Volkswagen New Beetle. Manual - part 2376

Fig. 6: Identifying Replace Spring Pins Installation Position: Slot Longitudinal To Line Of Force 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Bolts and nuts 

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Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.  

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Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten nuts 
and bolts in stages in a diagonal sequence.  

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Tightening torques as specified are for unoiled bolts and nuts.  

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Replace self-locking bolts and nuts.  

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Ensure that on bolted connections the areas around the contact surfaces as well as the visible surfaces of 
nuts and bolts are rewaxed after assembly, if necessary.  

Bearings 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

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Install new tapered roller bearings as supplied and do not lubricate additionally.  

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Install needle bearings with lettered side (thicker metal) towards fitting tool.  

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Tapered roller bearings fitted to one shaft must be replaced as a set. Use the same make of bearings.  

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Heat inner races to approx. 100° C before installing.  

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Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.  

Shims 

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Measure shims at several points with a micrometer. Tolerance variations make it possible to find the 
exact shim thickness required.  

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Check for burrs and damage.  

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Only install perfect shims.  

Synchronizer rings 

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Do not interchange. When reusing always fit to the same gear.  

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Check for wear and replace if necessary.  

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Coat with gear oil before installing.  

Selector gears 

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Before installing clean and heat on a hot plate to approx. 100° C.  

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Temperature can be checked with temperature tester V.A.G 1558.  

MANUAL TRANSMISSION - CONTROLS, HOUSING 

TRANSMISSION, DISASSEMBLING AND ASSEMBLING 

Sequence for disassembling and assembling. See ASSEMBLY SEQUENCE . 

Component overview 

1. Clutch housing  

2. Reverse shaft  

3. Output shaft for 5th, 6th and reverse gear  

4. Slave cylinder with release bearing  

5. Input shaft  

6. Output shaft for 1st-4th gear  

7. Differential  

8. Speedometer sender  

NOTE:

The following list refers to items in Fig. 7 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

9. 2nd gear  

10. 1st selector gear  

11. Selector gear for 4th gear  

12. Selector gear for 3rd gear  

13. Selector gear for 5th gear  

14. 6th gear 

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Spacer sleeve fitted in 5-speed transmission  

15. Reverse sliding gear  

16. Transmission housing  

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Fig. 7: Sectional View Of Transmission Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Assembly overview 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle