Volkswagen New Beetle. Manual - part 2465

z

Press input shaft in direction of dial indicator (arrow).  

z

Read and note clearance indicated on dial indicator (example 1.21). 

Fig. 104: Measuring Input Shaft Clearance 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

z

Remove input shaft and press tapered roller bearing outer race out of transmission housing using VW 
447i.  

NOTE:

Dial indicator does not return to original position.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Press tapered roller bearing outer race together with 1.175 shim into transmission housing using VW 510. 

z

Assemble transmission housing and tighten hex head bolts to 25 N.m and then turn an additional 90°.  

Table of adjustment shims 

ADJUSTMENT SHIMS (INPUT SHAFT) 

Measured

Shim

bearing clearance (mm)

Thickness (mm)

Part No.

0.671 ... 0.699

0.650

02A 311 140

0.700 ... 0.724

0.675

02A 311 140 A

0.725 ... 0.749

0.700

02A 311 140 B

0.750 ... 0.774

0.725

02A 311 140 C

0.775 ... 0.799

0.750

02A 311 140 D

0.800 ... 0.824

0.775

02A 311 140 E

0.825 ... 0.849

0.800

02A 311 140 F

0.850 ... 0.874

0.825

02A 311 140 G

0.875 ... 0.899

0.850

02A 311 140 H

0.900 ... 0.924

0.875

02A 311 140 J

0.925 ... 0.949

0.900

02A 311 140 K

0.950 ... 0.974

0.925

02A 311 140 L

0.975 ... 0.999

0.950

02A 311 140 M

1.000 ... 1.024

0.975

02A 311 140 N

1.025 ... 1.049

1.000

02A 311 140 P

1.050 ... 1.074

1.025

02A 311 140 Q

1.075 ... 1.099

1.050

02A 311 140 R

1.100 ... 1.124

1.075

02A 311 140 S

1.125 ... 1.149

1.100

02A 311 140 T

1.150 ... 1.174

1.125

02A 311 140 AA

1.175 ... 1.199

1.150

02A 311 140 AB

1.200 ... 1.224

1.175

02A 311 140 AC

1.225 ... 1.249

1.200

02A 311 140 AD

1.250 ... 1.274

1.225

02A 311 140 AE

1.275 ... 1.229

1.250

02A 311 140 AF

1.300 ... 1.324

1.275

02A 311 140 AG

1.325 ... 1.349

1.300

02A 311 140

1.350 ... 1.374

1.325

02A 311 140

1.375 ... 1.399

1.350

02A 311 140 A
02A 311 140 A

1.400 ... 1.424

1.375

02A 311 140 A

02A 311 140 B

1.425 ... 1.449

1.400

02A 311 140 B

 

2003 Volkswagen New Beetle GLS 

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

  

Measurement, checking 

z

Install measuring appliance and dial gauge 

02A 311 140 B

1.450 ... 1.474

1.425

02A 311 140 B
02A 311 140 C

1.475 ... 1.499

1.450

02A 311 140 C
02A 311 140 C

1.500 ... 1.524

1.475

02A311 140 C

02A311 140 D

1.525 ... 1.549

1.500

02A 311 140 D
02A 311 140 D

1.550 ... 1.574

1.525

02A 311 140 D

02A 311 140 E

1.575 ... 1.599

1.550

02A 311 140 E
02A 311 140 E

1.600 ... 1.624

1.575

02A 311 140 E

02A 311 140 F

1.625 ... 1.649

1.600

02A 311 140 F
02A 311 140 F

1.650 ... 1.674

1.625

02A 311 140 F

02A 311 140 G

1.675 ... 1.699

1.650

02A 311 140 G
02A 311 140 G

1.700 ... 1.724

1.675

02A 311 140 G
02A 311 140 H

1.725 ... 1.749

1.700

02A 311 140 H
02A 311 140 H

1.750 ... 1.774

1.725

02A 311 140 H

02A 311 140 J

1.775 ... 1.791

1.750

02A 311 140 J
02A 311 140 J

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 105: Installing Measuring Appliance And Dial Gauge 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Rotate input shaft so that tapered roller bearings settle.  

z

Press input shaft in direction of arrow. 

Bearing play should be min. 0.01 ... max. 0.09 mm. 

OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING 

Special tools and equipment 

NOTE:

If the bearing clearance cannot be measured, but input shaft play is perceptible 
and the input shaft turns freely, the adjustment is acceptable.

 

2003 Volkswagen New Beetle GLS 

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