Volkswagen New Beetle. Manual - part 2569

 

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Volkswagen New Beetle. Manual - part 2569

 

 

Removal & Installation (Left Flange Seal) 

1. Raise and support vehicle. Remove left front wheel. Remove center and left noise insulation trays, under 

engine/transmission, if equipped. Turn steering to left lock. Remove left drive axle shaft from 
transmission flange.  

2. Mark position of lower ball joint bolts (arrows), for installation reference. See Fig. 14 . Remove lower 

ball joint bolts. 

Fig. 14: Locating Ball Joint-To-Control Arm Bolts 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3.  

CAUTION: DO NOT damage paint on drive axle shaft. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:28 AM

Page 16 

© 2004 Mitchell Repair Information Company, LLC. 

Wire axle shafts as high as possible. Remove flange shaft securing bolts by screwing two bolts into 
flange, and counterhold flange shaft using a lever. Place container under vehicle. Remove flange shaft 
with spring.  

4. Using puller (VW 771 and VW 771/37), pull out seal for flange shaft. See Fig. 15 . 

Fig. 15: Pulling Left Flanged Shaft Oil Seal 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5. To install, using press piece (3305), drive NEW seal into sleeve onto stop, when doing this DO NOT tilt 

seal. See Fig. 16 . Fill space between sealing lip and dust lip with sealing grease (G052 128 A1). Insert 
flange shaft. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:28 AM

Page 17 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 16: Driving In New Oil Seal (Left Flange Seal) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

6. Secure flange shaft with countersunk bolt. Connect ball joint to control arm, using NEW bolts onto marks 

made during removal.  

7. Bolt drive axle shaft to transmission flange. Install left front wheel. Tighten bolts to specification. See 

TORQUE SPECIFICATIONS .  

8. Top off transmission oil. See LUBRICATION . Install sound insulation trays.  

Removal & Installation (Right Flange Seal) 

1. Raise and support vehicle. Remove center and right noise insulation trays, under engine/transmission, if 

equipped.  

2. Turn steering to right onto full lock stop. Remove left drive axle shaft from transmission flange. Mark 

position of lower ball joint bolts (arrows), for installation reference. See Fig. 14 . Remove bolts. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:28 AM

Page 18 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 17: Removing Drive Axle Shaft From Flange (Right Flange Seal) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3. Remove flange shaft securing bolts by screwing two bolts into flange, and counterhold flange shaft using 

a lever. Place container under transmission and engine. Remove flanged shaft with spring. Pry seal out.  

4. Using a drift sleeve (3158) drive seal into sleeve onto stop. See Fig. 18 . Fill space between sealing lip 

and dust lip with sealing grease (G052 128 A1). Insert flange shaft. 

NOTE:

If more clearance is needed to remove right flange seal, front drive axle 
shaft may need to be removed. See AXLE SHAFTS article. 

 

2003 Volkswagen New Beetle GLS 

2002-04 MANUAL TRANSMISSIONS Servicing - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:11:28 AM

Page 19 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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