Volkswagen New Beetle. Manual - part 2448

 

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Volkswagen New Beetle. Manual - part 2448

 

 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 49: Identifying T10148 Press Piece
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

1. Transmission housing 

z

If replaced: Adjust input shaft and differential. See Adjustment overview  

2. Needle roller bearing 

z

For output shaft  

z

Removing. See Driving out needle roller bearing  

z

Installing and securing. See Driving needle roller bearing in onto stop  

3. Oil filler plug, 30 N.m 

z

Without magnet  

4. Shim 

z

For input shaft  

z

Adjustment overview. See Adjustment overview  

5. Outer race/tapered roller bearing 

z

For output shaft  

z

Removing and installing. See Output shaft, disassembling and assembling  

z

If replaced: Adjust output shaft. See Output shaft, adjusting  

6. Outer race/tapered roller bearing 

z

For input shaft  

z

Removing and installing. See Output shaft, disassembling and assembling  

z

If replaced: Adjust input shaft. See Output shaft, adjusting  

7. Shim 

z

For input shaft  

z

Adjustment overview. See Adjustment overview  

8. Outer race/tapered roller bearing 

z

For input shaft  

z

Removing and installing. See Pressing out tapered roller bearing outer race  

z

If replaced: Adjust input shaft. See Input shaft, adjusting  

9. Needle bearing 

z

Removing and installing. See Pulling needle roller bearing out of clutch housing  

10. Dowel sleeve 

z

(Qty. 2)  

11. Starter bushing 

z

Not installed in all transmissions  

z

Pulling out. See Pulling out starter bushing 

NOTE:

The following list refers to items in Fig. 50 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Driving in. See Driving bushing for starter in flush  

z

Can be replaced without removing transmission  

12. Clutch housing 

z

If replaced: Adjustment overview. See Adjustment overview  

13. Guide sleeve 

z

With input shaft seal and a vulcanized O-ring  

z

Driving-out oil seal. See Driving oil seal out of guide sleeve  

z

Driving-in oil seal. See Drive oil seal into guide sleeve onto stop  

z

Remove guide sleeve to change oil seal  

z

If damaged replace guide sleeve and O-ring together  

14. Socket head bolt, 20 N.m 

z

Self-locking  

z

Always replace  

15. Oil seal 

z

Replacing with installed transmission. See FLANGE SHAFT OIL SEALS (TRANSMISSION 
INSTALLED), REPLACING
  

16. Sleeve 

z

For oil seal (Item 15)  

z

Removing. See Prying sleeve out with a screwdriver  

z

Installing. See Pulling sleeve in  

17. One piece oil seal and sleeve 

z

With damaged oil seal, replace both oil seal and sleeve  

z

Removing. See Pulling out sleeve and oil seal  

z

Installing. See Driving in sleeve and oil seal  

18. Speedometer drive 

z

For aluminum tighten to 30 N.m  

z

For synthetic material tighten to 10 N.m  

19. Oil drain plug, 30 N.m 

z

Without magnet  

20. Outer race/tapered roller bearing 

z

For differential  

z

Pressing in and out. See Differential, disassembling and assembling  

z

If replaced: Adjust differential. See Differential, adjusting  

21. Magnet 

z

Held in place by housing joint surface  

22. Outer race/tapered roller bearing 

z

For differential  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Pressing in and out. See Differential, disassembling and assembling  

z

If replaced: Adjust differential. See Differential, adjusting  

23. Shim 

z

For differential  

z

Adjustment overview. See Adjustment overview  

24. Oil seal 

z

Replacing. See FLANGE SHAFT OIL SEALS (TRANSMISSION INSTALLED), 
REPLACING
  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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