Volkswagen New Beetle. Manual - part 827

 

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Volkswagen New Beetle. Manual - part 827

 

 

Fig. 12: Pushing Engine/Transmission Assembly W/ Pry Bar 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

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

1. Remove any paint residue and corrosion on threads and splines of outer joint. Lubricate splines and 

threads of outer joint. Lubricate splines on hub. Lubricate contact surface and thread of wheel hub 12-
point nut. Insert NEW circlip on splines of inner joint.  

2. Guiding outer joint, into wheel hub splines as far as possible, insert axle shaft. Connect outer joint into 

wheel hub splines as far as possible. Using NEW bolts, connect ball joint to control arm. Tighten to 
specification. See TORQUE SPECIFICATIONS .  

3. Pull outer joint in wheel hub, until outer joint comes in position inside wheel bearing. Insert inner joint to 

axle shaft, and tighten bolts diagonal with 88 INCH lbs. (10 N.m). Tighten multi-point socket head bolts 
diagonally to specification. See TORQUE SPECIFICATIONS .  

4.  

NOTE:

If an angle measuring wrench is not available, go to step 5 . 

 

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 14 

© 2004 Mitchell Repair Information Company, LLC. 

Using an Angle Measuring Wrench (VAG 1756), install wheel hub 12-point nut. See Fig. 13 . Tighten to 
specification. See TORQUE SPECIFICATIONS .  

5. If an angle measuring wrench is not available, lower vehicle until wheels touch ground. Tighten wheel 

hub 12-point nut to 148 ft. lbs. (200 N.m). Loosen one and one-half turns, then tighten to 37 ft. lbs. (50 
N.m). Make a scribe mark on wheel hub 12-point nut (arrow A). See Fig. 14 . Make a second mark 
(arrow B) on edge of wheel hub. Turn wheel hub 12-point nut further until both lines align.  

Fig. 13: Identifying Angle Measuring Wrench (VAG 1756) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

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 15 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 14: Locating Wheel Hub 12-point Nut Marking 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Removal (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 .  

2. Mark installation position of ball joint bolts to control arm. Remove bolts. See Fig. 15 .  

3.  

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 16 

© 2004 Mitchell Repair Information Company, LLC. 

Using wedge (T10161), press axle shaft out from transmission. See Fig. 16 . Remove axle shaft.  

Fig. 15: Locating Ball Joint-To-Control Arm Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: DO NOT allow axle shaft to hang down. Inner joint may be damaged 

through over-flexing. 

NOTE:

Ensure sufficient clearance when removing axle shaft. 

 

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 17 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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