Volkswagen New Beetle. Manual - part 2536

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  2534  2535  2536  2537   ..

 

 

Volkswagen New Beetle. Manual - part 2536

 

 

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

  

z

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) 

z

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. 

z

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

  

to 25 N.m an additional 1/4 turn 90°. 

REVERSE SHAFT, DISASSEMBLING AND ASSEMBLING 

Special tools and equipment 

z

VW 454 Press piece  

z

VW 447 H Press plate  

z

VW 411 Press tool  

z

12-551 Centering mandrel  

z

VW 401 Press plate  

z

VW 408 A Press tool 

Fig. 146: Identifying Special Tools And Equipment

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

1. Clutch housing  

2. Needle roller bearing 

z

Pulling out. See Pulling needle roller bearing out of clutch housing  

z

Pressing in. See Pressing needle roller bearing into clutch housing  

3. Reverse gear wheel  

4. Circlip 

z

Always replace  

5. Reverse sliding gear wheel 

z

Before replacing remove circlip  

z

Shoulder faces to reverse gear wheel  

6. Reverse shaft 

z

Removing. See Assembly sequence  

7. Needle roller bearing 

z

Pressing out. See Pressing needle roller bearing out of reverse shaft support  

z

Pressing in. See Pressing needle roller bearing into reverse shaft support  

8. Reverse shaft support 

z

Removing and installing. See Assembly sequence

NOTE:

After disassembling, always replace needle roller bearing in clutch housing and 
reverse shaft support.

NOTE:

The following list refers to items in Fig. 147 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2534  2535  2536  2537   ..