change wheel VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Workshop Manual

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Note: Tightening torque remains unchanged.
1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm Page 13 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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Note:
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 Note: - Insert ball hub over both chamfers into the ball
cage. Any installed position is acceptable. Press
balls into the cage.
- Insert hub with cage and balls at right angle to the
joint. When inserting make sure that the wide spacing -
a- on joint housing is aligned with the narrow
spacing -b- on the hub after swivelling in. Chamfer on inner diameter of ball hub (splines)
must face larger diameter of joint housing. Page 63 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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The rubber mounting -A- is equipped with an
eccentric bushing which can change the position of
the control arm.
This rubber mounting may only be installed in the
control arm inner mounting. The camber and/or toe
can be changed according to installation position.
Note:
With this mounting the camber or toe can be altered
up to 18'. Fig. 8 Rubber mounting to correct camber/toe Installation position
Alteration
Eccentric upward Camber alteration negative
Eccentric downward Camber alteration pos.
Eccentric forward Toe alteration positive
Eccentric rearward Toe alteration negative Page 9 of 13Rear axle, servicing (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.3

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- Secure brake caliper housing with new self-
locking bolts. Note: - Attach parking brake cable (arrow) to brake caliper housing. After each brake pad change firmly depress brake
pedal several times with vehicle stationary, so
that the brake pads are properly seated in their
normal operating position. After changing brake pads check brake fluid level. Page 9 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5