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

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Sub-frame, stabilizer bar
and control arm (Base
suspension)
Note: If a vehicle has to be
moved after removing the
drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the
wheel bearing will be
damaged. Specifications for wheel
alignment Page 44-2 . Welding and straightening
operations are not
permitted on load bearing
suspension components or
those components which
locate the wheels. Always replace self-locking
nuts. Always replace corroded
nuts/bolts. Page 2 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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Wheel bearing,
suspension strut and
drive shaft, removing and
installing (Base running
gear)
Note: If a vehicle has to be
moved after removing the
drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the
wheel bearing will be
damaged. Welding and straightening
operations are not
permitted on load bearing
suspension components or
those components which
locate the wheels. Always replace self-locking
nuts. Always replace corroded
nuts/bolts. Wheel bolt tightening
torque: 110 Nm (81 ft lb). Page 14 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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Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 00 1 - Self-locking nut, 265
Nm (195 ft lb) Only loosen and tighten with the vehicle standing on its wheels
(danger of accident) Any paint residue
and/or corrosion on
the thread of the outer
joint must be removed
before the nut is
installed
2 - Washer
3 - Brake disc Application 4 - Brake caliper Do not loosen brake
hose when working on
front suspension Hang up with wire or
similar
5 - Hub Pressing out Fig. 3 Pressing in Fig. 8 Pulling off bearing
inner race Fig. 5 Page 15 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 - Brake caliper Do not loosen brake
hose when working on
front suspension Hang up with wire or
similar Replacing brake pads
Page 46-6 6 - Countersunk screw
7 - Hub Pressing out Fig. 2 Pressing in Fig. 6 Pulling off inner race
Fig. 3 8 - Speed sensor rotor Only for vehicles with
ABS
9 - Hex bolt, 10 Nm (7 ft lb) 10 - Splash plate Page 37 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. 8 Larger clamp, tensioning - Use pliers VAG 1682 as shown in illustration.
Ensure that the jaws of the pliers seat in the -arrow -B- of the clamp.
- Tension clamp by turning the spindle with a torque
wrench (do not tilt pliers). Note: Fig. 9 Smaller clamp, tensioning 40 The clamp can only be tensioned with pliers
V.A.G 1682. Tightening torque: 25 Nm (18 ft Ib). Use torque wrench with 5 - 50 Nm range (e.g.
V.A.G 1331). Make sure the spindle thread is not tight. If
necessary lubricate with MOS 2 grease If the thread is tight, e.g. dirty, the required
tensioning force for the hose clamp will not be
achieved inspite of correct tightening torque
settings. Page 57 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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Triple-rotor joint, disassembling - Open hose clamp - Open clamp on shaft small end and push back
boot. Note: - Drive screwdriver or similar tool into cover and pry
open. If the cover will not pry open, insert screwdriver
and pry from the opposite side. The cover is destroyed in the removal process. It
does not need to be replaced. Page 77 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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13 - Stop buffer Shorter on Wagon
than Sedan
14 - Protective tube Longer on Wagon than Sedan
15 - Plastic cap
16 - Coil spring Removing and
installing Fig. 1 Allocation Parts
catalog Wagon has protective
hose at top
17 - Packing
18 - Circlip
19 - Lower spring plate Page 11 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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3 - Speed sensor Only on vehicles with
ABS Before installing
sensor, clean
mounting hole inner
surface and coat with
lubricating paste G
000 650
4 - Brake hose bracket
5 - Hex socket head bolt,
65 Nm (48 ft lb)
6 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace 7 - Guide pins
8 - Protective cap
9 - Pad retaining spring Replace when
changing pads Page 11 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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4 - Boot for 94 mm
diameter constant
velocity joint Rubber version Check for tears and
chafing Installation position: At
cuff 1 to 1-1/2 grooves
visible Coat inside of cap with D3 Drive off with drift 5 - Drive axle Different drive axle
lengths - short shaft
right
6 - Hose clamp Always replace Tensioning Page 40-57 Page 3 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4