Volkswagen New Beetle. Manual - part 2102

SERVICING 

FRONT SUBFRAME WELDED NUT THREADS 

Servicing work may only be carried out once per thread. If servicing is necessary after this, the nuts must be 
replaced. Observe the operating instructions of the VAS (VW) repair kit.  

Have the thread repair checked by the responsible foreman or next person in charge. Correct any damage to the 
underbody sealant layer. Only use the VAS repair kit listed in the for service work .  

VAS THREAD REPAIR KIT 

REMOVAL & INSTALLATION 

BALL JOINT 

Removal & Installation 

1. Remove hub cap. Loosen 12-point axle nut or bolt. Raise and support vehicle. Remove wheel. On models 

equipped with 1.9L TDI, remove air duct between charge air cooler and turbocharger. On all models, 
remove sound insulation panel. Mark position of ball joint to lower control arm. Remove 3 ball joint-to-
lower control arm bolts.  

2. Remove axle nut. Using Press Tool (3283) or equivalent, press axle shaft out of hub. See Fig. 5 . Ensure 

sufficient clearance is available. Secure axle shaft to body with wire. Axle shaft must not be allowed to 
hang down, or inner joint will be damaged through overflexing. 

NOTE:

Wheel bearing and wheel hub are installed together in a housing. This wheel 
bearing/hub unit is maintenance and adjustment free. Adjusting and servicing is 
not possible. Replace wheel bearing and wheel hub if any damage exists. See 
WHEEL BEARING (WHEEL BEARING HOUSING REMOVED FROM VEHICLE) 
under REMOVAL & INSTALLATION. 

CAUTION: When drilling, it is essential that eye protection be worn! 

Thread 

VAS Part No. 

M10 

6024 

M12x1.5 

6058 

M14x1.5 

6027 

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

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Fig. 5: Pressing Axle Shaft From Hub Assembly 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3. Pull wheel bearing housing with ball joint out from control arm. Swing wheel with suspension strut 

outward and support.  

4.  

Using Ball Joint Puller (3287A) or equivalent, press out ball joint. See Fig. 6 . To protect ball joint 
threads and for safety reasons leave nut on a few turns.  

5. Install ball joint to wheel bearing housing. Using NEW self-locking nut counter-hold ball joint and 

tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse 
remaining removal procedure.  

WARNING:

Place engine/transmission jack VAG 1383/A, or similar, below 
control arm to ensure safety (danger of accident through falling 
parts when pressing out ball joint). 

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

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© 2004 Mitchell Repair Information Company, LLC. 

Fig. 6: Removing Ball Joint 
Courtesy of AUDI OF AMERICA, INC. 

LOWER CONTROL ARM 

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

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© 2004 Mitchell Repair Information Company, LLC. 

Removal 

1. Raise and support vehicle. Remove wheel.  

2. For four wheel drive vehicles, the coupling link for vehicle left front level control system sensor (G78) on 

front axle must be disconnected from the control arm bracket before removing the left control arm. See 
Fig. 7 . 

 

2003 Volkswagen New Beetle GLS 

1999-04 SUSPENSION Front - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:50 AM

Page 11 

© 2004 Mitchell Repair Information Company, LLC.