Volkswagen New Beetle. Manual - part 2408

Fig. 108: Identifying Installation Position 1st And 3rd Gear Wheel
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The higher shoulder -A- faces toward 2nd or 4th gear -B-. The recesses in the shoulder (arrows) engage in the 
lugs of the outer ring (arrow. See Fig. 106 ) 

Identifying Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub 

Fig. 109: Identifying Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The wider shoulder of the synchro-hub (arrow) faces toward 3rd gear. 

Pressing On 3rd And 4th Gear Synchro-Hub With Locking Collar 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 110: Pressing On 3rd And 4th Gear Synchro-Hub With Locking Collar 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking Synchro-Ring For Wear 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 111: Checking Synchro-Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

WEAR LIMIT (SYNCHRO-RING) 

Pressing On Tapered Roller Bearing Inner Race 

Gap "a"

New dimension

Wear limit

4th gear

1.0 ... 1.7 mm

0.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 112: Pressing On Tapered Roller Bearing Inner Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Determining Thickness Of Circlip 

 

2003 Volkswagen New Beetle GLS 

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