Volkswagen New Beetle. Manual - part 2399

Fig. 78: Pressing Tapered Roller Bearing Outer Race Without Shim Into Transmission Housing 
Onto Stop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install both output shafts and input shaft in clutch housing and assemble transmission housing. Tighten 
hex head bolts to 25 N.m and then turn 45 (1/8 turn) further.  

z

Mount measuring appliance and dial gauge in clutch housing. 

Fig. 79: Mounting Measuring Appliance And Dial Gauge In Clutch Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Before taking any measurements, rotate input shaft to allow bearings to settle. Set dial gauge to "O" with 
1 mm preload. 

z

Pull input shaft in direction of dial gauge.  

z

Read and note clearance indicated on dial gauge. 

NOTE:

This preparation is to be repeated for each subsequent measurement, 
otherwise the gauge will not return to the starting position.

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Fig. 80: Reading Clearance Indicated On Dial Gauge 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Determine thickness of shim from table. See TABLE OF ADJUSTMENT SHIMS .  

z

Remove input shaft and pull tapered roller bearing outer race out of transmission housing. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Fig. 81: Removing Input Shaft And Pulling Tapered Roller Bearing Outer Race Out Of 
Transmission Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

A. Counter support, e.g. Kukko 22/2  

B. Internal puller 46 to 58 mm, e.g. Kukko 21/7  

z

Press tapered roller bearing outer race together with 1.60 shim into transmission housing using VW 510.  

z

Assemble transmission housing and tighten new hex head bolts to 25 N.m and then turn 45 (1/8 turn) 
further.  

Table of adjustment shims 

TABLE OF ADJUSTMENT SHIMS (INPUT SHAFT) 

Measured

Shim

bearing clearance (mm)

Thickness (mm)

Part No.

1.480 ... 1.524

1.45

084 409 383 AG

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Measurement check 

z

Install measuring appliance and dial gauge 

Fig. 82: Installing Measuring Appliance And Dial Gauge

1.525 ... 1.574

1.50

084 409 383 AH

1.575 ... 1.624

1.55

084 409 383 AJ

1.625 ... 1.674

1.60

084 409 383 AK

1.675 ... 1.724

1.65

084 409 383 AL

1.725 ... 1.774

1.70

084 409 383 AM

1.775 ... 1.824

1.75

084 409 383 AN

1.825 ... 1.874

1.80

084 409 383 AP

1.875 ... 1.924

1.85

084 409 383 AQ

1.925 ... 1.974

1.90

084 409 383 AR

1.975 ... 2.024

1.95

084 409 383 AS

2.025 ... 2.074

2.00

084 409 383 AT

2.075 ... 2.124

2.05

084 409 383 BA

2.125 ... 2.174

2.10

084 409 383 BB

2.175 ... 2.224

2.15

084 409 383 BC

2.225 ... 2.274

2.20

084 409 383 BD

2.275 ... 2.324

2.25

084 409 383 BE

2.325 ... 2.374

2.30

084 409 383 BF

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle