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Could be a CV (constant velocity) joint going bad / gone bad. I would think the service folks would have noticed a split CV boot and tested for a bad CV joint, but you never know. A bad CV joint will produce a clicking / popping on a turn. It may be your tie rod ends. I had the same thing happen to my 1999 Passat and it was the outer tie rod ends. Probably is a cv joint. We just replaced one that went south at 23,000 miles. After you replace it, put the car out to pasture before it sucks you dry. These are common for bad a/c systems, motors and trannys.

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Q: What would cause a popping sound when turning or braking in your 2003 Passat and service people said they can hear it but can't find it and it's not the bushings?
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