front brake caliper pistons, removing and installing
Front brake caliper, servicing (Teves/Ate)
Rear brake caliper, servicing
Rear brake caliper piston, removing and installing
Pre-bleeding brake caliper
Brake pressure regulator, checking and adjusting
Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04
Load dependent brake pressure regulator specifications
Adjusting regulator
Brake system, bleeding
Brake system, bleeding (vehicles with and without ABS, ABS/EDL)
Brake system, bleeding (with pressure bleeder VAS 5234)
Brake system, bleeding (without pressure bleeder)

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Brakes Model

Sedan/Wagon
Output kW (hp) 55 (75)
Brake master cylinder mm dia. 22.2 (Vehicles with ABS: 23.81)
Brake servo dia. in inches 10
Front brake caliper, piston diameter mm 54
Front brake disc mm dia. 256
Front brake disc, thickness mm 13
Pad thickness mm 14
Rear brake drum mm dia. 230
Wheel cylinder mm dia. 20.64
Lining thickness mm 5
Lining width mm 40 Page 3 of 8Suspension, Wheels, Brakes, Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

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5 - Wheel bearing Servicing Vehicles with drum brakes Page 42-15 Vehicles with disc
brakes Page 42-24 6 - 80 Nm (59 ft lb) Use only self-locking
nuts with captive
washers When tightening nut, the axle beam must be in the horizontal
position (unladened
vehicle state)
7 - Hex bolt Installed from center of vehicle
8 - Shouldered bolt, 70 Nm (52 ft lb) If threads are
damaged, rework
captive nut in side
member Page 42-7 Page 2 of 14Rear Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1

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Wheel bearings,
servicing
Drum brakes (front wheel
drive vehicles), wheel
bearings, servicing
Note:
Careful sealing, absolute
cleanliness and precise
adjustment are requirements
for long wheel bearing service
life. Therefore note the
following points: Install oil seal and grease
cap as shown. Only reinstall clean
bearings, do not wash
bearings. Adjust wheel bearing play
carefully.
1 - Grease cap Pressing off Fig. 1
and Fig. 2 Driving in Fig. 3 Page 1 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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16 - Brake drum Before removing
release brake shoe
adjustment through
wheel bolt hole Fig. 5 When removing the
brake drum make sure
that the outer wheel
bearing does not fall
out. Fill hub with multi-purpose grease before installing Page 4 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

Downloaded from www.Manualslib.com manuals search engine 42-21
Fig. 5 Brake shoe adjustment, releasing - Insert a screwdriver through a hole in the brake
drum and push the wedge upward. Fig. 6 Outer wheel bearing outer race,
pressing in Page 7 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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Wheel speed sensor and rotor for speed
sensor, removing and installing

Speed sensor
When installing speed sensor ensure wiring is
not twisted.
Before installing speed sensor, clean mounting
hole and coat with lubricating paste, G 000 650.
Rotors
Before installing check that rotor is clean and
undamaged.

Front axle
Vehicles with base suspension Page 40-14 . Vehicles with plus suspension Page 40-23 .
Rear axle
Vehicles with rear drum brakes Page 42-15 . Vehicles with rear disc brakes (front and four
wheel drive Page 42-24 . Page 5 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Rear wheel brakes,
servicing (drum
brakes)
Notes Page 42-15 1 - Grease cap Removing and
installing from
Page 42-19 2 - Cotter pin Always replace 3 - Locking ring
4 - Hex nut Adjusting wheel
bearing play Page 42-20 5 - Thrust washer Page 1 of 4Rear wheel brakes, servicing (drum brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.3

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6 - Outer wheel bearing
7 - Wheel speed sensor
rotor Only on vehicles with
ABS
8 - Brake drum Vehicles with front
wheel drive Brake drum diameter:
230 mm Wear limit: 231.5 mm Clean thoroughly,
check for wear,
damage, tolerances,
damaged wheel bolt
threads and condition
of braking surface Fill hub with multi-
purpose grease Check for ovality 9 - Stub axle Page 2 of 4Rear wheel brakes, servicing (drum brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.3