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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B5 (from 1996 to 2004, the year of issue)

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Volkswagen Passat B5
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Damper strut
Removing and installing drive shaft
Quantity of greasing G 000 603 for external hinges of power shafts
Grease an internal three-humeral hinge
Filling SHRUS grease G6
Replacement of the internal hinge of equal angular speeds
Replacement of the external hinge of equal angular speeds
Dismantling of the external hinge of equal angular speeds
Malfunctions of power shafts
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Removing and installing drive shaft



The drive shaft joint trehplechim

1 - the external hinge of equal angular speeds,
2 - circlip,
3 - thrust ring,
4 - Aiba,
5 - a collar,
6 - a protective cover,
7 - a collar,
8 - drive shaft
9 - a collar,
10 - a protective cover,
11 - a collar,
12 - cover
13 - a sealing ring of square section,
14 - O-ring,
15 - a lock ring,
16 - Roller,
17 - three-humeral holder rollers
18 - a bolt M10x20 80 Nm
19 - joint housing

A warning

Outer constant velocity joint 1 at failure to be replaced. When mounted on the drive shaft CV joint press-fit plastic hammer to fix its lock ring.

When installing the retaining ring 2 is necessary to use a new lock ring. Before installing SHRUS circlip mounted in a groove of the drive shaft.

The concave side of the disc 4 to be adjacent to the thrust ring.

When installing the clamp 5 is necessary to use a new collar.

In the presence of abrasions and cracks need to use a new protective cover 6.

O-ring square section 13 is supplied with a repair kit.

When assembling do not need to install the O-ring 14.

The chamfer on the slots of the roller 17 should be directed to the drive shaft.


Withdrawal

A warning

In no event it is impossible to lower the car on wheels with the removed one or two drive shafts, as this will damage the wheel bearings. If you want to set the car on wheels and move it to remove the drive shaft instead of the drive shaft, set the outer joint of the drive shaft and tighten the pivot bolt to 50 Nm.


PERFORMANCE ORDER
1. On the car standing on wheels, loosen the bolts of external joints of the drive shaft to the front wheel hub.
2. Lift the front of the car and fix on supports.
3. Remove the front wheels.
4. Remove the bolts external hinges of power shafts to the front wheel hub.
5. Remove the screws (1), (see. Fig. Mounting bracket for mounting the sensor wires ABS (arrow)) securing internal hinges of power shafts to the drive flange transmission. Remove the brake caliper bracket on the wire gauge ABS.
6. Unscrew the nut (1), remove the bolt and pulling it up, remove the upper wishbone (2) of the steering knuckle, see. Fig. Elements of the top fastening of a rotary fist.
A warning

Do not extend the grooves in the knuckle when removing the upper wishbone. It is forbidden to unscrew bolts tie rod to the steering knuckle, as otherwise it will be necessary to adjust the angles of the front wheels (3 and 4). See fig. Elements of the top fastening of a rotary fist.


7. Reject towards the upper part of the knuckle (arrow). See fig. Elements of the top fastening of a rotary fist.
8. Remove the drive shaft.

Setting

PERFORMANCE ORDER
1. Install the drive shaft on the vehicle and connect it to the drive flange gearbox and wheel hub.
A warning

When installing the drive shaft trehplechim hinge pivot or move back. Before installing, using adhesive tape, fix the joint on the drive shaft. Before screwing the flange of the drive shaft, remove masking tape.


2. Screw the mounting bolts of the drive shaft to the hub by tightening the bolts at this stage of the hand.
3. Install the upper wishbones all the way into the steering knuckle and secure with bolt and nut tightening torque of 40 Nm (2). See Fig. Location hole in the socket spring.
4. Screw and torque tighten the bolts (M8, M10) the constant velocity joint of the drive shaft to drive flange of the gearbox. See table tightening moments.
5. Secure the ABS sensor on the brake caliper bracket.
6. Apply a thin coat of grease on the collar of the hub aligning the drive wheels. Install the wheel and secure it with screws. Lower the car and tighten the wheel bolts torque of 120 Nm.
7. Screw and torque tighten the bolts (M14, M16) external hinges of power shafts to the front wheel hub. See table tightening moments.
A warning

Tightening bolts driveshafts to the front hub is made only on the car standing on wheels.



The tightening moments

Bolt M8 40 Nm
Bolt M10 50 Nm
Bolt M14 115 Nm + tighten on 180 ?�
M16 bolt 190 Nm + tighten on 180 ?�




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Quantity of greasing G 000 603 for external hinges of power shafts

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