Volkswagen New Beetle. Manual - part 2546

Fig. 175: Identifying Installation Position Of Final Drive Gear Wheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The circular groove -A- faces toward bolt-on side of differential. 

Heating final drive gear wheel to approx. 100° C and installing

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 176: Heating Final Drive Gear Wheel To Approx. 100° C And Installing

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Use bolts -A- from repair kit to guide final drive gear into position during installation. 

Bolting final drive gear and differential housing together 

Fig. 177: Bolting Final Drive Gear And Differential Housing Together 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Use special bolts with plates and nuts according to parts catalog. 

Removing and installing differential pinion shaft spring pin 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 178: Removing And Installing Differential Pinion Shaft Spring Pin 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Cover tapered roller bearing inner race and speedometer drive gear to avoid possible damage and ingress 
of metal particles.  

z

Knock-out spring pin with chisel, inserting chisel into circumferential groove.  

Installing 

z

Knock fully into differential housing.  

Installing differential side gears and pinion gears 

 

2003 Volkswagen New Beetle GLS 

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