Volkswagen New Beetle. Manual - part 2547

Fig. 179: Installing Differential Side Gears And Pinion Gears 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Lubricate one piece thrust washer with transmission oil and install.  

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Install both side gears and secure (e.g. with flange shaft).  

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Insert pinion gears (180° apart) and pivot into position.  

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Push pinion shaft (arrow -A-) in until first pinion gear.  

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Position threaded pieces (arrow -B-) in side gears. Installation position: step faces side gear  

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Drive pinion shaft into final position and secure with spring pin.  

Changed thrust washer for tapered ring 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 180: Identifying Changed Thrust Washer For Tapered Ring 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installation position: 

When the pads -A- are not present, the shoulder (arrow) points to spring -B-. 

ADJUSTMENT OVERVIEW 

 

2003 Volkswagen New Beetle GLS 

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

  

INPUT SHAFT, OUTPUT SHAFT AND DIFFERENTIAL - ADJUSTMENT OVERVIEW 

DIFFERENTIAL, ADJUSTING 

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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30-205 Thrust plate  

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VW 407 Press tool  

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Measuring dial gauge  

NOTE:

If repairs have been carried out to the transmission it is necessary to adjust the 
input shaft, output shaft or differential if components have been replaced which 
have a direct effect on the adjustment of the transmission. Refer to the 
following table to avoid unnecessary adjustment:

 

Input shaft 

See INPUT SHAFT, 

ADJUSTING

Output shaft 

See OUTPUT 

SHAFT, 

ADJUSTING

Differential

See DIFFERENTIAL, 

ADJUSTING

Parts 
replaced:

Transmission 

housing

x

 

x

Clutch housing

x

x

x

Input shaft

x

 

 

Output shaft (final 

drive)

 

x

 

Differential housing

 

 

x

Input shaft tapered 

roller bearing

x

 

 

Output shaft 

tapered roller 

bearing

 

x

 

Differential tapered 

roller bearing

 

 

x

4th gear wheel

x

 

 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 181: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The differential must be adjusted, when 

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Transmission housing  

 

2003 Volkswagen New Beetle GLS 

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