Volkswagen New Beetle. Manual - part 2517

Selector segment assignment. See Identifying Selector Segments . 

MANUAL TRANSMISSION - GEARS, SHAFTS 

INPUT SHAFT, DISASSEMBLING AND ASSEMBLING 

Special tools and equipment 

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VW 407 H Press tool  

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VW 447 H Press plate  

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VW412 Press tool  

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VW 422 Tube  

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VW 401 Press plate  

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VW 408 A Press tool 

1st and 2nd gear selector segments with changed synchronization. See Changed springs 
for 5th gear synchronizer from transmission manufacture date November 11 01

88.4 ... 89.1

3rd/4th gear selector forks

96.0 ... 96.7

(1)

For dimension a, see Fig. 81 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 82: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VW 421 Tube  

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VW 454 Press piece  

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VW 447 i Thrust plate  

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VW510 Press piece  

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41-501 Drift sleeve  

 

2003 Volkswagen New Beetle GLS 

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

  

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3-Kukko 17/1 Separating device 

Fig. 83: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

1. Clutch housing  

2. Tapered roller bearing outer race 

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Removing. See Pressing out tapered roller bearing outer race  

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Pressing in. See Pressing in tapered roller bearing outer race  

3. Tapered roller bearing inner race 

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Pressing off. See Pressing off tapered roller bearing inner race .  

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Pressing on Pressing on tapered roller bearing inner race .  

4. Input shaft 

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Adjusting. See INPUT SHAFT, ADJUSTING  

5. 3rd gear wheel 

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Shoulder points to 4th gear  

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Pressing off. See Pressing off 4th gear wheel with tapered roller bearing and sleeve  

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Pressing on Pressing on 3rd gear wheel  

6. Circlip 

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Always replace  

7. 4th gear wheel 

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Press off with tapered roller bearing inner race and sleeve. See Pressing off 4th gear wheel with 
tapered roller bearing and sleeve  

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Pressing on Pressing on 4th gear wheel  

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Collar faces to 3rd gear  

8. Tapered roller bearing inner race 

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Pressing off with 4th gear wheel and sleeve. See Pressing off 4th gear wheel with tapered roller 
bearing and sleeve  

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Pressing on Pressing on tapered roller bearing inner race  

9. Thrust washer  

10. Tapered roller bearing outer race 

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Pressing out Pressing out tapered roller bearing outer race  

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Pressing in. See Pressing in tapered roller bearing outer race  

11. Shim 

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Determining thickness adjusting input shaft. See INPUT SHAFT, ADJUSTING  

NOTE:

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When installing new gear wheels, consult technical data. See Code letters, 
transmission application, ratios, capacities .  

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If the position of the tapered roller bearings is affected when exchanging 
parts, the input shaft must be readjusted. See adjustment overview. See 
Adjustment overview .  

NOTE:

The following list refers to items in Fig. 84 .

 

2003 Volkswagen New Beetle GLS 

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