Volkswagen New Beetle. Manual - part 2060

 

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Volkswagen New Beetle. Manual - part 2060

 

 

Fig. 40: Identifying Features For The Previous Tie Rod Ball Joint (Flats For Wrench On Shaft) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Flats for wrench on the shaft, marked with "R" or "L" 

wrench size 22 mm (.87 in.) 

Dimension -a-; 74-1 mm (2.92 0.04 in.) 

The shaft -arrow- is round 

WARNING:

This tie rod ball joint must not be installed to a tie rod which has a length 
of -a- 318.9 mm (12.56 in.)!

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

TIE RODS, MODIFIED 

The tie rods have been shortened. 

Tie rod dimensions 

z

Previous tie rod; dimension -a- 343.1 mm (13.51 in.)  

z

New tie rod; dimension -a- 318.9 mm (12.56 in.) 

Fig. 41: Identifying Tie Rod Dimension Measuring Points 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

A mixed installation of previous and new tie rods is not allowed!

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

PLAY, SECURITY AND BOOTS ON TIE ROD ENDS, CHECKING

z

With vehicle raised (wheels hanging free), check play by moving tie rods and wheels.  

z

Play: Zero play  

z

Checking mountings.  

z

Check boots are not damaged and are seated correctly.  

CENTER POSITION ON STEERING RACK, DETERMINING 

Steering rack should be positioned in the center before installing power steering gear. 

z

Slide rack until dimension -a- is achieved. 

Dimension -a- = 30.5 mm (1.20 in.) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

Fig. 42: Identifying Slide Rack Dimension
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

STEERING GEAR, ADJUSTING 

z

Raise vehicle on hoist.  

z

Wheels in straight-ahead position.  

z

First technician: turn steering wheel back and forth (approx. 30° from center axis).  

z

Knocking noise will be heard if there is excessive play  

z

The second technician carefully turns the adjustment screw into the cover until the knocking noise can no 
longer be heard inside the vehicle. 

NOTE:

Two technicians are required when adjusting. 

Adjust with engine switched off. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 STEERING Steering - New Beetle

  

 

 

 

 

 

 

 

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