Volkswagen New Beetle. Manual - part 831

 

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Volkswagen New Beetle. Manual - part 831

 

 

& VW 408A) press joint off axle shaft. See Fig. 26 .  

3.  

Swivel ball hub and ball cage in housing. Press out ball cage in direction of arrow. See Fig. 27 . Press ball 
bearings out of cage.  

4. Tilt ball hub out of ball cage over ball track (arrows). See Fig. 28 . Clean all components thoroughly, 

ensuring all components are free of grease and dirt. Check joint housing, ball hub, ball cage, and ball 
bearings for indentations (pitting) and signs of seizure.  

5.  

Install ball hub over both bevels into ball cage. Press specified amount of grease into joint body. See 
CONSTANT VELOCITY JOINT LUBRICATION table under LUBRICATION. Hub can be installed 
in any position. Press ball bearings into cage.  

6. Install hub together with cage and balls at right angle to joint. Ensure wide spacing (A) on joint housing is 

aligned with narrow spacing (B) on hub after swiveling in. See Fig. 29 .  

7.  

Swivel in ball hub. Press cage firmly until hub swings fully into position. Constant velocity joint is 
correctly assembled when ball hub can be moved by hand backward and forward over its entire axial 
movement range.  

8. Install spring washer (1) on axle shaft. See Fig. 30 .  

9.  

Press on joint up to stop. Install NEW circlip. Press specified amount of grease into constant velocity 
joint boot. See CONSTANT VELOCITY JOINT LUBRICATION table under LUBRICATION.  

10.  

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 

11.  

CAUTION: Ball hub and joint are paired and MUST NOT be interchanged. 

NOTE:

Bevel on inner diameter of ball hub (splines) must face larger diameter of 
joint housing. 

NOTE:

Hub must be swiveled out of cage far enough to allow ball bearings to 
install into ball tracks. 

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. 

NOTE:

Take care not to bend pliers when tightening hose clamp. 

 

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 30 

© 2004 Mitchell Repair Information Company, LLC. 

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 
.  

12.  

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 
.  

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

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 31 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 26: Pressing Off Inner Constant Velocity Joint 
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 8:01:13 AM

Page 32 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 27: Removing Ball Cage 
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 8:01:13 AM

Page 33 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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