Volkswagen New Beetle. Manual - part 2429

 

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Volkswagen New Beetle. Manual - part 2429

 

 

Fig. 177: Bolting Final Drive Gear -A- And Differential Housing -B- Together 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Use special bolts -1- with backing plates -2- and nuts -3- according to parts catalog. 

Removing and installing differential bevel gear shaft spring pin 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 178: Removing And Installing Differential Bevel Gear Shaft Spring Pin 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Cover tapered roller bearing inner race to avoid possible damage and ingress of metal particles.  

z

Knock out spring pin with chisel, inserting chisel into circumferential groove.  

Installing 

z

Knock fully into differential cage.  

Installing differential bevel gears 

z

Lubricate one piece thrust washer with transmission oil and install.  

z

Install both large differential bevel gears and secure (e.g. with flanged shaft).  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Insert small differential bevel gears (180° apart) and pivot into position. See Fig. 179 .  

z

Push differential bevel gear shaft (arrow -A-) in until first small bevel gear.  

z

Position threaded pieces (arrow -B-) in large bevel gears. 

Installation position: shoulder to bevel gear 

z

Drive differential bevel gear shaft into final position and secure with spring pin.  

Fig. 179: Installing Differential Bevel Gears 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ADJUSTMENT OVERVIEW 

NOTE:

If transmission repairs have been performed, it is only necessary to adjust the 
input shaft, output shaft for 1st-4th gear, output shaft 5th, 6th and reverse gear 
or differential if components have been replaced which have a direct effect on 

 

2003 Volkswagen New Beetle GLS 

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

  

ADJUSTMENT OVERVIEW 

DIFFERENTIAL, ADJUSTING 

Special tools and equipment 

z

VW 353 Transmission support  

z

VW 385/17 End measuring plate  

the adjustment of the transmission. Refer to ADJUSTMENT OVERVIEW table to 
avoid unnecessary adjustment.

 

To be adjusted:

 

Input shaft 

See Input 

shaft, 

adjusting

Output shaft 

1st-4th gear 

See Output 

shaft for 1st-4th 

gears, adjusting

Output shaft 

5th, 6th and 

reverse gear 

See Output shaft 

for 5th, 6th and 

reverse gear, 

adjusting

Differential

See 

DIFFERENTIAL, 

ADJUSTING

Replaced 
part:

Transmission 

housing part:

X

X

X

X

Clutch housing

X

X

X

X

Input shaft

X

 

 

 

Output shaft for 

1st-4th gear

 

X

 

 

Output shaft 

5th, 6th and 

reverse gear

 

 

X

 

Differential 

housing

 

 

 

X

Input shaft 

tapered roller 

bearing

X

 

 

 

Output shaft 1st-

4th gear 

tapered roller 

bearing

 

X

 

 

Output shaft 5th, 

6th and reverse 

gear tapered 

roller bearing

 

 

X

 

Differential 

tapered roller 

bearing

 

 

 

X

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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