VOLKSWAGEN PASSAT 1997 B3, B4 / 3.G Service Manual PDF

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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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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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Cuff seating tolerance "a": From cuff position to
chamfer up to 1
/
2 a groove visible. Fig. 12 Installation position of right drive shaft,
wheel end joint boot Page 59 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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Outer constant velocity joint, checking
The joint should be disassembled to replace dirty
grease or for checking the balls and ball tracks
for wear and damage.

Removing - Before disassembling mark position of the ball hub
in relation to the ball cage and housing with an
electric scriber or oil stone.
- Swivel ball hub and ball cage. - Remove balls one after the other. - Turn cage until the two rectangular windows
(arrow) are aligned with the joint housing.
- Lift out cage together with hub. Page 60 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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- Swivel in ball hub, whereby the hub must be
swivelled out of the cage (arrows) far enough to
allow the balls to fit into the ball tracks. Checking operation of constant velocity joint:
The constant velocity joint is correctly assembled
when the ball hub can be moved by hand backward
and forward over its entire axial movement range. - Swivel in the hub with balls by applying firm
pressure on the cage (arrow). Page 64 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 shaft with tripod
joint, repairing
1 - Outer constant velocity joint Replace complete Removing Fig. 1 Installing: Drive onto
the shaft with plastic
hammer until circlip
comes out Greasing Notes
Page 40-46 Checking Page 40-62 2 - Circlip Always replace Install in groove of
shaft
3 - Thrust ring
4 - Dished washer Larger diameter
(concave side)
contacts thrust ring Page 65 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 - Clamp Always replace Tightening, Fig. 2
and Fig. 3 6 - Boot for constant
velocity joint, 90 mm
dia. Check for cracks and
abrasion Before tightening the
small clamp, ventilate
boot briefly so
pressure is equalized,
Fig. 2 7 - Clamp Always replace Tightening, Fig. 2
and Fig. 4 8 - Drive shaft, left, with
inner tripod joint Repair of inner joint
and replacement of
boot not possible at
this time Replace if damaged Page 66 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