Volkswagen New Beetle. Manual - part 2548

 

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Volkswagen New Beetle. Manual - part 2548

 

 

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

  

z

Remove transmission housing and pull tapered roller bearing outer race out from transmission housing. 
See REMOVING .  

z

Insert shims of correct thickness, thickest shim first.  

The following shims are available: 

SHIM THICKNESS AVAILABILITY - DIFFERENTIAL BEARING PRELOAD 

If the size of shim required is larger than those listed in the table, insert two shims totalling the correct figure. 

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

z

Press outer race in again and tighten transmission housing securely. 

+ Preload (constant figure)

0.40 mm

Thickness of shim =

1.10 mm

Size (mm)

Part No.

0.65

02A 409 210

0.70

02A 409 210 A

0.75

02A 409 210 B

0.80

02A 409 210 C

0.85

02A 409 210 D

0.90

02A 409 210 E

0.95

02A 409 210 F

1.00

02A 409 210 G

1.05

02A 409 210 H

1.10

02A 409 210 J

1.15

02A 409 210 K

1.20

02A 409 210 L

1.25

02A 409 210 M

 

2003 Volkswagen New Beetle GLS 

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

  

1998-04 MANUAL TRANSMISSIONS 

Servicing - New Beetle (5-Speed, 02J) 

IDENTIFICATION 

On 02J transmission identification tag is located on transmission, identifying code letters and date of 
manufacture (1), and transmission model (2). See Fig. 1 .  

Fig. 1: Locating Identification Tag 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

LUBRICATION 

 

2003 Volkswagen New Beetle GLS 

1998-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5-Speed, 02J)

  

 

2003 Volkswagen New Beetle GLS 

1998-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5-Speed, 02J)

  

Helpmelearn Repair Manuals 

 

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© 2004 Mitchell Repair Information Company, LLC. 

Helpmelearn Repair Manuals 

 

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© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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