Volkswagen New Beetle. Manual - part 2425

 

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Volkswagen New Beetle. Manual - part 2425

 

 

Fig. 164: Identifying Special Tools And Equipment (1 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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40-105 Thrust plate  

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3005 Press disk  

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3259 Tube  

 

2003 Volkswagen New Beetle GLS 

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

  

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3296 Tube  

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3345 Tube  

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V.A.G 1332 Torque wrench or equivalent 

Fig. 165: Identifying Special Tools And Equipment (2 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

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V.A.G 1582 Tapered roller bearing puller  

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V.A.G 1582/6 Grip  

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1 -Kukko 21/7 Internal puller  

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4 - Kukko 22/2 Counter support 

Fig. 166: Identifying Special Tools And Equipment (3 Of 3)

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

1. Transmission housing  

2. Bolt  

3. Differential cage 

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Bolt to final drive gear  

4. Final drive gear 

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Rivited in production  

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Pressing off. See Pressing off final drive gear  

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Installation position: machined side faces toward bolting surface of differential housing  

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Heat to 100° C before installing  

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Fit to differential housing. See HEATING FINAL DRIVE GEAR TO APPROX. 100° C and 
installing
 .  

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Bolted. See Bolting final drive gear -A- and differential housing -B- together .  

5. Backing plate  

6. Nut, 40 N.m and turn 45 further  

7. Clutch housing  

8. Shim 

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For differential  

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Determining thickness. See DIFFERENTIAL, ADJUSTING  

9. Tapered roller bearing outer race 

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Pulling out. See Pulling tapered roller bearing outer race out of transmission housing .  

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Pressing in. See Pressing tapered roller bearing outer race into transmission housing .  

10. Tapered roller bearing inner race 

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Pulling off. See Pulling off tapered roller bearing inner race .  

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Pressing on Pressing on tapered roller bearing inner race .  

11. Differential housing 

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With riveted final drive gear  

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When replacing final drive gear drill out rivet heads. See Drilling out rivet heads  

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Attaching final drive gear with bolts. See Bolting final drive gear -A- and differential housing -
B- together
 .  

NOTE:

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Heat tapered roller bearing inner race to 100°C before installing.  

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Always replace both tapered roller bearings together as a set.  

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If tapered roller bearings, differential housing, transmission housing or 
clutch housing are replaced, adjust differential. See DIFFERENTIAL, 
ADJUSTING  

NOTE:

The following list refers to items in Fig. 167 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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