1996-2001 Volkswagen Passat B5 (3B) Service & Repair Manual

AXLE SHAFTS - FRONT Article Text 1997 Volkswagen Golf This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru ARTICLE BEGINNING 1997-98 DRIVE AXLES Volkswagen FWD Axle Shafts 1997: Cabrio, Golf, GTI, Jetta & Passat 1998: Beetle TROUBLE SHOOTING NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section. REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION AXLE SHAFT NOTE: Two different types of joints may be used on axle shaft. Types used are: Constant Velocity (CV) type joint, or tripod-type joint. CV joint uses a 6 ball and cage design, while tripod joint uses a triple-roller design. Three methods may be used to assemble axle shaft to hub assembly depending on hub spline type. Later model design and new replacement parts are revised, and require an updated installation procedure. NOTE: Tripod-type joints are used on Cabrio, Golf, GTI and Jetta models equipped with a 4-cylinder engine with an automatic transaxle. Engine/transaxle assembly must be raised to remove left-side axle shaft. It is not necessary to raise engine/transaxle assembly for right-side axle shaft removal. Removal 1) Remove axle shaft nut. Raise and support vehicle. Remove wheel. Remove air deflector plate from lower control arm or noise insulation panel (if equipped). On Beetle with TDI engine, remove air duct between charge air cooler and turbocharger. 2) Using Engine Support Bridge (10-222A) and Adapter (10-222 A/1), raise and support engine/transaxle assembly. On models equipped with tripod-type joint, remove bolt for rear transaxle mount, and bolt for front engine mount. On all models, Disconnect axle shaft(s) from transaxle drive flange. Mark position of lower control arm-to-ball joint bolts. 3) Remove both outer control arm-to-ball joint bolts. Loosen, but DO NOT remove inner control arm-to-ball joint bolt. On models equipped with compressed hub splines, use Press (3283) to press axle shaft from wheel hub. On Beetle with automatic transmissions, remove 2 bolts from transmission support to sub-frame. On all models, swing wheel assembly outward and support if necessary. Remove axle shaft assembly. Disassembly & Reassembly (CV-Type Joint)

1) Remove axle shaft boot(s). Using a drift, remove protective cap from CV joint (if equipped). Remove circlip from transaxle-side CV joint. See Fig. 1. Support CV joint with axle assembly on Support Stand (VW 402). 2) Using Driver (VW 408A), press inner CV joint off axle shaft. Using a soft mallet, drive off outer CV joint from axle shaft. DO NOT disassemble outer CV joint. Outer CV joint is not serviceable, and must be replaced as an assembly if worn. 3) Mark position of ball hub in relation to ball cage and housing for installation reference of inner joint. Rotate inner race and remove balls. Clean and inspect parts for galling or wear. Cover balls with grease and reinstall in race. 4) To reassemble, reverse disassembly procedure. Pack CV joints with specified amount of Joint Grease (G 000 603). See CV JOINT GREASE CAPACITY SPECIFICATIONS. Before assembling CV joint boot on axle shaft, mark boot position using paint or tape. On Beetle left inner CV boot, end of boot should be .669" (17 mm) from last groove in axle shaft. Right side inner CV boot should seat on larger diameter of axle shaft with clamp on smaller diameter of axle shaft. Use NEW circlips and boot clamps during assembly. Using CV Boot Clamp Tool (VAG 1682), tighten outer clamp (larger diameter) to 15 ft lbs. (20 N.m). Tighten inner clamp (smaller diameter) to 5-40 ft lbs. (5-50 N.m). Fig. 1: Exploded View Of Axle Shaft With CV-Type Joint (Typical) Courtesy of Volkswagen United States, Inc. Disassembly & Reassembly (Tripod-Type Joint) 1) Remove axle shaft boot(s). Using a drift, remove protective cap from tripod joint. Remove circlip from tripod joint. Remove joint from axle shaft. Mark position of tripod-roller assembly in relation to housing for installation reference. 2) Remove tripod-roller assembly from housing. Clean and inspect parts for galling or wear. Install housing with a NEW boot on axle shaft. Cover tripod-roller assembly with grease and install into housing using reference marks made during disassembly. 3) Push triple-roller assembly onto axle shaft with chamfered side of splines first. See Fig. 2. Install a NEW circlip. Fasten boot using a NEW clamp. Tighten clamp using appropriate pliers.

Fig. 2: Exploded View Of Axle Shaft With Tripod-Type Joint Courtesy of Volkswagen United States, Inc. NOTE: Bonded-type axle shafts use a locking fluid on mating axle shaft and hub splines. If reusing original hub assembly, apply Locking Fluid (D 185 400 A2) to axle shaft splines. Locking fluid is not needed if replacing hub assembly with revised part, since hub is a compress-fit design. Installation To install, reverse removal procedure. Clean bolts and nuts to ensure tightening torque is correct. Install a NEW axle shaft nut. See TORQUE SPECIFICATIONS. CV JOINT GREASE CAPACITY SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Oz. (g) Beetle Outer Joint 3.2" (81 mm) Diameter ................................. 2.8 (80) 3.5" (90 mm) Diameter ................................ 4.2 (120) Inner Joint 3.7" (94 mm) Diameter ................................. 3.2 (90)

3.9" (100 mm) Diameter ............................... 4.2 (120) Passat Outer Joint 3.4" (88 mm) Diameter ................................. 3.2 (90) 3.8" (98 mm) Diameter ................................ 4.2 (120) Inner Joint 3.9" (100 mm) Diameter ................................ 3.2 (90) 4.2" (108 mm) Diameter ............................... 4.2 (120) All Other Models ............................................... (1) (1) - Information not available. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ AXLE SHAFT LENGTH ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application In. (mm) Beetle ......................................................... (1) Passat ......................................................... (1) All Other Models Automatic Transaxle (096) Left Axle ......................................... 17.6 (447.4) Right Axle ........................................ 26.8 (681.5) Automatic Transaxle (01M) .................................... (1) Manual Transaxle (02A) Left Axle ......................................... 17.6 (447.4) Right Axle ........................................ 26.8 (681.5) Manual Transaxle (020) Left Axle ......................................... 17.9 (455.5) Right Axle ........................................ 27.1 (691.5) Vibration Dampener Position Beetle ....................................................... (1) Passat Left Axle ........................ (2) 20.47-20.55 (520.0-522.0) Right Axle ....................... (2) 10.35-10.43 (263.0-265.0) All Other Models 1.8L Engine ...................... (2) 21.26-21.34 (540.0-542.0) 1.9L Engine ...................... (2) 20.63-20.71 (524.0-526.0) 2.0L Engine ...................... (2) 21.26-21.34 (540.0-542.0) (1) - Information not available from manufacturer. (2) - Measured from outer surface of joint to outer surface of vibration damper. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Ft. Lbs. (N.m)

Axle Shaft Nut With Tripod-Type Joint ................................. 195 (265) With Bonded Axle Shaft Splines ............. 66 (90) Plus 1/8 Turn With Compressed Hub Splines .................................. (1) Axle Shaft-To-Transaxle Flange Bolt CV-Type Joint ............................................ 33 (45) Tripod-Type Joint Except Passat .......................................... 59 (80) Passat ................................................. 33 (45) Lower Control Arm-To-Ball Joint Bolt Beetle ................................................... 15 (20) Except Beetle ............................................ 26 (35) Transmission Support ....................................... 15 (20) Wheel Lug Nut ............................................. 81 (110) (1) - Tighten to 148 ft. lbs. (200 N.m), then back off one turn. Retighten to 37 ft. lbs. (50 N.m), plus an additional 30 degrees. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ END OF ARTICLE

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1996-2001 Volkswagen Passat B5 (3B) Service & Repair Manual

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