Volkswagen New Beetle. Manual - part 2387

 

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Volkswagen New Beetle. Manual - part 2387

 

 

Fig. 38: Pressing Needle Bearing -A- Into Transmission Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

CLUTCH HOUSING, SERVICING 

Special tools and equipment 

z

VW 407 Press tool  

z

30-21 Sleeve  

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3176 Centering mandrel  

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T40008 Press piece  

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1 - Kukko 21/2 Internal puller  

z

1 - Kukko 21/4 Internal puller  

z

4 - Kukko 22/1 Counter support  

z

4 - Kukko 22/2 Counter support 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 39: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Bushing 

NOTE:

The following list refers to items in Fig. 40 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

For selector rods  

z

Replace each time after removing  

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Pulling out. See Pulling Out Selector Rod Bushing  

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Driving in. See Driving Selector Rod Mounting Bushing In Flush  

2. Reverse gear selector fork axle 

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Axle cannot be removed with workshop tools  

z

Pressing axle into clutch housing. See Pressing Reverse Gear Selector Fork Shaft Into Clutch 
Housing
 .  

3. Needle bearing 

z

Replace each time after removing  

z

Pulling out. See Pulling Needle Bearing Out Of Clutch Housing .  

z

Pressing in. See Pressing Needle Bearing -A- Into Clutch Housing .  

4. Dowel sleeve 

z

Qty. 2  

5. Clutch housing 

z

If replaced: See Adjustment overview. See Adjustment overview .  

6. Input shaft oil seal 

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Removing. See Removing Input Shaft Oil Seal .  

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Installing. See Driving In Input Shaft Oil Seal Flush .  

7. Oil seal 

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Replace. See OIL SEALS FOR FLANGED SHAFTS, REPLACING .  

8. Shim 

z

For differential  

z

Always 0.65 mm thick  

9. Outer race/tapered roller bearing 

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For differential  

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

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If replaced: adjust differential. See Differential, adjusting .  

10. Oil deflector ring 

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Installation position: shoulder on drilling faces output shaft  

11. 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 
housing
  

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

12. Outer race/tapered roller bearing 

z

For 5th, 6th and reverse gear output shaft  

z

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

 

2003 Volkswagen New Beetle GLS 

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

  

assembling .  

z

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

13. Shim 

z

For output shaft  

z

Always 0.65 mm thick  

14. Outer race/tapered roller bearing 

z

For input shaft  

z

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

z

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

15. Magnet 

z

Held in place by housing joint surface  

16. Protective cap  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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