Volkswagen New Beetle. Manual - part 2477

 

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Volkswagen New Beetle. Manual - part 2477

 

 

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VW512 Press disk3114/2 Straightening tool  

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VW 407 Press tool  

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V.A.G1331 Torque wrench  

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Measuring dial gauge 

Fig. 143: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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1 - Kukko 21/6 Internal extractor  

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4 - Kukko 22/2 Retainer 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 144: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

It is necessary to readjust the output shaft when the following components are replaced: 

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Final drive  

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Clutch housing 

or 

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Tapered roller bearing 

Adjustment overview. See Adjustment overview 

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Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing. See 
Output shaft, disassembling and assembling .  

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Insert output shaft and tighten nuts for bearing support to 25 N.m, then turn 90°.  

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Mount dial gauge (3 mm measuring range) and set to "0" with 1 mm preload. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 145: Mounting Dial Gauge With 1 mm Preload 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

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Move output shaft up and down and note dial gauge reading (example: 0.30 mm).  

Determining thickness of shim 

The specified bearing preload is obtained by adding a constant preload figure of (0.20 mm) to the reading 
obtained (0.30 mm) and the thickness of the shim installed (0.65 mm). 

Example: 

DETERMINING THICKNESS OF SHIM (EXAMPLE) 

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Remove output shaft and pull out small tapered roller bearing outer race. See Output shaft, 
disassembling and assembling
  

The following adjustment shims are available: 

SHIM THICKNESS SPECIFICATION (OUTPUT SHAFT) 

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

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Press in small tapered roller bearing outer race together with correct shim (See Output shaft, 
disassembling and assembling
 ) and install output shaft. Tighten bearing support nuts in clutch housing 

Shim installed

0.65 mm

+ Reading

0.30 mm

+ Preload (constant)

0.20 mm

Thickness of shim

1.15 mm

Size (mm)

Part No.

0.65

020 311 391 P

0.70

020 311 391 Q

0.75

020 311 391

0.80

020 311 391 A

0.85

020 311 391 B

0.90

020 311 391 C

0.95

020 311 391 D

1.00

020 311 391 E

1.05

020 311 391 F

1.10

020 311 391 G

1.15

020 311 391 H

1.20

020 311 391 J

1.25

020 311 391 K

1.30

020 311 391 L

1.35

020 311 391 M

1.40

020 311 391 N

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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