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)
Rear axle, servicing (four wheel drive vehicles)
Rear drive shafts, servicing
Reworking cap nut in side member (four wheel drive vehicles)
Suspension strut, disassembling and assembling (four wheel drive
vehicles)
Wheel bearings, servicing - disc brakes (four wheel drive vehicles)
44 - Wheels, Tires, Wheel alignment
Vehicle alignment
Test requirements:
Vehicle alignment specifications (front wheel drive vehicles)
Vehicle alignment specifications (four wheel drive vehicles)
Front wheel camber, adjusting
Calculating the direction of travel:
45 - Anti-lock brake system
Anti-locking Brake System (ABS) and Anti-locking Brake System with
Electronic Differential Lock (ABS/EDL) Teves 04
Notes for repair work on ABS, ABS/EDL
Control module, removing and installing
Wheel speed sensor and rotor for speed sensor, removing and installing
Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock
(ABS/EDL), Teves 20 GI
Safety precautions
ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master
cylinder (Teves 20 GI), servicing
ABS hydraulic unit and ABS control module (Teves 20 GI), removing and
installing
Brake hydraulic system, bleeding and filling
Assembly overview - hydraulic unit, brake servo/brake master cylinder
Hydraulic unit, removing and installing
Brake Pedal Position Sensor, removing and installing
46 - Brakes - Mechanical components
Front brakes, servicing (Girling caliper)
Brake pads, removing and installing
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)
48 - Steering
Steering
Assembly overview: steering column, column tube, steering wheel and airbag
steering wheel
Airbag unit, removing and installing
Airbag steering wheel, removing and installing
Airbag Spiral Spring, removing and installing
Column tube for height adjustable steering wheel, removing and installing
Pump delivery pressure, checking
Power steering gear, removing and installing
Assembly overview: power assisted steering box (TRW)
Power steering gear, adjusting (TRW)
Power steering gear, disassembling and reassembling (TRW)
Power steering gear, disassembling
Inner sealing ring for toothed rod, pulling out
Checking toothed rod for scoring
Sealing ring on toothed rod, replacing
Sealing rings, installing on toothed rod piston
Power steering gear, assembling
Inner sealing ring for toothed rod, installing
Toothed rod, installing in housing
Adhesive tape, applying
Power steering gear, adjusting with new toothed rod
Assembly overview: power steering gear (ZF)
Power steering gear, adjusting (ZF)
Power steering gear, disassembling and reassembling (ZF)
Power steering gear, disassembling
Checking toothed rod for scoring
Sealing ring on toothed rod, replacing
Power steering gear, assembling
Tie rods, removing and installing (power steering gear - TRW and ZF)
Left-hand tie rod length, checking and adjusting
Assembly overview: vane pump, reservoir and hydraulic lines (vehicles with 4Cyl. engines)
Assembly overview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines)
Power steering vane pump, removing and installing (vehicles with 4-Cyl. engines)
V-belts, tensioning (4-Cyl. engines)
Assembly overview: Pressure and cooling lines (vehicles with VR6 engine)
Power steering vane pump, removing and installing (vehicles with VR6 engine]
Page
1
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
Suspension, Wheels, Brakes, Steering
00-1
Technical data
Model
Sedan/Wagon and syncro Base
Suspension 1)
Sedan/Wagon and syncro Base
Suspension 2)
Wheelbase mm 2625 2625
Track, unladen mm 1479 front, wheel offset 38
1422 rear, wheel offset 38
1485 front, wheel offset 35
1428 rear, wheel offset 35
1485 front, wheel offset 35
1441 rear, wheel offset 35
1489 front, wheel offset 33 3)
1445 rear, wheel offset 33 3)
1489 front, wheel offset 33 3)
1432 rear, wheel offset 3)
Turning circle m 10.7 11.5
Steering roll radius
mm 0.5 with offset 35
12 with offset 35
(negative)
3.5 with offset 38
15 with offset 38
Wheel lock angle inner
outer
1)
Base Suspension, explanation Page 40-1
2)
Plus Suspension, explanation Page 40-26
3)
Syncro
42
36
3745'
34 30'
00-2
Page
2
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
Steering
Model
Suspension version
Base Suspension
Sedan/Wagon and syncro
Plus Suspension
Steering gear Power assisted steering gear Power assisted steering gear
Steering wheel turns from lock to lock 3.33 3.14
Overall steering ratio 17.5:1 16.4:1
Wheel alignment specifications Page 44-2
00-3
Page
3
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
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
00-4
Page
4
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
Model
Sedan/Wagon
Output kW (hp) 85 (115) 128 (172)
Brake master cylinder mm dia. 23.81
Brake servo dia. in inches 10
Front brake caliper dia. mm 54
Front brake disc mm dia. 256 288
Front brake thickness mm 20 13
Pad thickness mm 11 14
Rear brake caliper dia. mm 38
Rear brake disc mm dia. 226
Rear brake disc, thickness mm 10
Pad thickness mm 12
00-5
Page
5
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
Model
Passat syncro
Output kW (hp) 85 (115) 128 (172)
Brake master cylinder mm dia. 23.81
Brake servo dia. in inches 10
Front brake caliper dia. mm 54
Front brake disc mm dia. 256 288
Front brake disc thickness mm 20 25
Pad thickness mm 11 14
Rear brake caliper dia. mm 38
Rear brake disc mm dia. 239
Rear brake disc, thickness mm 10
Pad thickness mm 12
00-6
Page
6
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
Wheels, tires
Engine output (kW) Model
55 gas
55, 66 - Diesel
Tire size 1)
Sedan/Wagon 185/65 R 14 86 S
195/60 R 14 86 S
205/50 R 15 86 S
185/65 R 14 85 Q (M+S)
195/60 R 14 85 Q (M+S)
205/50 R 15 85 Q (M+S)
55 Sedan/Wagon T 125/70 R 15 95 M
(Temp. spare)
1)
Tire pressures Sticker on vehicle
Wheel
6 J x 14
6 J x 14
6 J x 15
6 J x 14
6 J x 14
6 J x 15
3 1/2 J x 15
Offset Hole pattern
38
4-hole
38
38
38
38
38
40
00-7
Page
7
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
Engine output (kW)
Model
Tire size 1)
85 kW Sedan/Wagon 185/65 R 14 86 H
195/60 R 14 86 H
205/50 R 15 86 H
185/65 R 14 85 Q (M+S)
195/60 R 14 85 Q (M+S)
205/50 R 15 85 Q (M+S)
85 kW Sedan/Wagon T 125/70 R 15 95 M
(Temp. spare)
128 kW Sedan/Wagon 205/50 ZR 15 86 W
195/55 R 15 85 T (M+S)
195/55 R 15 85 T (M+S)
Wheel
6 J x 14
6 J x 14
6 J x 15
6 J x 14
6 J x 14
6 J x 15
3 1/2 J x 15
6 J x 15
6 J x 15
6 1/2 J x 15
Offset Hole pattern
38
4-hole
38
35
38
38
35
40
35
35
33
205/50 R 15 85 T (M+S)
128 kW Sedan/Wagon T 125/70 R 16 95 M
(Temp. spare)
1)
Tire pressures Sticker on vehicle
6 J x 15
3 1/2 J x 16
35
38
00-8
Page
8
of 8Suspension, Wheels, Brakes, Steering
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1
Engine output
(kW)
Model
85 kW Sedan/Wagon
syncro
85 kW Sedan/Wagon
syncro
128 kW Sedan/Wagon
syncro
Tire size 1)
185/65 R 14 86 H
195/60 R 14 86 H
205/50 R 15 86 H
185/65 R 14 86 Q
(M+S)
195/60 R 14 86 Q
(M+S)
205/50 R 15 86 Q
(M+S)
T 125/80 R 15 95 M
(Temp. spare)
205/50 ZR 15 86 W
205/50 R 15 86
Wheel Offset
6 J x 14
6 J x 14
6 J x 15
6 J x 14
6 J x 14
6 J x 15
3 1/2 J x
38
38
35
38
38
35
40
15
6 J x 15
6 J x 15
35
35
Hole
pattern
4-hole
5-hole
128 kW Sedan/Wagon
syncro
1)
Tire pressures Sticker on vehicle
(M+S)
T 125/70 R 16 95 M
(Temp. spare)
3 1/2 J x
16
38
40-1
Page
1
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Front Wheel
Suspension, Shafts
and Axle
Front suspension,
servicing (Base
suspension)
I - Removing and installing
subframe, stabilizer bar and
control arm (Base suspension)
Page 40-2
II - Removing and installing
wheel bearings, suspension
strut and drive shaft (Base
suspension) Page 40-14
The Base suspension is
installed in Passat 1995
vehicles up to 85 kW.
40-2
joint and tighten to 50 Nm
Page
2
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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
(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.
40-3
necessary, replace ball
observe this instruction
Secured to control arm
Page
3
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
1 - Hex bolt, 35 Nm (26 ft
lb)
2 - Ball joint
Checking Page 40-
10
Check rubber boot for
damage and if
joint
Mark installation
position. If replaced
set to center of
elongated hole and
check toe
Elongated holes are
not for camber
adjustment. Failure to
may result in damage
to drive shafts!
3 - Captive lock nuts
4 - Air deflector plate
by clip
5 - Control arm
40-4
Page
4
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
6 - Control arm rear
mounting
Installation position
Fig. 3
Pressing out and in
Fig. 4
7 - Hex bolt M 12 x 1.5 x 82
50 Nm (37 ft lb) and
turn 90 further
8 - Hex bolt M 12 x 1.5 x 65
70 Nm (52 ft lb) and
turn 90further
9 - Hex bolt M 12 x 1.5 x 78
70 Nm (52 ft lb) and
turn 90further
10 - Control arm front
mounting
Pressing out Fig. 1
Pressing in Fig. 2
11 - Connecting link
With rubber mounting
40-5
Collar faces away from
locking hex nut, 25
Page
5
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
12 - Connecting link
mounting
Conical side toward
control arm
13 - Washer
mounting
14 - Self-
Nm (18 ft lb)
15 - Sub-frame
Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 5
Remove sub-frame
from below with VAG
1383 (with control arm
but without steering
gear). After installing
check position of
steering wheel and
align front end.
Aligning enginetransmission assembly
Repair Manual, Engine
Mechanical, Repair Group 10
40-6
locking hex nut, 25
Page
6
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
16 - Hex bolt, 65 Nm (48 ft
lb)
17 - Stabilizer bar mounting
18 - Stabilizer bar
19 - Stabilizer bar clamp
20 - Hex bolt, 25 Nm (18 ft
lb)
To secure stabilizer
bar
21 - Vibration damper
Note installation
position, large part
must protrude from
sub-frame
22 - Self-
Nm (18 ft lb)
23 - Cap nut
Repairing in side
member Page 40-
11
40-7
Page
7
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Front control arm mounting, pressing
out
Fig. 2 Front control arm mounting, pressing in
Note:
Before pressing in, coat with acid-free lubricant, e.g.
soft soap.
40-8
Page
8
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 3 Control arm rear mounting, installation
position
One of the embossed arrows points toward the
recess in the control arm and the kidney shaped
opening (arrow A) faces towards center of vehicle.
Fig. 4 Control arm rear mounting, pressing
Note:
out and in
If bonded rubber bushing is tight because of
corrosion, cut rubber out, saw through steel casing
and drive bushing out.
40-9
Page
9
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 5 Supporting engine/transmission
assembly with 10-222 A and legs 10-222
A/1
40-10
Page
10
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Ball joint, checking (Base and Plus
suspension)
Checking axial clearance
- Forcibly pull ball joint down and press up again.
Checking radial play
- Press lower part of wheel outward and inward.
Note:
There must be no perceptible or visual "play"
during either test.
Observe ball joint during checks.
Take into account possible existing wheel bearing
play or "play" in upper suspension strut mounting.
40-11
Page
11
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Reworking cap nut in side member
(Base and Plus suspension)
If the threads of the cap nut in the side member
are damaged, the thread must either be retapped
or the cap nut must be drilled out.
When drilling out proceed as follows.
- Support engine/transmission assembly with 10222 A and legs 10-222 A/1.
- Remove the sub-frame.
- Drill out the damaged side member cap nut with
a 10.2 mm diameter drill from underneath.
Note:
When drilling do not tilt the drill.
WARNING!
Wear protective goggles.
- Cut new M 12 x 1.5 thread in cap nut.
- Use a new bolt/washer assembly to secure subframe Page 40-13 .
40-12
Page
12
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Bolt/washer assemblies for sub-frame
Securing point
Front sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9
Thread
Bolt
Part No.
N 101 612.01 1)
Rear sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01
Sub-frame bracket M10 M10 x 38 10.9 N 019 541.1
Engine front cross-member to side member M10 M10 x 75 10.9
1)
These bolts are not listed in the parts catalog. They must be specially ordered.
N 904 078.01 1)
40-13
Page
13
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Note:
Tightening torque remains unchanged.
1 - Bolt/washer
2 - Cap nut
3 - Side member
4 - Sub-frame
5 - Bonded rubber mounting/control arm
40-14
joint and tighten to 50 Nm
Page
14
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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
(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).
40-15
tighten with the vehicle
Page
15
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
1 - Self-locking nut, 265
Nm (195 ft lb)
Only loosen and
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
Repair Manual, Suspension,
Wheels, Brakes, Steering,
Repair Group 00
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
40-16
locking hex nut, 35
locking hex nut, 50
Page
16
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
6 - Speed sensor rotor
Only on vehicles with
ABS
7 - Hex bolt, 10 Nm (7 ft lb)
8 - Splash plate
9 - Circlip
Ensure correctly
seated
10 - Wheel bearing
Pressing out Fig. 6
Replace, as it is
destroyed during
pressing out
Pressing in Fig. 7
11 - Self-
Nm (26 ft lb)
12 - Wheel bearing housing
13 - Self-
Nm (37 ft lb)
14 - Hex bolt
Clamping bolt for ball
joint
40-17
locking hex nut, 95
Page
17
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
15 - Self-locking
bolt/washer assembly,
125 Nm (92 ft lb)
For securing brake
carrier
16 - Socket head multi-
point bolt, 45 Nm (33 ft
lb)
17 - Drive shaft
To remove and install
separate ball
joint/control arm
connection Fig. 2
Repairing Page 40-
46
18 - Circlip
Ensure correctly
seated
19 - Self-
Nm (70 ft lb)
20 - Hex bolt
Shank diameter 11
mm
Adjusting camber
Page 44-6
Mark position before
loosening
40-18
locking hex nut, 60
Page
18
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
21 - Self-
Nm (44 ft lb)
Loosening and
tightening Fig. 1
22 - Stop
23 - Suspension strut
bearing
24 - Suspension strut
Removing and
installing Fig. 1 and
Fig. 2
Disassembling and
assembling Page
40-23
25 - Bracket
26 - Hex bolt
27 - Tie rod
Removing and
installing Page 48-
77
28 - Countersunk screw
29 - Screw
40-19
Wheel bearing housing/suspension strut
Page
19
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Suspension strut to body, loosening
and tightening
Fig. 2
joint, separating
Note:
Camber must be adjusted each time joint is loosened.
40-20
Page
20
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 3 Ball joint/control arm connection,
separating
To take drive shaft out, remove bolts (arrows).
Note:
First mark installation position.
Fig. 4 Hub, pressing out of wheel bearing
housing
40-21
Page
21
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 5 Bearing race, pulling out of hub
Only use puller with leg clamp e.g. Kukko 204-2
(commercial type).
Fig. 6 Wheel bearing, pressing out of wheel
bearing housing
40-22
Page
22
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 7 Wheel bearing, pressing into wheel
bearing housing
Fig. 8 Hub, pressing into wheel bearing
housing
40-23
Page
23
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Front suspension strut,
servicing (Base and Plus
suspension)
1 - Shock absorber
Can be replaced
individually
Check shock absorber
for leaks and noises
After replacing, adjust
camber and toe
Page 44-1
2 - Buffer stop
3 - Protective sleeve
40-24
Outer surface of spring
locking hex nut, 60
Page
24
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
4 - Coil spring
Removing and
installing Fig. 2
Observe color coding
must not be damaged
Is slightly curved
5 - Spring plate
6 - Axial bearing
7 - Hex nut, 60 Nm (44 ft
lb)
Loosening and
tightening Fig. 2
8 - Suspension strut
mounting
9 - Stop
10 - Self-
Nm (44 ft lb)
Loosening and
tightening Fig. 1
40-25
Page
25
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Hex nut, loosening and tightening
Fig. 2 Spring, removing and installing
40-26
Page
26
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Front suspension,
servicing (Plus
suspension)
I - Removing and installing
subframe, stabilizer bar and
control arm (plus suspension)
Page 40-27
II - Removing and installing
wheel bearing, suspension
strut and drive shaft (plus
suspension) Page 40-36
The following components are
different when comparing the
plus suspension with the base
suspension:
Control arm, ball joint, wheel
bearing housing, stabilizer bar,
drive shaft, brake disc, hub,
wheel and tie rods.
The Plus suspension is
installed in Passat models with
engine output 110 kW (148 hp)
and above.
40-27
necessary, replace ball
locking hex nut, 45
Page
27
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Sub-frame, stabilizer bar
and control arm,
removing and installing
(Plus suspension)
Notes Page 40-2
1 - Hex bolt, 35 Nm (26 ft
lb)
2 - Ball joint
Checking Page 40-
10
Check rubber boot for
damage and if
joint
Removing and
installing Page 40-
33
Mark installation
position. If replaced
set to center of
elongated hole and
check track
3 - Self-
Nm (33 ft lb)
4 - Captive locknuts
40-28
Secured to control arm
Page
28
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
5 - Control arm rear
mounting
Installation position
Fig. 2
Pressing out and in
Fig. 3
6 - Control arm
Elongated holes are
not for camber
adjustment!
7 - Air guide plate
by clip
8 - Control arm front
mounting
Pressing out and in
Fig. 1
9 - Hex bolt M 12 x 1.5 x 78
70 Nm (52 ft lb) and
turn 90 further
10 - Hex bolt M 12 x 1.5 x 65
70 Nm (62 ft lb) and
turn 90 further
11 - Connecting link
With rubber mounting
40-29
Collar faces away from
locking hex nut, 25
Page
29
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
12 - Mounting for
connecting link
Conical side towards
control arm
13 - Washer
mounting
14 - Self-
Nm (18 ft lb)
15 - Hex bolt M 12 x 1.5 x 82
50 Nm (37 ft lb) and
turn 90 further
16 - 25 Nm (18 ft lb)
17 - Hex bolt, 25 Nm (18 ft
lb)
To secure stabilizer
bar
18 - Hex bolt, 65 Nm (48 ft
lb)
19 - Clamp for stabilizer bar
40-30
from below with control
transmission jack VAG
Page
30
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
20 - Vibration damper
Not installed on
vehicles with VR 6
engine
21 - Sub-frame
Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 4
Remove sub-frame
arm but without
steering gear using
1383 or equivalent.
After installing check
position of steering
wheel and align front
end.
Aligning
engine/transmission
assembly
Repair Manual, Engine
Mechanical, Repair Group 10
22 - Stabilizer bar mounting
23 - Stabilizer bar
24 mm diameter
24 - Cap nut
Reworking in side
member Page 40-
11
40-31
Page
31
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Control arm front mounting, pressing
out and in
Note:
Before pressing in, coat with lubricant, e.g. soft soap.
Fig. 2 Control arm rear mounting, installation
position
One of the embossed arrows points toward the
recess in the control arm and the kidney shaped
opening -arrow -A- in mounting faces towards center
of vehicle.
40-32
Page
32
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 3 Control arm rear mounting, pressing
out and in
Fig. 4 Engine/transmission assembly,
supporting with 10-222 A and 10-222
A/3
40-33
Page
33
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Ball joint, removing and installing (Plus
running gear)
Removing
- Loosen 12-point nut with vehicle standing on its
wheels.
- Disconnect drive shaft at transmission drive
flange.
- Remove bolts -arrow -A-.
- Loosen bolt -arrow -B-.
- Separate connection between ball joint/control
arm. (First mark installation position).
- Swing wheel and suspension strut outward and
support.
40-34
joint).
Page
34
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Install ball joint splitter as shown in illustration and
press out ball joint.
1 - Splitter. Matra V 176
Note:
Place transmission jack VAG 1383/A, or
equivalent, underneath (danger of accident
through falling parts when pressing out the ball
Protect ball joint threads by threading nut on a
few turns.
Installing
- Install ball joint in wheel bearing housing.
- Thread on new self-locking nut, and counterhold
with hex key (6 mm AF).
1 - Hex key (6 mm AF), shortened by approx. 10
mm.
2 - Crowfoot insert or slotted ring socket insert
Page 40-35
3 - VAG 1331
- Secure ball joint to control arm (align to old marks).
40-35
Page
35
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Note:
Make sure that the boot is not damaged or
twisted.
Tightening torques
Ball joint to wheel bearing housing: 45 Nm (33 ft
lb)
Ball joint to control arm: 35 Nm (26 ft lb)
1 - Box insert (commercial type, 19 mm AF)
2 - Crowfoot insert (commercial type, 19 mm AF)
40-36
Page
36
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Wheel bearing and
suspension strut,
removing and installing
(Plus suspension)
Notes Page 40-14
1 - Wheel bolt, 110 Nm (81
ft lb)
2 - Self-locking 12-point
nut
90 Nm (66 ft lb) and
turn 45 further (1/8 )
Loosening and
tightening Page 40-
44
Any paint residue
and/or corrosion on
thread of the outer
joint must be removed
before the nut is
installed.
3 - Screw
4 - Brake disc
Repair instructions
Page 46-1
40-37
Page
37
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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
40-38
Always replace, as it is
locking hex nut, 35
Page
38
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
11 - Circlip
Ensure seated
correctly
12 - Wheel bearing
Pressing out Fig. 4
destroyed during
pressing out
Pressing in Fig. 5
13 - Self-
Nm (26 ft lb)
14 - Wheel bearing housing
15 - Self-locking
bolt/washer, 125 Nm
(92 ft lb)
16 - Drive shaft
Removing and
installing Page 40-
43
Repairing Page 40-
46
17 - Socket head multi-
point bolt, 45 Nm (33 ft
lb)
40-39
locking hex nut, 60
locking hex nut, 95
Page
39
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
18 - Hex bolt
Camber adjustment
Page 44-1
Before loosening,
mark installation
position
19 - Hex bolt
20 - Bracket
21 - Stop
22 - Self-
Nm (44 ft lb)
Loosening and
tightening Fig. 1
23 - Suspension strut
Disassembling and
assembling Page
40-23
24 - Self-
Nm (70 ft lb)
25 - Tie rod
Removing and
installing Page 48-
77
40-40
Page
40
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Suspension strut to body, loosening
and tightening
Fig. 2 Hub, pressing out of wheel bearing
housing
40-41
Page
41
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 3 Inner race, pulling off hub
Only use puller with leg clamp e.g. Kukko 204-2
(commercial type).
Fig. 4 Wheel bearing, pressing out of wheel
bearing housing
40-42
Page
42
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 5 Wheel bearing, pressing into wheel
bearing housing
Fig. 6 Hub, pressing into wheel bearing
housing
40-43
Page
43
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Drive shaft, removing and installing
(Plus running gear)
Removing
- Loosen 12-point nut with vehicle standing on its
wheels.
- Disconnect drive shaft from transmission drive
flange.
- Remove bolts (arrow -A-).
- Loosen bolt (arrow -B-).
- Separate connection between ball joint/control
arm. (First mark installation position).
- Press drive shaft out. Install tool as shown in
illustration.
Note:
When pressing drive shaft out ensure sufficient
clearance is available.
40-44
Page
44
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Installing
- Remove remains of locking fluid from outer joint
and hub splines. (Splines must be free of oil and
grease).
- Apply locking fluid D 185 400 A2 to splines as
shown in illustration. Bead cross section approx. 3
mm.
- Install drive shaft.
- Connect ball joint to control arm.
- Install drive shaft to transmission flange shaft and
secure.
- Install 12-point nut to drive shaft and tighten.
Note:
To tighten 12-point nut we recommend the angle
measuring wrench VAG 1756 or equivalent.
Only loosen and tighten with vehicle standing on
its wheels (danger of accident).
40-45
Page
45
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Tightening torques:
Drive shaft to flange shaft/transmission 45 Nm
(33 ft lb)
Drive shaft to wheel bearing 90 Nm (66 ft lb) and
housing turn 45 further (1/8 turn)
Ball joint/control arm 35 Nm (26 ft lb)
40-46
Page
46
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Drive shaft, repairing
Drive shafts on vehicles with Plus suspension
have shorter and finer splines on the outer joint.
The wheel bearing is secured by a 12-point nut.
The splines of the outer joint and the hub on Plus
suspensions are secured with locking fluid D 185
400 A2.
Drive shaft, removing and installing
Vehicles with Base suspension Page 40-14
Vehicles with Plus suspension Page 40-43
Note:
Grease quantity:
- - Outer constant velocity joint 100 g of G-6.3
grease
- - Inner constant velocity joint 110 g of G-6.3
grease
Greasing outer joint: press half of the grease
into the joint, and the other half evenly into the
boot.
Greasing inner joint: press half of the grease
into the inner joint from both sides, the other
half evenly into the boot.
When replacing the boot grease joint as
required.
40-47
Page
47
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
1 - Circlip
Always replace
Remove and install
with VW161 a
2 - Gasket
Always replace. Pull
off protective foil and
stick onto joint. (Only
on 100 mm diameter
constant velocity joints
3 - Inner constant velocity
joint 100 mm diameter
Only replace complete
Pressing off Fig. 3
Pressing on Fig. 4
Greasing Notes
Page 40-46
Checking Page 40-
62
4 - Dished washer
Inner diameter splined
Installation position:
outer diameter
(concave side)
contacts constant
velocity joint
40-48
Coat inside of cap with
Page
48
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
5 - Boot for 100 mm
diameter constant
velocity joint
Rubber version
With vent hole
Check for tears and
chafing
Installation position for
left drive shaft Fig. 5
Installation position for
right drive shaft Fig.
6
D3
Drive off with drift
6 - Drive shaft
Left shaft, solid bar
(not illustrated)
Right shaft, tube
7 - Clamp
Always replace
Tensioning Fig. 7
and Fig. 8
40-49
Page
49
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
8 - Boot for 90 mm
diameter constant
velocity joint
Polyester elastomer
version
Check for tears and
chafing
The balance pressure
briefly ventilate boot
before tensioning the
small clamp Fig. 7
Installation position for
left shaft, wheel end
Fig. 10 and Fig. 11
Installation position for
right shaft, wheel end
Fig. 12
9 - Clamp
Always replace
Tensioning Fig. 7
and Fig. 8
40-50
Outer constant velocity
Page
50
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
10 - Dished washer
Outer diameter
(concave side)
contacts thrust washer
11 - Thrust washer
12 - Circlip
Always replace
Insert in shaft groove
13 -
joint, 90 mm 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
40-51
Outer constant velocity
Only replace complete
Exception: On vehicles
Page
51
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
14 -
joint, 90 mm diameter
For vehicles with 16V
and VR6
Wedge splines, larger
diameter
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.
with 85 kW (115 hp)
and manual
transmission 02C only
installed on left solid
drive shaft
40-52
Page
52
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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)
40-53
Page
53
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Vibration damper, removing and
installing
The damper consists of two halves. Both halves are
joined to one another by spring pins (arrow).
Installation position Fig. 1
Note:
Only replace vibration damper with drive shaft
removed
Before driving in spring pin protect shaft paint
finish against damage.
To prevent axial movement apply adhesive tape
or a suitable adhesive to internal diameter.
Fig. 1 1 Vibration damper, installation position
When installing vibration damper -A- note correct
installation position. Ensure dimension "a" is
maintained.
Dim. "a" = 521 1 mm right shaft
264 1 mm left shaft (if installed)
40-54
Page
54
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 2 Outer constant velocity joint, removing
- Drive joint off drive shaft with a firm blow from an
aluminium hammer.
Fig. 3 Inner constant velocity joint, pressing
off
Note:
First drive boot off with drift
Support ball hub
40-55
Page
55
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 4 Inner constant velocity joint, pressing
on
- Press on joint up to stop.
- Install circlip.
Note:
Chamfer on inner diameter of ball hub (splines) must
face the contact shoulder on the drive shaft.
Fig. 5 Installation position of left drive shaft
transmission end joint boot - rubber
version
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.
40-56
Page
56
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 6 Installation position of right drive shaft
transmission end joint boot
The large diameter of vent chamber -A- must fit on
the larger diameter.
B - Vent hole
Fig. 7 Joint boot, ventilating
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.
40-57
arrow
Page
57
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 8 Larger clamp, tensioning
- Use pliers VAG 1682 as shown in illustration.
Ensure that the jaws of the pliers seat in the -
-B- of the clamp.
- Tension clamp by turning the spindle with a torque
wrench (do not tilt pliers).
Fig. 9 Smaller clamp, tensioning 40
Note:
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.
40-58
Page
58
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 10 Installation position of left drive shaft
wheel end joint boot, shaft diameter 27
mm
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. 11 Installation position of left drive shaft,
wheel end, shaft diameter 22 mm
Cuff installation position: Cuff butts against shaft
shoulder (arrow).
40-59
Page
59
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 12 Installation position of right drive shaft,
wheel end joint boot
Cuff seating tolerance "a": From cuff position to
chamfer up to 1/2 a groove visible.
40-60
Page
60
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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.
40-61
- Press in the balls one after the other from opposite
Page
61
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Swing segment of hub into rectangular cage
window.
- Tilt hub out of cage.
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
- 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.
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.
40-62
Page
62
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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.
- Swivel ball hub and ball cage.
- Press out ball cage in direction of arrow.
- Press balls out of cage.
Note:
The ball hub and joint are paired and must not be
interchanged.
- 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.
40-63
Page
63
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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
- 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.
Note:
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.
40-64
Page
64
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- 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.
- Swivel in the hub with balls by applying firm
pressure on the cage (arrow).
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.
40-65
Outer constant velocity
Page
65
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Drive shaft with tripod
joint, repairing
1 -
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
40-66
Page
66
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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
40-67
Inner splined screw, 45
Page
67
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
9 -
Nm (33 ft lb)
10 - Drive shaft, right, with
inner tripod joint
Repair of inner joint
and replacement of
boot not possible at
this time
Replace if damaged
40-68
Page
68
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Constant velocity joint, outer, removing
- Drive off from drive shaft with forceful blow using
an alloy hammer.
Fig. 2 Boot, ventilating
The boot is pressed on forcefully when installing on
the joint body. This creates a vacuum in the boot that
makes a dent during driving (arrow). Briefly ventilate
the boot at the small diameter after installation to
provide equalize pressure.
40-69
- Install pliers VAG 1682 as in illustration. Make sure
Page
69
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 3 Clamp, tightening on large diameter
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).
Note:
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
MoS2 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
40-70
Page
70
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
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.
40-71
Page
71
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- 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.
40-72
Page
72
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Disconnect drive axle from transmission drive
flange.
- Mark installation position of bolts (arrows) and
remove.
- 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.
Installing
- Install in reverse order of removal.
40-73
Outer constant velocity
Page
73
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Drive axle with triple-rotor
joint, servicing
1 -
(CV) joint
Replace complete part
only
Removing Fig. 1
Installing: drive onto
shaft with plastic
hammer until circlip
seats (springs into
groove)
Greasing page 4012
2 - Circlip
Always replace
Insert in groove in
shaft
3 - Thrust ring
4 - Belleville spring
Larger diameter
(concave side)
contacts with thrust
ring
5 - Clamp
Always replace
Tightening page 40-
7
6 - Boot
Check for tears and
chafing
7 - Clamp
8 - Axle shaft
40-74
Page
74
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
9 - Clamp
For triple-rotor joint
10 - Boot
11 - Clamp
For triple-rotor joint
12 - Cover
Destroyed when
disassembling
No longer required for
assembly; not
available as
replacement part
13 - Rectangular sealing
ring
Included in repair kit;
not used in production
14 - O-ring
Not required for
assembly
15 - Circlip
16 - Roller
17 - Triple-rotor star
Chamfer -arrow- goes
onto axle shaft splines
first
18 - Multi-point socket-
head bolt
M10 x 20
80 Nm (59 ft lb)
19 - Housing
40-75
Page
75
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Fig. 1 Removing outer CV joint
- Drive joint off axle shaft with firm blow from soft
mallet.
40-76
Fig. 2 Tightening outer CV joint boot clamp
Page
76
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Position VAG 1682 pliers or equivalent (e.g. SnapOn YA 3080) as shown in illustration.
Make sure plier jaws seat in grooves of clamp (arrows
-B-)
- Tension clamp by using torque wrench to turn
spindle (keep pliers at right angle to shaft).
Tightening torque: 20 Nm (15 ft lb)
Note:
Due to the hardness of the boot material
(compared to rubber), it is necessary to use a
stainless steel clamp. The clamp can only be
properly tightened using VAG 1682 pliers.
Use a torque wrench with 5-50Nm (4-37 ft lb)
range (e.g. VAG 1331 or equivalent).
Make sure that the spindle threads of the pliers
are not tight. If necessary coat the threads with
MoS2 grease to ensure smooth operation.
If the spindle threads are tight (e.g. dirty) the force
necessary for correctly tightening the clamp will
not be achieved, despite correct torque readings.
Fig. 3 Tightening small end clamp
40-77
Page
77
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Triple-rotor joint, disassembling
- Open hose clamp
- Open clamp on shaft small end and push back
boot.
- Drive screwdriver or similar tool into cover and pry
open.
Note:
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.
40-78
Page
78
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Remove O-ring -arrow- from groove.
- Mark installation positions of parts -1-, -2- and -3-.
1 - Triple-rotor joint housing
2 - Triple-rotor star
3 - Axle shaft
Note:
Noises while driving may result if the indicated
parts are not reassembled to their prior positions.
Use a waterproof felt-tipped pen for marking
parts.
- Remove rubber gasket (arrow) from groove.
- With triple-rotor joint housing clamped in vise, pull
axle shaft together with triple-rotor star upward out
of housing.
CAUTION!
Do not let the rollers slide off the triple-rotor star
and fall to the floor.
- Hold axle shaft in straight alignment to triple-rotor
joint and slowly push back triple-rotor joint housing
with other hand.
- Mark installation position of rollers -1- on triplerotor star -2- using felt-tipped marker.
40-79
Page
79
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Remove rollers and place on clean surface.
- Remove circlip.
-1- Pliers Commercially available
- Press triple-rotor star off axle shaft.
- Pull triple-rotor joint housing off axle shaft.
- Clean shaft and triple-rotor joint housing.
40-80
Page
80
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
Triple-rotor joint, assembling
- Slide small diameter boot clamp onto shaft.
- Slide triple-rotor joint boot onto shaft.
- Slide triple-rotor joint housing onto shaft.
Mounting triple-rotor star
Note:
The side of the star with a chamfer (arrow) goes onto
the axle shaft splines first.
- Place triple-rotor star on axle shaft according to
previously marked position.
- Install circlip and make sure that it is correctly
seated.
- Install rollers according to previously marked
positions.
- Push triple-rotor joint housing over rollers and
secure (clamp housing in vise).
40-81
Page
81
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Install rectangular sealing ring (arrow) from repair
kit.
Note:
A seal is formed directly between the triple-rotor joint
and the drive flange by the rectanular sealing ring.
The cover is no longer required.
- Press 180 grams of axle shaft grease from repair
kit into triple-rotor joint .
90 grams into joint and 90 grams behind joint
- Install triple-rotor joint boot.
- Install boot clamp.
40-82
Page
82
of 82Front Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1
- Tighten small diameter clamp with VAG 1275
pliers or equivalent (e.g. KD 474).
CAUTION!
Secure the triple-rotor joint with tape so that
the housing is not inadvertently pushed back
when installing the axle shaft.
Remove tape just prior to bolting to drive
flange.
42-1
locking hex nut, 70
Page
1
of 14Rear Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1
Rear Wheel
Suspension, Shafts
and Axle
Rear axle, servicing
(vehicles with front wheel
drive)
Note:
The rear axle and wheel
bearings are identical on
Base and Plus suspension
versions.
Welding and straightening
of the axle beam is not
permissible.
1 - Wheel bolt 110 Nm (81
ft lb)
2 - Self-
Nm (52 ft lb)
When tightening the
nut the axle beam
must be in the
horizontal position
(unladened vehicle
state)
3 - Hex bolt, 25 Nm (18 ft
lb)
4 - Suspension strut
Removing and
installing Fig. 1 to
Fig. 3
Disassembling and
assembling Page
42-9
42-2
Servicing Vehicles with
the axle beam must be
Installed from center of
Shouldered bolt, 70 Nm
Page
2
of 14Rear Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1
5 - Wheel bearing
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,
in the horizontal
position (unladened
vehicle state)
7 - Hex bolt
vehicle
8 -
(52 ft lb)
If threads are
damaged, rework
captive nut in side
member Page 42-7
42-3
Page
3
of 14Rear Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1
9 - Mounting bracket with
retainer for brake
pressure regulator
Installation position
Fig. 4
Check and if
necessary adjust rear
axle total toe after
installation
If possible do not
loosen when removing
the rear axle
10 - Hex nut/washer, 35 Nm
(26 ft lb)
11 - Regulator spring
bracket
12 - Bonded rubber
mounting
Note installation
position Fig. 7
Pressing out Fig. 5
and Fig. 6
Pressing in Fig. 8
Only replace as pair
13 - Axle beam
Stub axle contact
surfaces and threaded
holes are to be free of
paint and dirt
14 - Parking brake cable
bracket
42-4
Suspension strut at body, removing and
Suspension strut at body, removing and
Page
4
of 14Rear Wheel Suspension, Shafts and Axle
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1
Fig. 1
installing
- Removing and installing inertia reel cover
Repair Manual, Body Exterior, Interior, Repair
Group 70.
- Removing and installing inertia reel
Repair Manual, Body Exterior, Interior, Repair
Group 68.
Inertia reel bolt (arrow) tightening torque: 40 Nm (30 ft
lb)
Fig. 2
installing
Remove and install both securing bolts (arrows) from
interior of vehicle (viewed through rear left side
window).
Tightening torque: 25 Nm (18 ft lb)
Loading...