Where to start-
Control Arms (Twice)
Tie Rods.
Wheel Bearings.
Fuel Sending unit.
Mass Air Flow Sensor.
Sway Bar.
Door Locks.
Valve Cover gasket.
This is the worst car I have ever owned. And I owned a Ford Escort once. My 1989 Chevy Blazer with 168,000 when I got rid of it was more reliable than this waste of sheet metal.
Stay away from VW's. They have no interest in standing behind their cars. As soon as mine gets out of the dealership for the 3rd time this year, I'm selling it.
Please contact NHTSA about the fuel sending unit you had to replace. Plug in NHTSA in Google for their number and they'll send you a form.
VW has a recall on certain models (2000 Passat & 98-01 Audi) for the fuel sending unit, but not your car or mine. They used the exact same part (fuel sending unit) but are selective in their recall. I filed a complaint with NHTSA because my sending unit failed twice and VW states this is normal. The more claims with NHTSA the better chance of a mass recall. Let's hold VW accountable.
I have a 1998 Passat GLS with 71000 miles and have been having problems with the tie rods and control arms. The car now makes a really bad knocking noise and "spring" sound. When I took it to the VW dealership.. they suggested it was the tie rods. I had the tie rods replaced and the noise is now worse. I love the car, but could seriously deal without the problems.
I have owned my passat for 16 months it has cost me £700 in repairs S/H ECU, AIRFLOW METER, door handle cable came adrift, water leaks from w/wiper mtg.bolt.drivers E/Wswitch, press down it goes up, sunroof closes when it wants to, battery packed in (OK they do do) but with all the other things it gets a bit to much. Front oil seal on camshaft is now leaking ah well that's passat ownership. what a heap think I a will buy a montego or something that rover has made. At least we know will have problems and be prepapared for them.
Bought a '98 GLS used in 2001, and in the past 2 yrs have fixed:
Fuel pump
3 of 4 control arms
tie rods
water pump
timing belt
4 tires w/less than 30k miles
all 4 rotors
battery
driver's door window mechanism.
Still having problems with sunroof opening and closing at will (currently stuck open), driver's side lock control not working, blown speakers in back, passenger rear window closing and opening randomly, factory installed CD changer rejecting factory burned CD's... Car has been a maintenance nightmare, at only 75K. Dealers in area less than cooperative, and mechanic I now take this car to has voiced similar complaints about price of VW parts. Bought a German sedan after good years with an '88 BMW. Thought we were saving $ by switching to VW, but has cost us much more than we ever paid for fixing the 14 yr old 325i.