Volkswagen New Beetle. Manual - part 2405

Fig. 98: Pressing On Tapered Roller Bearing Inner Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Inner Ring For 1st, 2nd And 3 Gear For Wear 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 99: Checking Inner Ring For 1st, 2nd And 3 Gear For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge. 

WEAR LIMIT (INNER RING FOR 1ST, 2ND AND 3 GEAR) 

Checking 1st, 2nd And 3rd Gear Synchro-Rings For Wear 

Gap "a"

New dimension

Wear limit

1st, 2nd and 3rd gear

0.75 ... 1.25 mm

0.3 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 100: Checking 1st, 2nd And 3rd Gear Synchro-Rings For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler 
gauge. 

WEAR LIMIT (1ST, 2ND AND 3RD GEAR SYNCHRO-RINGS) 

Installation Position Of Outer Ring, Inner Ring And 2nd Gear Synchro Ring 

Gap "a"

New dimension

Wear limit

1st, 2nd and 3rd gear

1.2 ... 1.8 mm

0.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 101: Identifying Installation Position Of Outer Ring, Inner Ring And 2nd Gear Synchro Ring 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Place inner ring -A- on 2nd gear wheel. 

 

2003 Volkswagen New Beetle GLS 

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