Volkswagen New Beetle. Manual - part 2500

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Unscrew bolt for selector mechanism for reverse gear -B-. 

Fig. 28: Removing Selector Forks With Selector Plates 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove nuts for output shaft bearing support. See ASSEMBLING , item -B-  

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Remove reverse gear -A-, input shaft -B- and output shaft -C- one after other from clutch housing. 

Fig. 29: Removing Reverse Gear, Input Shaft And Output Shaft From Clutch Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Take out differential.  

Assembling 

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Install differential.  

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Always replace sealing rings (arrows) for output shaft bearing support. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 30: Installing Sealing Rings To Output Shaft Bearing Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install input shaft, output shaft and reverse shaft together.  

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Tighten nuts for output shaft bearing support.  

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Clean locking fluid remnants from threads in reverse shaft support. See INSTALLATION POSITION 
5TH GEAR WHEEL . Remnants can be removed using a tap.  

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Install reverse shaft support.  

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Install selector mechanism/reverse gear. 

Installation position reverse gear 

NOTE:

The illustration only shows 3 of the 4 sealing rings.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 31: Installation Position Reverse Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install selector forks together with selector plates.  

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Screw M 8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after installing 
transmission housing. 

 

2003 Volkswagen New Beetle GLS 

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