Volkswagen New Beetle. Manual - part 2410

 

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Volkswagen New Beetle. Manual - part 2410

 

 

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2050 Thrust piece  

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3235 Press  

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V.A.G 1331 Torque wrench  

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1 -Kukko 21/7 Internal puller  

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4 - Kukko 22/2 Counter support 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 117: Identifying Special tools and equipment (2 Of 2)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

General information 

It is necessary to readjust the output shaft when the following components are replaced: 

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Transmission housing  

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Clutch housing  

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Output shaft for 1st-4th gear 

or 

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Tapered roller bearing  

Adjustment overview. See Adjustment overview . 

Requirements 

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Sealing surfaces of clutch and transmission housings must be free of sealant.  

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When taking measurements, install only the shaft to be measured.  

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Press tapered roller bearing outer race with a 1.70 mm thick shim into transmission housing, supporting 
transmission housing directly under bearing support with thrust piece 2050. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 118: Pressing Tapered Roller Bearing Outer Race With Shim 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set complete 1st-4th gear output shaft in clutch housing.  

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Fit transmission housing and tighten bolts -A- and -B- diagonally to correct torque.  

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Fit measuring tools and secure with bolt (arrow) to clutch housing. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 119: Fitting Measuring Tools And Securing With Bolt To Clutch Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Set dial gauge (3 mm measuring range) to zero with 1 mm preload.  

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Loosen clutch housing/transmission housing securing bolts diagonally until bolts release transmission 
housing or output shaft.  

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Read play on gauge and note reading (example: 0.14 mm)  

Determining thickness of shim 

The specified bearing pretension will be attained by subtracting the measured value (0.14 mm) from the inserted 

NOTE:

If the dial gauge indicates no value when the clutch housing/transmission 
housing securing bolts are loosened, install shim 1.95 mm (Part No. 084 409 383 
AS) or, if necessary, shim 2.20 mm (Part No. 084 409 383 BD).

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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