Volkswagen New Beetle. Manual - part 2488

 

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Volkswagen New Beetle. Manual - part 2488

 

 

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Use bolts -A- from repair kit to guide final drive gear into position during installation. 

Bolting final drive gear and differential housing together 

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

Use special bolts with plates and nuts according to parts catalog. 

Removing and installing differential pinion shaft spring pin 

 

2003 Volkswagen New Beetle GLS 

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

  

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

Removing 

z

Cover tapered roller bearing inner race and speedometer drive gear 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 housing.  

Installing differential side gears and pinion gears 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 179: Installing Differential Side Gears And Pinion Gears 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Lubricate one piece thrust washer with transmission oil and install.  

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Install both side gears and secure (e.g. with flange shaft).  

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Insert pinion gears (180° apart) and pivot into position.  

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Push pinion shaft (arrow -A-) in until first pinion gear.  

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Position threaded pieces (arrow -B-) in side gears. Installation position: step faces side gear  

z

Drive pinion shaft into final position and secure with spring pin.  

Changed thrust washer for tapered ring 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 180: Identifying Changed Thrust Washer For Tapered Ring 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installation position: 

When the pads -A- are not present, the shoulder (arrow) points to spring -B-. 

ADJUSTMENT OVERVIEW 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2486  2487  2488  2489   ..