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
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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.
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AXLE SHAFT LENGTH
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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.
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
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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.
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VW VOLKSWAGEN PASSAT 1998-2000 Service Repair Manual
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Description
This VW VOLKSWAGEN PASSAT 1998-2000 Service Repair Manual is a comprehensive guide for maintaining and repairing your Volkswagen Passat during the years 1998-2000.
Whether you are a DIY enthusiast or a professional mechanic, this manual provides detailed instructions and step-by-step diagrams to help you perform various repairs and maintenance tasks on your Passat.
- Covers all Passat models from 1998 to 2000
- Includes detailed instructions for engine repairs
- Provides guidance for electrical system troubleshooting
- Offers step-by-step procedures for transmission repairs
- Explains how to perform routine maintenance tasks such as oil changes, brake pad replacement, and more
- Contains wiring diagrams and specifications for easy reference
With this Service Repair Manual, you can save money on costly repairs by doing them yourself. It is a must-have for any Passat owner or professional mechanic working on these models.
