Volkswagen New Beetle. Manual - part 834

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  832  833  834  835   ..

 

 

Volkswagen New Beetle. Manual - part 834

 

 

Hold triple-rotor joint and remove axle shaft from vise. Hold axle shaft and triple-rotor joint housing 
vertical and using other hand slowly slide housing back.  

5. Using felt tipped pen, mark relative positions of rollers (1) and triple-rotor star (2). See Fig. 35 .  

6. Remove rollers (1) and place on clean surface. Install axle shaft in press. Using pliers, remove circlip. See 

Fig. 36 .  

7. Install axle shaft in press. See Fig. 33 . Hold axle shaft, and press triple-rotor star off axle shaft. Pull joint 

together with triple-rotor joint boot off shaft. Clean shaft and housing.  

8. Slide triple-rotor joint boot clamp onto shaft. Slide triple-rotor joint boot onto shaft. Slide triple-rotor 

housing joint onto shaft.  

9.  

Using a press, install triple-rotor star onto shaft stop. Install NEW circlip, ensuring it is seated correctly. 
Install rollers onto triple-rotor star per markings. See Fig. 32 . Slide joint over rollers and hold.  

10. Press specified amount of grease from repair kit, into triple roller joint and reverse side of triple-roller 

joint. See TRIPLE ROLLER JOINT (AAR 2900) table under LUBRICATION. Place seal from repair 
kit into groove of triple roller joint.  

11.  

Install axle shaft in press. Press cover into triple roller joint until circlip can be installed. Insert circlip, 
and ensure it is seated correctly.  

12. Install joint protective cover. Position triple roller joint approximately in middle of sliding part, between 

"min" and "max". Hold triple roller joint in this position and lift boot slightly (arrow) to vent boot. See 
Fig. 37 .  

13.  

Install NEW cover, positioning tabs on straight surfaces of joint housing. See Fig. 31 . Holes of cover and 
joint housing must align. Install hose clip. Ensure crimp in clip (A) is located between securing flanges on 
joint housing (B). See Fig. 34 . Tighten clamp with pliers V.A.G. (1275)  

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

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

CAUTION: Ensure pressure does not exceed 6000 psi when pressing axle onto 

stop. 

NOTE:

Bevel on star faces toward shaft. This is used as an assembly aid.If 
necessary, coat axle shaft splines and star with lubricating paste (G 052 
142 A2). 

NOTE:

Circlip must be heard when it seats. 

NOTE:

Holes of cover and joint housing must align. 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 42 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 35: Identifying Rollers & Triple-Rotor Star 
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 8:01:14 AM

Page 43 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 36: Removing Circlip 
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 8:01:14 AM

Page 44 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 37: Installation Position Of Triple Roller Joint 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Disassembly, Inspection & Reassembly (AAR 3300i) 

1. Open clamp at joint and slide back joint boot. Open clamp on shaft and slide back axle shaft joint boot. 

Pull joint off rollers from tripod star. Using pliers (VX 161 A) or equivalent, remove circlip. See Fig. 36 

2. Insert axle shaft in press. Press out triple roller star off axle shaft. See Fig. 33 . Pull axle shaft protective 

boot from shaft. Clean shaft, joint and groove for oil seal.  

3. Slide small clamp for joint protective boot into shaft. Slide axle shaft protective boot into shaft.  

4.  

CAUTION: Ensure pressure does not exceed 6000 psi when pressing axle onto 

stop. 

NOTE:

Bevel on star faces toward shaft. This is used as an assembly aid. If 
necessary, coat axle shaft splines and star with lubricating paste (G 052 
142 A2). 

 

2003 Volkswagen New Beetle GLS 

1998-04 DRIVE AXLES Axle Shafts - New Beetle

  

Helpmelearn Repair Manuals 

 

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

Page 45 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

Content   ..  832  833  834  835   ..