Volkswagen New Beetle. Manual - part 2471

Fig. 121: Identifying Installation Position 1st And 2nd Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The locking collar splines (arrow -1-) point to splines for 3rd/4th gear synchro-hub -A-. 

The wide shoulder of the synchro-hub (arrow -2-) then faces to 1st gear -B-.

 

2003 Volkswagen New Beetle GLS 

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

  

Pressing on 1st and 2nd gear locking collar/synchro-hub

Fig. 122: Pressing On 1st And 2nd Gear Locking Collar/Synchro-Hub

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Identifying 1st and 2nd gear synchro-rings 

Fig. 123: Identifying 1st And 2nd Gear Synchro-Rings 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

1st gear synchro-ring: 3 x 1/2 ground-down half teeth (arrow)  

z

2nd gear synchro-ring: 3x1/2 ground down half teeth (arrow) or 2 ground-down half teeth 

Only the version with 2x1/2 ground-down half teeth is available as a spare part for the 2nd gear synchro-
ring. 

Distinguishing 1st and 2nd gear synchro-rings 

NOTE:

Before pressing on, place 1st gear synchro-ring on 1st gear wheel.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 124: Distinguishing 1st And 2nd Gear Synchro-Rings 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

1st gear synchro-ring - no recesses  

z

2nd gear synchro-ring - three recesses (arrows)  

Checking 2nd gear synchro-ring for wear 

 

2003 Volkswagen New Beetle GLS 

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