Volkswagen New Beetle. Manual - part 825

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  823  824  825  826   ..

 

 

Volkswagen New Beetle. Manual - part 825

 

 

Courtesy of VOLKSWAGEN UNITED STATES, INC. 

09G 6-SPEED AUTOMATIC TRANSMISSION 

To identify transmission, see Fig. 5 and Fig. 6 .  

Fig. 5: Identifying Transmission (1 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 6: Identifying Transmission (2 Of 2) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

LUBRICATION 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:12 AM

Page 6 

© 2004 Mitchell Repair Information Company, LLC. 

CONSTANT VELOCITY JOINT LUBRICATION 

TRIPLE ROLLER JOINT (AAR 2000) 

TRIPLE ROLLER JOINT (AAR 2900) 

TRIPLE ROLLER JOINT (AAR 3300 i) 

Application 

Grease: Total Quantity 

- Oz. (G) 

Amount In Joint - 

Oz. (G) 

Amount In CV Boot - 

Oz. (G) 

Outer Joint 

81 Mm 
Diameter 

2.8 (80) 

1.4 (40) 

1.4 (40) 

90 Mm 
Diameter 

4.2 (120) 

2.8 (80) 

1.4 (40) 

Inner Joint 

94 Mm 
Diameter 

3.2 (90) 

1.4 (40) 

1.8 (50) 

100 Mm 
Diameter 

4.2 (120) 

1.8 (50) 

2.5 (70) 

Application 

Grease: Total Quantity 

- Oz. (G) 

Amount In Joints - 

Oz. (G) 

Amount In CV Boot - 

Oz. (G) 

Outer Joint 

90 Mm 
Diameter 

3.53 (100) 

1.76 (50) 

1.76 (50) 

Inner Joint 

100 Mm 
Diameter 

3.88 (110) 

1.94 (55) 

1.94 (55) 

108 Mm 
Diameter 

3.88 (110) 

1.94 (55) 

1.94 (55) 

Application  Grease: Total Quantity - 

Oz. (G) 

Amount In Joints - 

Oz. (G) 

Amount In CV Boot - 

Oz. (G) 

Outer Joint 

90 Mm 

3.53 (100) 

1.76 (50) 

1.76 (50) 

Inner Joint 

124 Mm 

4.94 (140) 

2.47 (70) 

2.47 (70) 

Application  Grease: Total Quantity - 

Oz. (G) 

Amount In Joints - 

Oz. (G) 

Amount In CV Boot - 

Oz. (G) 

Outer Joint 

98 Mm 

4.23 (120) 

2.82 (80) 

1.41 (40) 

Inner Joint 

123 Mm 

4.59 (130) 

2.47 (70) 

2.12 (60) 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:12 AM

Page 7 

© 2004 Mitchell Repair Information Company, LLC. 

REMOVAL & INSTALLATION 

FRONT AXLE SHAFT 

Removal (All Except AAR 3300i, W/ 09G 6-Speed Auto. Trans.) 

1. Lift vehicle until load on front axle is relieved. Loosen wheel hub 12-point nut. Raise and support 

vehicle. Remove wheels. Remove noise insulation panel. See Fig. 7 

NOTE:

The AAR 3300i axle shaft is used with the 09 G 6-speed automatic transmission. 
To identify this transmission, see 09G 6-SPEED AUTOMATIC TRANSMISSION 
under IDENTIFICATION. 

CAUTION: Wheel bearings must not be loaded when wheel hub 12-point nuts are 

loose. If wheel bearings are loaded by vehicle's own weight, bearings will 
be stressed and their service life reduced. 

CAUTION: If vehicle has to be moved after removing axle shaft, install outer CV joint 

and tighten to 37 ft. lbs. (50 N.m) or else wheel bearing will be damaged. 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:12 AM

Page 8 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 7: Locating Noise Insulation Panel Bolts (1.9L TDI) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

2. On 1.8L (turbo) and 2.0L engines, remove left side noise insulation panel. See Fig. 8 . Remove center, 

left and right insulation panels. See Fig. 9 Remove intake air duct between charge air cooler and 
turbocharger. 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:12 AM

Page 9 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  823  824  825  826   ..