Volkswagen New Beetle. Manual - part 2421

Fig. 152: Identifying Special Tools And Workshop (2 Of 2)
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

It is necessary to readjust the output shaft when the following components are replaced: 

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Transmission housing  

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Clutch housing  

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Output shaft for 5th, 6th and reverse gears 

or 

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Tapered roller bearing 

Adjustment overview. See Adjustment overview . 

Requirements 

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Sealing surfaces of clutch and transmission housings must be free of sealant.  

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When taking measurements, install only the shaft to be measured.  

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Press tapered roller bearing outer race with a 1.70 mm thick shim into transmission housing, supporting 
housing directly under bearing support with thrust piece 2050. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 153: Pressing Tapered Roller Bearing Outer Race With Shim Into Transmission Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set complete 5th, 6th and reverse gear output shaft in clutch housing.  

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Fit transmission housing and tighten bolts -A- and -B- diagonally to correct torque. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 154: Fitting Transmission Housing And Tightening Bolts -A- And -B- Diagonally To Correct 
Torque 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install measuring tools. Put washers with a total thickness of 8 mm on bolt -arrow- securing installation 
tool VW 792 to clutch housing. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 155: Installing Measuring Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set dial gauge (3 mm measuring range) to zero with 1 mm preload.  

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Loosen clutch housing/transmission housing securing bolts diagonally until output shaft moves freely in 
transmission housing.  

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Read play on gauge and note reading (Example: 0.27 mm)  

Determining thickness of shim 

The specified bearing pretension will be attained by subtracting the measured value (0.27 mm) from the inserted 

NOTE:

If dial gauge indicates no value when clutch housing/transmission housing 
securing bolts are loosened, install shim 1.95 mm (Part No. 084 409 383 AS) or, 
if necessary, shim 2.20 mm (Part No. 084 409 383 BD).

 

2003 Volkswagen New Beetle GLS 

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