Volkswagen New Beetle. Manual - part 2107

 

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Volkswagen New Beetle. Manual - part 2107

 

 

Fig. 20: Locating Center, Left & Right Insulation Tray (New Beetle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

9. On all vehicles, remove axle shaft-to-drive flange bolts. Remove right-side noise insulation. 

 

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 28 

© 2004 Mitchell Repair Information Company, LLC. 

10. Remove lower strut-to-wheel bearing housing bolt and nut. Insert Spreader (3424) into slot. See Fig. 18 . 

See SPECIAL TOOLS . Using ratchet handle turn spreader 90°. Press brake disc in direction of 
suspension strut by hand. Otherwise the shock absorber tube can cant in wheel bearing housing hole. Pull 
wheel bearing housing from shock absorber downward.  

11. Remove wiper arms. Remove plenum chamber cover. Remove hex nut for upper shock absorber 

mounting (1) with ratchet handle and adapters (1 - Ratchet handle, 2 - T10001/8, 3 - T10001/11 and 4 - 
T10001/5). Remove strut from vehicle.  

Installation (New Beetle) 

To install, reverse removal procedure. Ensure that strut-to-wheel bearing housing bolt is installed with point 
installed towards front of vehicle. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS 
Check wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL 
ALIGNMENT.  

SUBFRAME 

Removal (Except New Beetle) 

1. Raise and support vehicle. Remove wheel. 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 shaft-to-drive flange bolts. Pull wheel bearing housing with ball joint outwards from control 
arm. Swing wheel with suspension strut outward and support with a piece of wood placed between strut 
and body.  

3. Remove pendulum support-to-subframe bolts (1) and (2). See Fig. 21 . Remove steering gear bolts (5). 

Remove stabilizer bar link rod nuts (7). On vehicles equipped with 1.9L TDI engines, remove exhaust 
system bolts (6).  

4. Support suspension assembly with transmission jack. Remove subframe bolts (3) and (4). Lower 

subframe and remove from vehicle.  

NOTE:

Do NOT allow axle shaft to hang free. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:51 AM

Page 29 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 21: Locating Subframe Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Installation (Except New Beetle) 

1. Before inserting bolts for subframe, position steering gear on subframe and insert bolts for steering gear. 

The threaded sleeve (1) must seat in subframe hole. See Fig. 22 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:51 AM

Page 30 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 22: Positioning Subframe In Body 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:55:51 AM

Page 31 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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