Volkswagen New Beetle. Manual - part 2406

Angled lugs (arrow -1-) point toward outer ring -B-.

z

Fit outer ring -B-. 

Lugs (arrow -2-) engage in gear wheel recesses (arrow 3). 

z

Fit synchro-ring -C-. 

The recesses (arrow -4-) engage in lugs (arrow -1-) of inner ring -A-. 

Disassembling And Assembling 1st And 2nd Gear Locking Collar And Synchro-Hub 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 102: Disassembling And Assembling 1st And 2nd Gear Locking Collar And Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Spring  

 

2003 Volkswagen New Beetle GLS 

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

  

2. Locking piece  

3. Locking collar  

4. Synchro-hub  

z

Slide locking collar over synchro-hub.  

The recesses for locking pieces in synchro-hub and locking collar must align. 

Assembling 1st And 2nd Gear Locking Collar/Synchro-Hub 

Fig. 103: Assembling 1st And 2nd Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

The locking collar has been pushed over the synchro-hub.

z

Insert locking pieces and install springs 120° offset. Angled end of spring must locate in hollow locking 
piece.  

Installation Position Of 1st And 2nd gear Locking Collar/Synchro-Hub 

Fig. 104: Identifying Installation Position Of 1st And 2nd Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Identification groove (arrow -1-) and narrow collar (arrow -2-) of synchro-hub point toward 1st gear. 

Pressing On 1st and 2nd Gear Locking Collar/Synchro-Hub 

 

2003 Volkswagen New Beetle GLS 

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