Volkswagen New Beetle. Manual - part 2417

Installation position of reverse gear synchro-hub

Fig. 137: Identifying Installation Position Of Reverse Gear Synchro-Hub

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Reverse gear locking collar stop (arrow -A-) faces toward toothing of output shaft (arrow -B-). 

Pressing on reverse gear synchro-hub 

Fig. 138: Pressing On Reverse Gear Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pressing on sleeve -A- 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 139: Pressing On Sleeve -A- 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installation position: Wide collar faces toward reverse gear. 

Checking synchro-ring for wear 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 140: Checking Synchro-Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

WEAR LIMIT (OUTPUT SHAFT FOR 5TH, 6TH AND REVERSE GEAR) 

Disassembling and assembling 5th and 6th gear locking collar and synchro-hub  

1. Spring  

2. Locking piece  

3. Locking collar  

4. Synchro-hub 

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Slide locking collar over synchro-hub.  

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

Gap "a"

New dimension

Wear limit

5th and 6th gear

1.0 ... 1.7 mm

0.5 mm

NOTE:

The following list refers to items in Fig. 141 .

 

2003 Volkswagen New Beetle GLS 

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