Volkswagen New Beetle. Manual - part 2521

Fig. 95: Pressing Out Tapered Roller Bearing Outer Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Pressing in tapered roller bearing outer race 

Fig. 96: Pressing In Tapered Roller Bearing Outer Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install with adjusting shim after adjusting input shaft.  

5th gear synchronizer 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 97: Identifying 5th Gear Synchronizer 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Springs for lock pieces  

2. Locking collar 

With 3 recesses (arrows A) for the locking pieces (item 4) 

3. Synchro-hub  

4. Locking pieces 

Installation position: The thin extension (arrow B) faces the pointed teeth of the locking collar (item -2-) 

Assembling 5th gear locking collar/synchro-hub 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 98: Assembling 5th Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Push locking collar over synchro-hub. 

Pointed teeth -A- of the locking collar and shoulder -B- of the syncro-hub face in one direction. The cut 
outs for the locking piece in the locking collar and the syncro-hub must be in-line with one another (See 
5th gear synchronizer and Fig. 122 ). 

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Insert locking pieces (Installation position: see 5th gear synchronizer ).  

z

Insert springs offset by 120° underneath lug - C-. Angled ends of spring must be directly behind locking 
pieces (arrows).  

Changed springs for 5th gear synchronizer from transmission manufacture date November 11 01 

 

2003 Volkswagen New Beetle GLS 

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