Volkswagen New Beetle. Manual - part 2484

 

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Volkswagen New Beetle. Manual - part 2484

 

 

Fig. 163: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VW 408 A Press tool  

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VW 473 Thrust piece  

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30-205 Thrust plate  

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3144 Sleeve  

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2007 Thrust pad 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 164: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Transmission housing  

2. Bolt  

3. Differential cage 

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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Adjust differential if tapered roller bearings, differential housing, 
transmission housing or clutch housing are being replaced. See 
DIFFERENTIAL, ADJUSTING .  

NOTE:

The following list refers to items in Fig. 165 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Bolt to final drive gear  

4. Final drive gear wheel 

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Riveted in production  

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Is paired with output shaft, only replace as a set  

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Pressing off. See Pressing off final drive gear  

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Installation position. See Installation position of final drive gear wheel  

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Heat to 100° C before installing  

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Install to differential housing. See Heating final drive gear wheel to approx. 100° C and 
installing
 .  

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Bolted. See Bolting final drive gear and differential housing together  

5. Backing plate  

6. Nut, 70 N.m 7  

7. Shim 

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For differential  

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Determining thickness. See DIFFERENTIAL, ADJUSTING  

8. Tapered roller bearing outer race 

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Pulling out 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  

9. 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  

10. 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 and differential housing 
together
  

11. Speedometer drive wheel 

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Install onto differential housing as far as stop before pressing on inner race  

12. 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  

13. Tapered roller bearing outer race 

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Pressing out. See Pressing tapered roller bearing outer race out of clutch housing  

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

14. Clutch housing  

15. 15-Sleeve 

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Installed together with springs behind flange shafts  

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To accept oil seal (item 16)  

 

2003 Volkswagen New Beetle GLS 

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

  

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Removing and installing. See Pulling sleeve in  

16. Oil seal 

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

17. One piece oil seal and sleeve 

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If seal is damaged, replace oil seal and sleeve together. See FLANGE SHAFT OIL SEALS 
(TRANSMISSION INSTALLED), REPLACING
 .  

18. Cone head bolt, 25 N.m 

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Bolt into threaded piece (item 26)  

19. Flange shaft 

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Removing and installing. See FLANGE SHAFT OIL SEALS (TRANSMISSION 
INSTALLED), REPLACING
  

20. Spring for flange shaft 

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Installed behind flange shafts  

21. Thrust washer 

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Installation position: Shoulder toward spring, tongue to tapered ring  

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Installation position with changed thrust washer. See Changed thrust washer for tapered ring .  

22. Tapered ring 

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With grooves to secure thrust washer  

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Installation position: Taper toward differential housing  

23. Securing clip 

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Holds tapered ring, thrust washer and spring in position when drive flange is removed  

24. One-piece thrust washer 

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Coat with transmission oil when installing  

25. Sun gear 

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Installing. See Installing differential side gears and pinion gears  

26. Threaded piece 

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Installing. See Installing differential side gears and pinion gears  

27. Differential pinion shaft 

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Knock out with drift  

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Installing. See Installing differential side gears and pinion gears  

28. Spring pin 

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For securing planet pinion axis shaft  

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Removing and installing. See Removing and installing differential pinion shaft spring pin  

29. Differential pinion gear 

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Installing. See Installing differential side gears and pinion gears  

30. Differential side gear 

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Installing. See Installing differential side gears and pinion gears

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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