Volkswagen New Beetle. Manual - part 832

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  830  831  832  833   ..

 

 

Volkswagen New Beetle. Manual - part 832

 

 

Fig. 28: Removing Ball Hub 
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 34 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 29: Contacting Positions Of Joint Housing & Hub 
Courtesy of AUDI OF AMERICA, 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 35 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 30: Locating Spring Washer (Inner Joint) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

TRIPLE ROLLER JOINT 

Disassembly, Inspection & Reassembly (AAR 2000) 

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

2. Open clamp on joint and slide back protective boot on joint. Using a screwdriver, lift open cover tabs, and 

pry off cover. See Fig. 31 .  

3. Using a waterproof felt tipped pen, mark installation positions of triple-rotor joint housing (1), triple-rotor 

star (2), and axle shaft (3). See Fig. 32 . Remove "O" ring (arrow) from groove. Remove circlip (4). 
Holding rotor joint, take axle shaft out of vise.  

4.  

Install axle shaft in press. See Fig. 33 . Hold axle shaft, and press triple-rotor star off axle shaft. Remove 
triple-rotor star with roller and place them on a clean surface.  

5. Pull joint off shaft. Pull boot off shaft. Clean shaft and housing thoroughly.  

6. Slide triple-rotor joint boot onto shaft. Slide triple-rotor joint housing onto shaft.  

7.  

CAUTION: Ensure rollers DO NOT slide off triple-rotor star and fall off. 

 

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 36 

© 2004 Mitchell Repair Information Company, LLC. 

Install triple-rotor star onto shaft per markings and press onto stop. Install circlip, and ensure it is seated 
correctly.  

8. Press half of specified quantity of joint grease from repair kit into triple roller joint. See TRIPLE 

ROLLER JOINT (AAR 2000) table under LUBRICATION. Press other half of specified quantity of 
joint grease from repair kit into reverse side of triple roller joint.  

9.  

Install joint boot. Remove axle shaft from vise and re-clamp triple-rotor joint housing in vise. Install 
NEW seal (arrow) into groove. See Fig. 32 .  

10. Install NEW cover, positioning tabs on straight surfaces of joint housing. See Fig. 31 . Holes of cover and 

joint housing must align. Install hose clamp. Ensure crimp in clamp (A) is located between securing 
flanges on joint housing (B). See Fig. 34 . Tighten clamp with pliers V.A.G. (1275)  

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

NOTE:

Bevel on star faces toward shaft. This is used as an assembly aid. 

NOTE:

Ridge in joint boot must seat in joint groove. 

 

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 37 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  830  831  832  833   ..