Volkswagen New Beetle. Manual - part 828

 

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Volkswagen New Beetle. Manual - part 828

 

 

Fig. 16: Locating Wedge (T10161) To Remove Axle Shaft From Transmission 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Installation (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.  

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

of axle shaft in splines of transmission. Ensure axle shaft is secure in transmission.  

4.  

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

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

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Pull control arm downward in direction of arrow (A). See Fig. 17 . Press wheel bearing housing on brake 
caliper inward direction of arrow (B). Ensure axle shaft is secure in joint housing. 

Fig. 17: Positioning Control Arm & Wheel Bearing Housing 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5. Press axle shaft into transmission onto stop. If axle shaft cannot be pressed into transmission by hand, 

lightly tap axle shaft in using rubber hammer. Joint housing is correctly installed when a maximum gap of 
1 mm is between joint housing and transmission. Carefully move joint housing in and out to ensure 
correct placement in transmission.  

6. Using NEW bolts, locate old impression marks, and install ball joint to control arm. Tighten to 

specification. See TORQUE SPECIFICATIONS .  

7.  

CAUTION: Ensure axle shaft is positioned correctly in inner joint to avoid 

damage of rollers from tripod star. 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:13 AM

Page 19 

© 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 .  

8. 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.  

OVERHAUL 

CONSTANT VELOCITY JOINT (OUTER) 

Disassembly, Inspection & Reassembly 

1. Remove axle shaft. See FRONT AXLE SHAFT under REMOVAL & INSTALLATION.  

2. Remove constant velocity boot. Using an aluminum hammer, drive joint off axle shaft with a firm blow.  

3. Using an electric scribe or oil stone, mark position of ball hub in relation to ball cage and housing. Swivel 

ball hub and ball cage in housing. See Fig. 18 . Remove ball bearings one at a time.  

4. Turn cage until two rectangular openings (arrow) are aligned with joint housing. See Fig. 19 . Lift out 

cage together with hub.  

5. Swing segment of hub into rectangular opening of cage and tilt out of cage. See Fig. 20 . Clean all 

components thoroughly, ensuring all components are free of grease and dirt.  

6. Press specified amount of grease into joint body. See CONSTANT VELOCITY JOINT 

LUBRICATION table under LUBRICATION. Install cage with hub in joint housing. Press in balls 
separately from alternate sides, ensuring that original alignment of hub to cage and joint housing is 
restored. Distribute specified amount of grease in constant velocity joint boot.  

7. Install spring washer (1) and thrust washer (2) on axle shaft. See Fig. 21 .  

8.  

Press on joint up to stop. Install NEW circlip.  

9.  

NOTE:

If an angle measuring wrench is not available, go to step 8 . 

NOTE:

The six ball bearings for each joint belong to a tolerance group. Check stub 
axle, hub, cage and ball bearings for small indentations (pitting) and signs of 
seizure. Excessive backlash in joint will be noticed as a knock when changing 
from acceleration to deceleration or vice versa. Replace joint if necessary. 
Polished areas and ball track marks are not reasons for replacing joint. 

NOTE:

Ensure bevel on inner diameter of ball hub (splines) faces contact 
shoulder of axle shaft. 

NOTE:

DO NOT damage the paint (scratch or score paint surface) by using a 
sharp tool. 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:13 AM

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© 2004 Mitchell Repair Information Company, LLC. 

On left axle, using paint or adhesive tape, mark 17 mm in place of position (A). Install boot as shown. 
See Fig. 22 . On right axle, ensure vent chamber is seated on tube, and install boot as shown. See Fig. 23 

10.  

On both sides, place a hose clamp on larger diameter of boot. Install V.A.G. (1682) constant velocity 
joint boot clamp tool, so that jaws of pliers seat in corners of clamp (B). See Fig. 24 . Using a torque 
wrench, tighten hose clamp by turning spindle (A). Tighten to specification. See TORQUE 
SPECIFICATIONS 
.  

11.  

Place hose clamp on smaller diameter of boot. Use torque wrench (C) with a range of 5-40 ft. lbs. (5-50 
N.m). See Fig. 25 . Ensure spindle (A) turns freely. Tighten to specification. See TORQUE 
SPECIFICATIONS 
.  

12. Install axle shaft. See FRONT AXLE SHAFT under REMOVAL & INSTALLATION. 

NOTE:

Take care not to bend pliers when tightening hose clamp. 

NOTE:

If necessary, lubricate spindle threads with MOS 2 grease. If spindle does 
not turn freely, clamping force on clamp will not be achieved even though 
correct tightening torque is indicated. 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:01:13 AM

Page 21 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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