Volkswagen New Beetle. Manual - part 2514

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 72: Changing Selector Mechanism Cover And Selector Shaft
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

As of date of manufacture of August 6th 2001 the selector shaft is manufactured with the recesses -A-. 

The spring -B- is fitted in the selector mechanism cover. 

Function 

With one selected forward gear, the selector shaft is secured via one of the recesses -A- with the spring -B- in 
the selector mechanism cover. 

SELECTOR FORKS, DISASSEMBLING AND ASSEMBLING 

Special tools and equipment 

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VW 402 Press plate  

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3290/1 Press piece from mounting device 3290  

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3301 Mounting device  

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VW 431 Press piece  

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VW 472/2 Spacer sleeve  

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10-206 Drift 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 73: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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80-200 Removal lever  

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10-508 Assembly mandrel  

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2070 Tensioning device  

1. Selector segment 5th gear 

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Identification. See Identifying Selector Segments  

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After installing circlip selector segment must rotate freely 

NOTE:

The selector fork group (item 7) does not need disassembling and assembling 
the selector segments to disassemble the bearings and the circlips.

NOTE:

The following list refers to items in Fig. 74 .

 

2003 Volkswagen New Beetle GLS 

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

  

2. Circlip 

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Always replace  

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Removing. See Installing circlip  

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Installing. See Installing circlip  

3. 5th gear selector fork 

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Adjusting. See ADJUSTING 5TH GEAR:  

4. Bolt, 25 N.m  

5. 5th gear selector jaw  

6. Bearing 

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4 Pieces  

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Removing. See Removing bearing inner race  

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Pressing inner ring into outer ring. See Pressing Bearing Inner Ring Into Outer Ring  

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Pressing in. See Pressing Inner Race In Selector Fork Onto Stop  

7. Selector fork group with selector rails  

8. Selector segment 1st/2nd gear 

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Identification. See Identifying Selector Segments  

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After installing the circlip the segment must rotate freely  

9. Selector segment 3rd/4th gear 

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Identification. See Identifying Selector Segments  

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After installing the circlip the segment must rotate freely  

10. Domed sliding piece  

11. Spring  

12. Reverse gear selector fork  

13. Support for reverse gear selector fork  

14. Circlip  

 

2003 Volkswagen New Beetle GLS 

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