Volkswagen New Beetle. Manual - part 2422

 

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Volkswagen New Beetle. Manual - part 2422

 

 

shim (1.70 mm) and adding a constant for pressing (0.20 mm).

Example: 

DETERMINING SHIM THICKNESS (OUTPUT SHAFT FOR 5TH, 6TH AND REVERSE GEAR, 
EXAMPLE)
 

z

Determine thickness of shim from table. See SHIM TABLE .  

z

Remove transmission housing and pull tapered roller bearing outer race out of housing. 

A. Counter support, e.g. Kukko 22/2  

B. Internal puller 46 to 58 mm, e.g. Kukko 21/7  

Fig. 156: Removing Transmission Housing And Pulling Tapered Roller Bearing Outer Race Out Of 
Housing
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove inserted shim (1.70 mm thick) from clutch housing.  

Shim table 

Inserted shim

1.70 mm

- Measured value

0.27 mm

+ Preloading (constant)

0.20 mm

Shim thickness

1.63 mm

 

2003 Volkswagen New Beetle GLS 

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

  

SHIM SELECTION (OUTPUT SHAFT FOR 5TH, 6TH AND REVERSE GEAR) 

Varying tolerances make it possible to obtain the exact shim thickness required. 

z

Press in tapered roller bearing outer race together with determined shim (in Example 1.65 mm) while 
supporting transmission housing with thrust piece 2050 directly under bearing support.  

Perform check measurement 

z

Determined shim installed. 

{

Install measuring tools. Put washers with a total thickness of 8 mm on bolt -arrow- securing 
installation tool VW 792 to clutch housing. 

Size (mm)

Part No.

1.40

084 409 383 AF

1.45

084 409 383 AG

1.50

084 409 383 AH

1.55

084 409 383 AJ

1.60

084 409 383 AK

1.65

084 409 383 AL

1.70

084 409 383 AM

1.75

084 409 383 AN

1.80

084 409 383 AP

1.85

084 409 383 AQ

1.90

084 409 383 AR

1.95

084 409 383 AS

2.00

084 409 383 AT

2.05

084 409 383 BA

2.10

084 409 383 BB

2.15

084 409 383 BC

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 157: Install Measuring Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

{

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

{

Loosen clutch housing/transmission housing securing bolts diagonally until output shaft moves 
freely in transmission.  

{

If correct shim has been selected, dial gauge will indicate a value of 0.15 mm to 0.25 mm.  

FINAL DRIVE, DIFFERENTIAL 

OIL SEALS FOR FLANGED SHAFTS, REPLACING 

Transmission in vehicle 

Oil seal for left flanged shaft, replacing 

 

2003 Volkswagen New Beetle GLS 

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

  

Special tools and equipment 

z

VW 771 Multipurpose tool  

z

VW 771/37 Puller hooks  

z

3303 Press piece  

z

V.A.G 1331 Torque wrench  

z

V.A.G 1332 Torque wrench 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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