Volkswagen New Beetle. Manual - part 2489

 

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Volkswagen New Beetle. Manual - part 2489

 

 

INPUT SHAFT, OUTPUT SHAFT AND DIFFERENTIAL - ADJUSTMENT OVERVIEW 

DIFFERENTIAL, ADJUSTING 

Special tools and equipment 

z

VW 387 Universal dial gauge bracket  

z

VW 385/17 End measuring plate  

z

30-205 Thrust plate  

z

VW 407 Press tool  

z

Measuring dial gauge  

NOTE:

If repairs have been carried out to the transmission it is necessary to adjust the 
input shaft, output shaft or differential if components have been replaced which 
have a direct effect on the adjustment of the transmission. Refer to the 
following table to avoid unnecessary adjustment:

 

Input shaft 

See INPUT SHAFT, 

ADJUSTING

Output shaft 

See OUTPUT 

SHAFT, 

ADJUSTING

Differential

See DIFFERENTIAL, 

ADJUSTING

Parts 
replaced:

Transmission 

housing

x

 

x

Clutch housing

x

x

x

Input shaft

x

 

 

Output shaft (final 

drive)

 

x

 

Differential housing

 

 

x

Input shaft tapered 

roller bearing

x

 

 

Output shaft 

tapered roller 

bearing

 

x

 

Differential tapered 

roller bearing

 

 

x

4th gear wheel

x

 

 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 181: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The differential must be adjusted, when 

z

Transmission housing  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Clutch housing  

z

Differential housing 

or the 

z

Differential tapered roller bearing  

have been replaced. 

Adjustment overview. See ADJUSTMENT OVERVIEW . 

z

Press tapered roller outer race into clutch housing using press plate 30-205. See REMOVING . 

z

Press tapered roller outer race into transmission housing, without adjustment shim, using press plate 30-
205. See REMOVING .  

z

Insert differential into clutch housing.  

z

Install transmission housing and tighten 5 bolts to 25 N.m.  

z

Mount dial gauge and "0" with 1 mm preload.  

z

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

NOTE:

Tapered roller bearing inner and outer races are paired. Do not 
interchange!

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 182: Measuring Differential End Play 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Determining shim thickness 

The specified bearing preload is obtained by adding a constant figure (0.40 mm) to the reading obtained. 

Example: 

DETERMINING SHIM THICKNESS - DIFFERENTIAL BEARING PRELOAD 

Reading

0.70 mm

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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