Having problems with your 2003 Volkswagen Beetle TDI ?
How do you change an axle, 2003 TDI Beetle - 2003 Volkswagen Beetle TDI
If it is a half-shaft, which I suspect it is, like my 2001 VW passat. Get at least half the car on jack stands, and block tires from moving if you leave the other on the ground. Take off the wheel, first. Then remove the brake caliper from the disk, usually two 14mm bolts. Hang the assembly from struts using bailing wire or wire hanger...make sure brake lines don't get messed up and stay attached. Remove large wheel bolt in center of hub. This one will be tight, about 150lbs. I would spray some PB lube on it and let it set for at least one hour to loosen its grip. Use an impact/and or a breaker bar as big as you can get. Remove brake disk. You will need to remove the steering rod and upper support arms. Putting these back on is a little tough without a tool like pliers that brings the two ends back together using a ratchet. Now you should be able to get to the bolts to remove the shaft with a long extention...I use two extentions and an electric impact wrench. Find the easiest one to access first. After you remove it, place the gear in N and grab the shaft and rotate it so the next bolt will line up in the same place, then put back in P to remove, and repeat untill all are removed. It should just slide out with some coaxing. Try not to bend the ends of the new shaft past 40% or it may do damage. Install is the opposite. A digital camera is always a help when taking apart, so you will have a better idea of how to reinstall. You will probably need some metric torques for the shaft bolts and the big hub bolt needs a big socket allen. A new shaft cost $100. I do not recommend a rebuild, but you can get one for $65.
Repair Help & Product Troubleshooting for 2003 Volkswagen Beetle TDI
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