Volkswagen New Beetle. Manual - part 2464

The bended end points always from synchronizer body (direction of arrow).

INPUT SHAFT, ADJUSTING 

(Determining input shaft adjustment shim) 

Special tools and equipment 

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VW 387 Universal dial gauge bracket  

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VW 385/17 End measuring plate  

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VW510 Press piece  

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VW 447 i Thrust plate  

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VW 407 Press tool  

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V.A.G 1331 Torque wrench  

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Measuring dial gauge 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 101: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

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Transmission housing  

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Clutch housing  

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Input shaft  

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4th gear wheel 

or the 

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Tapered roller bearings  

Adjustment overview. See Adjustment overview 

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Press tapered roller bearing outer race without shim into transmission housing onto stop, using VW 510. 

Fig. 102: Installing Tapered Roller Bearing Outer Race

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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Install input shaft in clutch housing and assemble transmission housing. Tighten hex head bolts to 25 N.m 
and then turn an additional 90°.  

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Install dial indicator in clutch housing (large tapered roller bearing in transmission housing).  

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

Fig. 103: Installing Dial Indicator In Clutch Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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 Spd. Manual Transmission 02J - New Beetle