manual transmission VOLKSWAGEN PASSAT 1997 B3, B4 / 3.G Service User Guide

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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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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

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Cuff seating tolerance "a": 1
/
2 to 11
/
2 grooves visible
at end of cuff.
Note:
This installation position tolerance is also valid for the
left drive shaft transmission end boot (polyester
elastomer version). Fig. 10 Installation position of left drive shaft
wheel end joint boot, shaft diameter 27
mm Cuff installation position: Cuff butts against shaft
shoulder (arrow). Fig. 11 Installation position of left drive shaft,
wheel end, shaft diameter 22 mm Page 58 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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Removing and installing viscous coupling
Repair Manual, 5 Spd. Manual Transmission 02A; Repair Group 39
Tightening torque -A-: 45 Nm (33 ft lb) Fig. 9 Final drive, removing and installing
from axle beam Page 10 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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11 - Circlip Always replace Insert in shaft groove 12 - Outer constant velocity joint: 81 mm diameter Only replace complete Removing Page 40-54 Installing: drive onto
shaft with plastic
hammer until
compressed circlip
seats Greasing Notes
Page 42-46 Checking Page 40-60 13 - Inner support rings Prevents boot inflating Only installed on left
drive shaft
transmission end Page 5 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

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Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30
Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 6 - Brake pedal return
spring
7 - Return spring
mounting tube
8 - Brake pedal mounting
bushing
9 - Brake pedal
10 - Clutch pedal Removing and
installing 11 - Pedal cluster mounting bracket
12 - Clutch pedal pivot pin
13 - Clutch pedal mounting
bushing
14 - Over-center spring
mounting
15 - Over-center spring Before removing,
remove clutch pedal Page 6 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6