Volkswagen New Beetle. Manual - part 2439

Fig. 15: Removing Transmission Housing Cover
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove 5th gear selector fork (arrow) 

Fig. 16: Removing 5th Gear Selector Fork 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove spring for locking piece.  

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Remove locking collar and take off locking piece.  

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Slide locking collar, without selector fork, over synchro-hub again.  

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Remove bolts -A- for synchro-hub and 5th gear, to do this select 5th (arrow -1-) and 1st gear (arrows -2- 
and -3-). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 17: Removing Synchro-Hub And 5th Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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After engaging both gears input shaft and output shaft are locked, synchro-hub and gear wheel cannot 
turn. Both bolts can now be loosened.  

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Take off locking collar.  

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Pull off synchro-hub and 5th gear wheel and remove together with needle roller bearing. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

A. Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.  

B. Hex bolt M10 x 20  

Fig. 18: Removing Synchro-Hub And 5th Gear Wheel With Needle Roller Bearing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Pull off 5th gear wheel 

A. Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.  

B. Hex bolt M10 x 20  

Sequence for removing: 

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Install two arm puller and centralize by turning screw (arrow).  

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Heat gear wheel with hot air blower VAG 1416 and pull off. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 19: Removing 5th Gear Wheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove both flange shafts. 

NOTE:

When pulling off the gear wheel make sure that the hooks do not bend 
outward, if necessary tighten screw (arrow). After 5th gear wheel has been 
removed check for damage.

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle