Volkswagen New Beetle. Manual - part 2121

 

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Volkswagen New Beetle. Manual - part 2121

 

 

BONDED RUBBER BUSHING (NON-HYDRAULIC) 

Removal (Except Beetle) 

1. Measure dimension a from the center of the wheel to the lower edge of the wheel housing. See Fig. 2 . 

Make a note of the measurement. This is necessary to tighten the bolts for the rear axle to the bearing 
bracket.  

2. Install brake pedal loading device V.A.G1869/2 to apply brakes. Actuate the brake pedal with brake pedal 

loading device. The bearing bracket should not be removed to remove the rear axle!  

3. Raise and support vehicle.  

4. Remove wheels. Separate brake lines (arrow A) and remove clip. See Fig. 11 . Remove left brake hose 

from bracket (2). Remove right brake hose from rear axle. Remove parking brake cable from brackets. 
(arrow B). 

NOTE:

Before attempting replacement of bonded rubber bushing read notes 
concerning bushings under DESCRIPTION . 

NOTE:

On vehicles equipped with replaceable bonded rubber bushing, bushing can be 
replaced without removing axle beam. 

 

2003 Volkswagen New Beetle GLS 

1999-2004 SUSPENSION Rear - Golf, GTI, Jetta & New Beetle

  

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Wednesday, December 14, 2005 8:56:44 AM

Page 13 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 11: Locating Brake Lines 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5. Place engine/transmission jack V.A.G1383A under axle beam. Remove bolt (1) for bearing bracket on 

rear axle on both sides. See Fig. 11 . Lower rear axle using engine and transmission jack V.A.G1383A.  

6. Tighten rear axle with tensioning strap T10038 over mounting from muffler system. See Fig. 12 

 

2003 Volkswagen New Beetle GLS 

1999-2004 SUSPENSION Rear - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:56:44 AM

Page 14 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 12: Installing Tensioning Strap On Axle Beam 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

7. On vehicles with automatic headlight range control, removing connecting link from Left Rear Level 

Control System Sensor from rear axle. See Fig. 5 .  

8. On all vehicles, place engine/transmission jack V.A.G1383A with universal transmission support 

V.A.G1359/2 under the control arm (danger of accident from falling parts when pulling out the wheel hub 
and the wheel bearing).  

9. Press out rear axle beam bonded rubber bushing using special tools. See Fig. 13 . 

z

1 - VAS6178  

z

2 - VAS6180/1  

z

3 - VAS6180/4 long  

z

4 - VAS6180/3  

z

5 - Thrust tube 3416/2  

z

6 - VAS6180/2  

 

2003 Volkswagen New Beetle GLS 

1999-2004 SUSPENSION Rear - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:56:44 AM

Page 15 

© 2004 Mitchell Repair Information Company, LLC. 

z

7 - V.A.G1383A with V.A.G1359/2  

Fig. 13: Removing Rear Axle Beam Bonded Rubber Bushing 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Installation (Except Beetle) 

1. Bonded rubber bushing is marked on face with the marks (1). See Fig. 14 . They must align with the edge 

(arrow) on trailing arm (2). Mark position of marks (1) on bonded rubber bushing. 

NOTE:

Edges of separating device VAS6180/2 must come in position between the 
collar of the bonded rubber bushing and the connection of the control 
arm. The note "Top" on the separating device VAS6180/2 must point to the 
control arm. 

 

2003 Volkswagen New Beetle GLS 

1999-2004 SUSPENSION Rear - Golf, GTI, Jetta & New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:56:45 AM

Page 16 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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