Volkswagen New Beetle. Manual - part 2431

 

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Volkswagen New Beetle. Manual - part 2431

 

 

Fig. 183: Mounting Dial Gauge On Differential 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Move differential up and down and recall play indicated on dial gauge (Example: 0.70 mm).  

Determining shim thickness 

The specified bearing preload is obtained by adding a constant figure (0.30 mm) to reading obtained. 

Example: 

DETERMINING SHIM THICKNESS (EXAMPLE) 

Reading 0.70 mm
+ Preload (constant figure) 0.30 mm
Thickness of shim = 1.00 mm

 

2003 Volkswagen New Beetle GLS 

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

  

z

Take off transmission housing.  

z

Pull tapered roller bearing outer race out of transmission housing. 

Fig. 184: Pulling Tapered Roller Bearing Outer Race Out Of Transmission Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

A. Counter support, e.g. Kukko 22/2  

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

z

Insert shims of correct thickness, thickest shim first. 

The following shims are available: 

SHIMS SIZES (DIFFERENTIAL BEARING PRELOAD) 

Size (mm)

Part No.

0.65

02B 409 210

 

2003 Volkswagen New Beetle GLS 

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

  

z

Press outer race in again and tighten transmission housing to torque setting.  

0.70

02B 409 210 A

0.75

02B 409 210 B

0.80

02B 409 210 C

0.85

02B 409 210 D

0.90

02B 409 210 E

0.95

02B 409 210 F

1.00

02B 409 210 G

1.05

02B 409 210 H

1.10

02B 409 210 J

1.15

02B 409 210 K

1.20

02B 409 210 L

1.25

02B 409 210 M

1.30

02B 409 210 N

1.35

02B 409 210 P

1.40

02B 409 210 Q

0.70+0.75 = 1.45

02B 409 210 A/B

0.75+0.75 = 1.50

02B 409 210 B/B

0.75+0.80 = 1.55

02B 409 210 B/C

0.80+0.80 = 1.60

02B 409 210 C/C

0.80+0.85 = 1.65

02B 409 210 C/D

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 TRANSMISSION

5 Spd. Manual Transmission 02J - New Beetle 

GENERAL, TECHNICAL DATA 

TRANSMISSION IDENTIFICATION 

The 5-speed manual transmission 02J is installed in the New Beetle from 1998 in conjunction with 4-cylinder 
engines. 

Application. See CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, CAPACITIES . 

Location on transmission 

Code letters and date of manufacture (arrow 1) manual transmission 02J (arrow 2) 

Fig. 1: Locating Code Letters And Date Of Manufacture 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Manual transmission 02J (arrow -2-) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

 

 

 

 

 

 

 

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