The standard beetle
body is bolted to the floor pan along each side with 9 13mm
(head) bolts and two 17mm at the front.
|
|
Inside the car there
are 4 more 13mm bolts under the backseat and sometime 2 more
17mm just behind these in the corners. I always remove all the
seats first.
|
|
Under each rear
fender near the top shock bolt is another 17mm bolt in a
bracket.
|
|
All this is the same
on a super beetle since they are identical from the windshield
back. On the standard beetle (we will come back to the super
later) there are 2 more 17mm bolts under the gas tank, which
is easily removed.
|
|
Now unfasten the
steering column either at the coupler or at the box.
|
|
Unplug the stop
light switch and remove the line from the brake fluid
reservoir. Now remove the left front hubcap and remove the
clip from the end of the speedo cable and pull it out the rear
of the spindle. Let it hang.
|
|
I always pull the
motor but if you want to leave it with the chassis you can
disconnect the wiring. The cables are OK. You will have to
remove the wires from the starter. You can leave the battery
cable. There may be a couple of easily disconnected heater
vent cables at the rear of the tunnel on the later bugs but
that is about it on the standard. Four guys in pretty good
shape can lift the body off. Here is a way one guy can do it
alone. We have a couple of 8' wide saw horses we set the body
on.
|
|
With the body lose
you can jack up the front of the car from under the chassis
and then set the saw horse under the bumper and bolt it with a
safety chain. (We wiggled one off once so we always use them)
Now let the chassis down and do the same in the rear. Now you
can roll the chassis out from under if you like. (You may need
to remove the gear shifter to clear the sawhorse.) On the
super beetle there are 2 13mm bolts under some plugs in the
bottom of the spare tire well. There is also a plug there
covering a 15mm bolt in the steering damper that needs to be
removed.
|
|
Now look under the
front of the car and you will see a 17mm bolt on each side
just behind the anti sway bar. Just loosen these a little for
now.
|
|
We will let the body
pivot on these as we lift the rear up first. Now unbolt the
tie rod ends on both side and separate them either with a tool
for this or a pickle fork if you are not worried about ruining
the boot.
|
|
Remove the clip that
holds the brake line to the body (you can leave the line
connected). Disconnect the speedo cable. Now jack up the rear
of the car and set it on the horses. Set the rear of the
chassis back and move the jack to the front. Disconnect the
fuel line and stop it up. Unplug the stop light switches and
unplug the brake reservoir lines from the master cylinder. Now
jack up the front of the car and set the body on the sawhorse
and secure the safety chains.
|
|
Now remove the 3
14mm nuts on each side that hold the strut assembly to the
body. Don't remove the nut from the middle of the strut.
|
|
With the jack still
under the chassis remove the two 17mm bolts we loosened
earlier at the front of the chassis. Lower the chassis. You
will notice that the front wheels have folded under and are
now very wobbly. You will have to pull the chassis out from
under the body with it on the jack. Note* I'd suggest that
anyone with a louvered front skirt check for a/c connections
before lifting the body, they're pretty well hidden.
|
|
Once out you can
fabricate 3 pieces of angle iron to support the struts. Run
two back to the front bolt of the shifter and one between the
struts. Another piece bolted to the spindles will keep the
wheels going the same direction so you can easily push the
chassis where you want it.
|
|