Volkswagen New Beetle. Manual - part 2443

Courtesy of VOLKSWAGEN OF AMERICA, INC.

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Install pivot pin (arrow) for selector forks. To do this align selector mechanism with a screwdriver so that 
relevant pivot pin can be installed. 

Fig. 34: Installing Pivot Pin 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install selector shaft cover  

 

2003 Volkswagen New Beetle GLS 

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

  

Install selector shaft as follows: 

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Place selector plates in neutral.  

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Locate lug (arrow -1-) in recess in transmission housing. Position selector shaft so that selector finger 
(arrow -2-) is inserted in selector plates. 

Fig. 35: Installing Selector Shaft 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install selector shaft cover.  

Installation position 5th gear wheel 

The circumferential groove (arrow) faces to transmission housing.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 36: Identifying Installation Position 5th Gear Wheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Drive on 5th gear wheel. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 37: Installing Drive On 5th Gear Wheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking 5th gear synchro-ring 

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Before installing 5th gear wheel and synchro-ring press synchro-ring onto cone of gear wheel and 
measure gap -a- with a feeler gauge. 

 

2003 Volkswagen New Beetle GLS 

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