Volkswagen New Beetle. Manual - part 2384

 

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Volkswagen New Beetle. Manual - part 2384

 

 

Fig. 28: Identifying 1 - Kukko 21/2 Internal Puller 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Transmission housing 

z

Clamping in assembly bracket. See Securing transmission housing to assembly bracket with 
bolts
 .  

z

If replaced: adjust input shaft, output shafts and differential. See Adjustment overview .  

2. Oil seal 

z

Always replace  

3. Oil drain plug, 30 N.m 

z

Always replace  

NOTE:

The following list refers to items in Fig. 29 .

 

2003 Volkswagen New Beetle GLS 

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

  

4. Stop sleeves 

z

Driving out. See Driving out stop sleeve  

z

Driving in. See Driving stop sleeve in onto stop  

5. Oil filler plug, 30 N.m 

z

Always replace  

6. Locking pin 

z

Is pressed into gate of selector shaft when adjusting outer selector mechanism. See SELECTOR 
MECHANISM
 .  

z

Driving out. See Driving out locking pin  

z

Driving in. See Driving in locking pin onto stop  

7. Bushing 

z

For selector rods  

z

Replace each time after removing  

z

Pulling out. See Pulling out mounting bushing for selector rod .  

z

Installing. See Driving selector rod mounting bushing in flush .  

8. Needle bearing 

z

Replace each time after removing  

z

Pulling out Pulling reverse shaft needle bearing out of transmission housing .  

z

Pressing in. See Pressing needle bearing into transmission housing .  

9. Shim 

z

For input shaft  

z

Adjustment overview. See Adjustment overview .  

10. Outer race/tapered roller bearing 

z

For input shaft  

z

Removing and installing. See from Input shaft, disassembling and assembling .  

z

If replaced: Adjust input shaft. See Input shaft, adjusting .  

11. Outer race/tapered roller bearing 

z

For 5th, 6th and reverse gear output shaft  

z

Removing and installing. See from Output shaft for 5th, 6th and reverse gear, disassembling 
and assembling
 .  

z

If replaced: adjust 5th, 6th and reverse gear output shaft. See Output shaft for 5th, 6th and 
reverse gear, adjusting
 .  

12. Shim 

z

For 5th, 6th and reverse gear output shaft  

z

Adjustment overview. See Adjustment overview .  

13. Outer race/tapered roller bearing 

z

For 1st-4th gear output shaft  

z

Removing and installing. See Pulling tapered roller bearing outer race out of transmission 

 

2003 Volkswagen New Beetle GLS 

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

  

housing .  

z

If replaced: Adjust 1st-4th gear output shaft. See Output shaft for 1st-4th gears, adjusting .  

14. Shim 

z

For 1st-4th gear output shaft  

z

Adjustment overview. See Adjustment overview .  

15. Outer race/tapered roller bearing 

z

For differential  

z

Removing and installing. See from Differential, disassembling and assembling .  

z

If replaced: adjust differential. See Differential, adjusting .  

16. Shim 

z

For differential  

z

Adjustment overview. See Adjustment overview .  

17. Oil seal 

z

Replace. See OIL SEALS FOR FLANGED SHAFTS, REPLACING .  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 29: Identifying Components Of Transmission Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Securing transmission housing to assembly bracket with bolts 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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