Volkswagen New Beetle. Manual - part 2123

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  2121  2122  2123  2124   ..

 

 

Volkswagen New Beetle. Manual - part 2123

 

 

Tightening bearing bracket is only possible, when the measured value (a) from the middle of wheel hub to 
lower edge bordering wheel housing is reached. See Fig. 10 . Otherwise the bonded rubber bushing will 
be distorted, resulting in reduced service life. Turn the wheel hub until one of the holes for the wheel 
bolts is at the 12 o'clock position. Install the support T10149 with a wheel bolt. Lift the wheel bearing 
housing using the engine and transmission jack until dimension a is reached.  

8. Tighten bolts from bearing bracket to rear axle with tightening torque. See TORQUE 

SPECIFICATIONS .  

9. Further installation is in reverse order. Bleed brake system. For Golf, GTI and Jetta, see DISC article in 

BRAKES. For New Beetle, see DISC article in BRAKES.  

Removal (Beetle) 

1. Measure dimension a from the center of the wheel to the lower edge of the wheel housing. See Fig. 3 . 

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 that secures axle beam to body should not be removed to remove the 
rear axle!  

3. Raise and support vehicle.  

4. On vehicles without ABS, remove bolts fastening brake pressure regulator. See Fig. 8 .  

5. On all models, disconnect brake lines (arrow A) and remove clip. See Fig. 11 . Pull left brake hose out of 

retainer (2). Pull right brake hose out of rear axle beam. Pull parking brake cables out of retainers (arrow 
B). Place transmission jack V.A.G 1383 A in position. Remove bolts (1) on rear axle bearing bracket on 
both sides.  

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

7. 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). 

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

z

1 - VAS6179  

z

2 - VAS6180/1  

z

3 - VAS6180/4 long  

z

4 - VAS6180/3  

z

5 - 3416/2 Press Piece  

z

6 - VAS6180/2  

z

7 - V.A.G1383A with V.A.G1359/2  

vehicle longer than necessary. 

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 21 

© 2004 Mitchell Repair Information Company, LLC. 

Installation (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.  

2. Install bonded rubber bushing using special tools on rear axle. See Fig. 15 . 

z

1 - VAS6179  

z

2 - VAS6180/1  

z

3 - VAS6180/6  

z

4 - VAS6180/7  

z

5 - Bonded rubber bushing  

z

6 - VAS6180/8  

z

7 - V.A.G1383A with V.A.G1359/2  

3. BEFORE installing bonded rubber bushing, make sure that the mark (arrow A) align with the edge (arrow 

B) of trailing arm. See Fig. 16 .  

4. Press in bonded rubber bushing until a gap of 0.008 in. (0.2 mm) is available. See Fig. 17 . Measure this 

gap (arrow) with a measure gauge (A). Check position of bonded rubber bushing after installing.  

5.  

Tighten vehicle to the lifting platform. Remove the plugs from the trailing arm (3). See Fig. 4 . Tighten 
the tensioning strap (1). Support arm of lifting platform (2). Tightening strap T10038. The vehicle must 
be tightened with the tensioning straps on left and right side.  

6. Grease bonded rubber bushing kidney shaped cavity with assembly paste G052150A2 before installing 

rear axle. If the rear axle is not "lubricated" when installed, it will be noisy while driving.  

7.  

Tightening bearing bracket is only possible, when the measured value (a) from the middle of wheel hub to 
lower edge bordering wheel housing is reached. See Fig. 10 . Otherwise the bonded rubber bushing will 
be distorted, resulting in reduced service life. Turn the wheel hub until one of the holes for the wheel 
bolts is at the 12 o'clock position. Install the support T10149 with a wheel bolt. Lift the wheel bearing 
housing using the engine and transmission jack until dimension a is reached.  

8. Tighten bolts from bearing bracket to rear axle with tightening torque. See TORQUE 

SPECIFICATIONS .  

9. Further installation is in reverse order. Bleed brake system. For Golf, GTI and Jetta, see DISC article in 

BRAKES. For New Beetle, see DISC article in BRAKES. 

NOTE:

The note "Top" on the device VAS6180/8 points to the control arm. 

CAUTION: If the vehicle is not secured, there is a risk that it may slip off the 

hoist. 

CAUTION: Do not raise or lower vehicle while engine and transmission jack is 

under vehicle. Do not leave engine and transmission lift under the 
vehicle longer than necessary. 

 

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 22 

© 2004 Mitchell Repair Information Company, LLC. 

BONDED RUBBER BUSHING (HYDRAULIC) 

Removal 

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

Fig. 3 . 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 which supports axle beam to body 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).  

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 .  

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.  

To press out center of hydraulic bonded rubber bushing, install special tools on rear axle. See Fig. 18 . 
Pull a plastic bag over the special tools and control arm to pick up the escaping oil when pressing out the 
center of bonded rubber bushing. Press out the center of bonded rubber bushing using special tools. 

z

1 - VAS6178  

NOTE:

After removing the hydraulic bonded rubber bushings, only "conventional" 
bonded rubber bushings must be installed. The hydraulic bonded rubber 
bushings must be replaced on both sides of rear axle. A mixed installation is 
not allowed. 

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. 

NOTE:

The 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 23 

© 2004 Mitchell Repair Information Company, LLC. 

z

2 - VAS6180/1  

z

3 - VAS6180/4 long  

z

4 - VAS6180/3  

z

5 - VAS6180/2  

z

6 - V.A.G1383A with V.A.G1359/2  

Fig. 18: Pressing Out Center Of Hydraulic Bonded Rubber Bushing 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

10.  

Pressing out sleeve of hydraulic bonded rubber bushing using special tools. See Fig. 19 . 

z

1 - VAS6179  

z

2 - VAS6180/1  

NOTE:

The note "Top" on the device VAS6180/8 points 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 24 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  2121  2122  2123  2124   ..