Volkswagen Passat B4 - Rear axle - Front Wheel Drive Vehicles, servicing Page 1 / 22

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 Page 2 / 22

„ 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, re-

work cap nut in longmember
Rear axle - Front Wheel Drive Vehicles, servicing Page 3 / 22

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 42-1,
Removing

„ Installing 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 Page 4 / 22

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 Page 5 / 22

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’ 1 .

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 Page 6 / 22

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 Page 7 / 22

- 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 Page 8 / 22

- 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 Page 9 / 22

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 Page 10 / 22

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 Page 11 / 22

- 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 Page 12 / 22

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 Page 13 / 22

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 Page 14 / 22

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 80 Nm
Use new bolts and nuts!
Brake pressure regulator to rear axle 35 Nm

Cap nut in longitudinal member - vehicles with Front

Wheel Drive, reworking
Rear axle - Front Wheel Drive Vehicles, servicing Page 15 / 22

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 Page 16 / 22

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 Page 17 / 22

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 Part no. Quantity

ABS cable channel 535 971 851 B 1
(For vehicles with ABS only) 535 971 852 B 1
Bracket - 1 - 1H0 611 797 C 2
(brake line)
Bracket - 3 - 191 611 797 A 2
(brake line)
Brake line - 4 - (self-prepared) See Electronic parts catalog "ETKA" -
Clip - 6 - 1H0 609 734 D 2
(parking brake cable)

Suspension strut - vehicles with Front Wheel Drive,

disassembling and assembling
Rear axle - Front Wheel Drive Vehicles, servicing Page 18 / 22

„ 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 Page 19 / 22

„ 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 Page 20 / 22

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 Page 21 / 22

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 offset toward axis - A - of shock

absorber eye.
Rear axle - Front Wheel Drive Vehicles, servicing Page 22 / 22

Pressing cap into suspension strut bearing