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Volkswagen Passat B4 - Rear axle - Front Wheel Drive Vehicles, servicing

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42 - 1

Rear axle - Front Wheel Drive Vehicles, servicing


Note :

Rear axle and wheel bearing are identical for both Basic and Plus suspension. Axle beam must not be welded or straightened.

Wheel bolt, 110 Nm Self-locking hex nut, 70 Nm


Axle beam must be in horizontal position (curb weight condition) when tightening nut.

Rear axle - Front Wheel Drive Vehicles, servicing

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Hex bolt, 25 Nm Suspension strut


Removing and installing 42-1, Removing and installing suspension strut to body to 42-1, Removing and installing suspension strut Disassembling and assembling 42-1, Suspension strut - vehicles with Front Wheel Drive, disassembling and assembling

Wheel bearing

Servicing, vehicles with drum brakes 42-3, Wheel bearing - Front-Wheel Drive Vehicles - drum brakes, servicing Servicing, vehicles with disc brakes 42-3, Wheel bearing - Front Wheel Drive Vehicles - disc brakes, servicing

Self-locking hex nut, 80 Nm


Only use self-locking nut with permanent washer Axle beam must be in horizontal position (curb weight condition) when tightening nut

Hex bolt

Install, starting from vehicle center

Bolt with collar, 70 Nm


If thread is damaged, rework cap nut in longmember

Rear axle - Front Wheel Drive Vehicles, servicing

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42-1, Cap nut in longitudinal member vehicles with Front Wheel Drive, reworking

Mounting bracket with bracket for brake pressure regulator


Installation position 42-1, Bolt mounting bracket to axle beam After installing, check overall toe of rear axle, adjust if necessary Do not loosen when removing rear axle, if possible

Hex collar nut, 35 Nm Bracket for regulator spring Bonded rubber bushing

Interior: Note installation position Topic 42-1 Exterior: Note installation position Topic 42-1 Removing Removing Installing 42-1, 42-1, Installing

Only replace as a pair

Axle beam

Contact surface and threaded holes for stub axle free of paint and dirt

Bracket for parking brake cable

Rear axle - Front Wheel Drive Vehicles, servicing

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Removing and installing suspension strut to body

- Remove and install automatic belt retractor cover

Repair Manual, Body Exterior, Interior, Repair Group 70, . - Remove and install automatic belt retractor

Repair Manual, Body Exterior, Interior, Repair Group 68, . Tightening torque for bolt of automatic belt retractor arrow - : 40 Nm.

Removing and installing suspension strut to body

Remove and install both mounting bolts - arrows - from

Rear axle - Front Wheel Drive Vehicles, servicing

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vehicle interior (direction of view through left rear side window). Tightening torque: 25 Nm

Removing and installing suspension strut

For bolting, suspension strut is also engaged with 4 retaining tabs to body. To remove, turn suspension strut until retaining tabs are above recesses.

Bolt mounting bracket to axle beam

Tilt angle to axle beam 13

30

Bonded rubber bushing, removing and installing

Repair procedure was modified due to the introduction of new special tools.

Rear axle - Front Wheel Drive Vehicles, servicing

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Special tools, testers and auxiliary items required


Bushing Press 3111 Torque Wrench 40-200Nm VAG1332 Engine-/Gearbox Jack VAG1383A with universal transmission support V.A.G 1359/2 Brake Pedal Actuator VAG1869/2 Tensioning Strap T10038 Wheel Hub Support T10149 Hydraulic Press VAS6178 VAS6178 Hollow Piston Cylinder VAS6179 Basic Set For Hydraulic Bearing VAS6180 Assembly tool VAS6295

Removing

- Measure dimension - a - from wheel center to lower edge of wheelhousing using, for example, a tape measure. - Note the measured value. It will be needed for tightening rear axle bolts to mounting bracket. - Insert Brake Pedal Actuator VAG1869/2 .

Rear axle - Front Wheel Drive Vehicles, servicing

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- Raise vehicle to installation height. Note:


Use rust solvent (commercially available) for bushing seat and, if possible, and leave it for a while.

Vehicles with ABS

- Fold up rear seatbench and disconnect harness connectors - 1 - . - Loosen rubber grommets - arrows - from underbody and push wheel speed sensor wire out of interior. Continuation for all vehicles - Remove parking brake cables from brackets.

- Disconnect brake lines - arrow A - and pull brake hose 1 - out of retainer. Vehicles with brake pressure regulator - Remove bolts - arrows B - . Continuation for all vehicles - Place Engine-/Gearbox Jack VAG1383A underneath.

Rear axle - Front Wheel Drive Vehicles, servicing

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- Unbolt mounting bracket bolt - 2 - at rear axle on both sides. - Lower rear axle using Engine-/Gearbox Jack VAG1383A .

- Re-install mounting bolts for rear axle - 1 - in mounting bracket and secure. - Secure rear axle on both sides using Tensioning Strap T10038 - 2 - . Note:

Place Engine-/Gearbox Jack VAG1383A with universal transmission support V.A.G 1359/2 under control arm (danger of accident from components falling out when pulling out bushing).

- Attach pressure plate VAS6295/2 - 1 - at inner bushing and insert pressure pin VAS6295/4 - 3 - into bushings from outside.

Rear axle - Front Wheel Drive Vehicles, servicing

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The cut edges of the pressure plate VAS6295/2 - 1 must point toward the axle and must be securely inserted between bushing and axle - arrows - . - Attach Hydraulic Press VAS6178 VAS6178 with Pressure Plate 3111/5 behind outer bonded rubber bushing The cut edges of the Pressure Plate 3111/5 - 2 - must point toward the axle and must be securely inserted between bushing and axle - arrows - . - Secure Pressure Plate 3111/5 using bolts of pressure plate VAS6295/2 - Press out bonded rubber bushing. 1 - Pressure Plate VAS6295/2 2 - Pressure Plate 3111/5 3 - Pressure pin VAS6295/4 4 - Pressure pin VAS 6180/4 long 5 - Pull rods VAS6295/3 6 - Cylinder mount VAS6295/1 7 - Hydraulic Press VAS6178 VAS6178 - Attach Hydraulic Press VAS6178 VAS6178 with Pressure Plate 3111/5 and press out bonded rubber bushing

The cut edges of the Pressure Plate 3111/5 - 1 - must point toward the axle and must be securely inserted between bushing and axle - arrows - .

Rear axle - Front Wheel Drive Vehicles, servicing

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1 - Pressure Plate 3111/5 2 - Pressure pin VAS6295/4 3 - Pressure disc VAS6295/6 4 - Pressure pin VAS6180/4 long 5 - Pull rods VAS6295/3 6 - Cylinder mount VAS6295/1 7 - Hydraulic Press VAS6178 VAS6178
Installing

Installation position of inner bonded rubber bushing

Protruding lip - arrow - points in direction of travel.

- Preassemble bonded rubber bushing with the special tools to facilitate centering in rear axle. 1 - Pressure disc VAS6295/6 2 - Bonded rubber bushing 3 - Adaptor 3111/9 4 - Pressure pin VAS6295/4

Rear axle - Front Wheel Drive Vehicles, servicing

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- Now, attach bonded rubber bushing - 1 - with Adaptor 3111/9 - 2 - and Pressure pin VAS6295/4 - 3 - to rear axle. - Attach Hydraulic Press VAS6178 VAS6178 with Pressure Plate 3111/5 and press in bonded rubber bushing.

The cut edges of the Pressure Plate 3111/5 - 1 - must point toward the axle and the eye for the bonded rubber bushing must be free - arrows - . 1 - Pressure Plate 3111/5 2 - Bonded rubber bushing 3 - Adaptor 3111/9 4 - Pressure pin VAS6295/4 5 - Pressure pin VAS6180/6 6 - Pull rods VAS6295/3 7 - Cylinder mount VAS6295/1

Rear axle - Front Wheel Drive Vehicles, servicing

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8 - Hydraulic Press VAS6178 VAS6178 Installation position of outer bonded rubber bushing

Protruding lip - arrow - points in opposite to direction of travel.

- Now, attach bonded rubber bushing - 1 - with Adaptor 3111/9 - 2 - and Pressure pin VAS6295/4 - 3 - to rear axle. Note:

Make sure that Pressure pin VAS6295/4 engages in the already pressed in bonded rubber bushing, thus centering the bonded rubber bushing to be pressed in.

- Attach Hydraulic Press VAS6178 VAS6178 with Pressure Plate 3111/5 and press in bonded rubber bushing.

Rear axle - Front Wheel Drive Vehicles, servicing

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The cut edges of the Pressure Plate 3111/5 - 1 - must point toward the axle and must be securely inserted between inner bushing and axle - arrows - . 1 - Pressure Plate 3111/5 2 - Bonded rubber bushing 3 - Adaptor 3111/9 4 - Pressure pin VAS6295/4 5 - Pull rods VAS6295/3 6 - Pressure pin VAS6180/6 7 - Cylinder mount VAS6295/1 8 - Hydraulic Press VAS6178 VAS6178 - Raise rear axle using Engine-/Gearbox Jack VAG1383A , remove Tensioning Strap T10038 and mounting bolts. - Insert rear axle into mounting brackets and secure using mounting bolts and new nuts. - Re-install mounting bolts for rear axle in mounting bracket and secure. Secure vehicle to lifting platform Caution! If the vehicle is not secured, there is danger that the vehicle could slip off the lift!

Rear axle - Front Wheel Drive Vehicles, servicing

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Bolting mounting bracket at rear axle must only occur after dimension - a - measured before installation between the wheel hub center and the lower edge of wheelhousing has been attained! Otherwise, the rubber bushing will be stressed resulting in a shortened service life. - Turn wheel hub far enough until one of the holes for wheel bolts is on top. - Install Wheel Hub Support T10149 with wheel bolt. - Using engine/transmission jack, lift wheel bearing housing until dimension - a - has been reached. Warning!

Do not lift or lower vehicle with engine/transmission jack below vehicle. Do not leave engine/transmission jack below vehicle any longer than necessary.

- Tighten threaded connection of mounting bracket to rear axle to tightening torque. Rest of installation is the reverse of removal. - Bleed brake system 47-6, Brake system - vehicles with and without ABS, ABS/EDL, bleeding . Tightening torque Mounting bracket to rear axle Use new bolts and nuts! Brake pressure regulator to rear axle
Cap nut in longitudinal member - vehicles with Front Wheel Drive, reworking

80 Nm 35 Nm

Rear axle - Front Wheel Drive Vehicles, servicing

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If cap nut thread is damaged in longitudinal member, either thread must be cut or cap nut must be drilled through. When drilling, proceed as follows: - Remove rear axle. - Drill upward through damaged cap nut in longitudinal member using drill 10.2 mm . Note:

Do not cant drill when drilling.

Warning! Use safety goggles. - Cut new thread M12 x 1.5 in cap nut. - For mounting of rear axle, use new bolt N10 127 4 (M12 x 1.5 x 30) and washer N 11 531 7. Tightening torque: 70 Nm Note:

The procedure described here, must only be performed on one cap nut per vehicle side.

Modified welded studs for mounting brake lines and parking brake cables

The welded T-pins at the rear axle were replaced by threaded welded studs. The clips of the brake lines and parking brake cables were also modified. After current supplies of rear axles are exhausted, only rear axles with threaded welded studs are available as a replacement part.
Rear axle for vehicles up to July 1994

Rear axle - Front Wheel Drive Vehicles, servicing

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Characteristics: 1 - T-pins for bracket of brake line and ABS cable channel 2 - Grooved pin for clip of parking brake cable 3 - Clip for parking brake cables with protective sleeve 4 - Parking brake cable with protective sleeve Dimension - A - : 15 mm
Rear axle for vehicles as of August 1994

Characteristics: 1 - Bracket for brake line

Rear axle - Front Wheel Drive Vehicles, servicing

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2 - Threaded welded stud for bracket of brake line and clip for parking brake cable 3 - Bracket for brake line and ABS cable channel Dimension - A - : 12 mm 4 - Brake line (as a replacement part by the meter) - Make sure that brake lines make no contact with longitudinal member of body and rear muffler when rear axle is at maximum spring loading. 5 - Parking brake cable without protective sleeve If this rear axle is installed in a vehicle manufactured up to July 1994, the replacement parts listed in the table must also be used. Replacement parts required: Nomenclature ABS cable channel (For vehicles with ABS only) Bracket - 1 (brake line) Bracket - 3 (brake line) Brake line - 4 - (self-prepared) Clip - 6 (parking brake cable) 535 971 851 B 535 971 852 B 1H0 611 797 C 191 611 797 A See Electronic parts catalog "ETKA" Part no. Quantity 1 1 2 2 2

1H0 609 734 D

Suspension strut - vehicles with Front Wheel Drive, disassembling and assembling

Rear axle - Front Wheel Drive Vehicles, servicing

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Concealment cap

Pry out using screwdriver press in 42-1, Pressing cap into suspension strut bearing

O-ring Self-locking hex nut, 25 Nm Belleville washer Upper rubber bushing Seal (foam)

Replace

Suspension strut bearing

Rear axle - Front Wheel Drive Vehicles, servicing

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Always replace foam seat Welded nuts must lie in grooves of spring seat Align welded nuts and cap toward center of shock absorber 42-1, Align suspension strut bearing toward shock absorber center

Spacer tube Lower rubber bushing Cap (metal)


For Wagon higher than for Sedan

Washer Spring seat


For Wagon thinner than for Sedan Installation position 42-1, Installation position of spring seat

Buffer stop

For Wagon shorter than for Sedan

Protective tube

For Wagon longer than for Sedan

Cap (plastic) Coil spring


Removing and installing 42-1, Spring, removing and installing Allocation Electronic parts

Rear axle - Front Wheel Drive Vehicles, servicing

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catalog "ETKA"

For Wagon with upper protective hose

Base plate Securing ring Lower spring plate Shock absorbers


individually replaceable Removing and installing 42-1, Removing and installing suspension strut to body Disposal Special information, suspension No 2 Check shock absorber for leaks and noises Special information, suspension No. 17 Allocation Electronic parts catalog "ETKA"

Spring, removing and installing

Rear axle - Front Wheel Drive Vehicles, servicing

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Note:

Instead of V.A.G 1403 , Spring Compressor VAG1752/1 can also be used.

Installation position of spring seat

Align suspension strut bearing toward shock absorber center

A - Axis of shock absorber eye B - Axis of suspension strut bearing a - 50 Axis - C - of cap 90 absorber eye. offset toward axis - A - of shock

Rear axle - Front Wheel Drive Vehicles, servicing

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Pressing cap into suspension strut bearing