Volkswagen New Beetle. Manual - part 2496

z

Always replace  

3. Output shaft 

z

Disassembling and assembling. See Output shaft, disassembling and assembling  

4. Reverse shaft support 

z

Disassembling and assembling. See item6 Reverse Shaft  

5. Reverse shaft 

z

Disassembling and assembling. See Reverse shaft, disassembling and assembling  

6. Input shaft 

z

Disassembling and assembling. See INPUT SHAFT, DISASSEMBLING AND ASSEMBLING  

7. Reverse gear selector fork 

z

Disassembling and assembling. See SELECTOR FORKS, DISASSEMBLING AND 
ASSEMBLING  

z

Installation position. See ASSEMBLING  

8. Torx socket head bolt, 25 N.m  

9. Selector mechanism 

z

(Selector forks)  

z

Disassembling and assembling. See SELECTOR FORKS, DISASSEMBLING AND 
ASSEMBLING  

10. Clutch housing 

z

Servicing. See TRANSMISSION HOUSING AND CLUTCH HOUSING, SERVICING  

11. Hex nut, 25 N.m and then turn 90° further 

z

4 nuts for bearing support  

12. Flange shaft with spring 

z

Removing and installing. See ASSEMBLY SEQUENCE  

z

Assembling. See item 19 Flange Shaft  

13. Cone head bolt, 25 N.m  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 12: Identifying Input Shaft, Output Shaft (Pinion Shaft), Differential And Selector Forks 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Disassembling and assembling transmission housing cover, transmission housing, selector mechanism, input shaft, 
output shaft (pinion shaft), differential and selector forks 

Special tools and equipment 

z

VW 309 Holding plate  

z

VW 353 Transmission support  

z

VW 295 Drift  

z

VW 244 B Fitting sleeve  

 

2003 Volkswagen New Beetle GLS 

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

  

z

VAG 1416 Hot air blower 

Fig. 13: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Disassembling 

z

Mount transmission on repair stand. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 14: Mounting Transmission On Repair Stand 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Drain transmission oil.  

z

Remove clutch release lever and release bearing. See CLUTCH RELEASE BEARING .  

z

Remove guide sleeve. See CLUTCH RELEASE BEARING . 

 

2003 Volkswagen New Beetle GLS 

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