Volkswagen New Beetle. Manual - part 2525

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VW 415 A Tube  

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VW 447 H Press plate  

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VW 454 Press piece  

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VW 455 Fitting sleeve  

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41-501 Drift sleeve 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 108: Identifying Special Tools And Equipment (3 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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1 - Kukko 21/6 Internal extractor  

 

2003 Volkswagen New Beetle GLS 

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

  

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4 - Kukko 22/2 Retainer  

1. Hex nut, 25 N.m plus an additional 1/4 turn 90° 

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4 nuts for bearing support  

2. Clutch housing  

3. Shim 

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For output shaft  

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Adjustment overview. See Adjustment overview  

4. Small tapered roller bearing outer race 

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Removing. See Output shaft, disassembling and assembling  

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Pressing in. See Pressing in small tapered roller bearing outer race  

5. Small tapered roller bearing inner race 

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Pulling off. See Pulling off small tapered roller bearing inner race  

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Pressing on Pressing on small tapered roller bearing inner race  

6. Output shaft 

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Is paired with final drive gear wheel, always replace together as a set  

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Adjusting. See OUTPUT SHAFT, ADJUSTING  

7. Large tapered roller bearing inner race 

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Pulling off. See Pulling off large tapered roller bearing inner race  

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Pressing on Pressing on large tapered roller bearing inner race  

8. Sealing ring 

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Place sealing rings (Qty. 4) on bearing support bolts  

9. Bearing support 

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With large tapered roller bearing outer race and bolts 

NOTE:

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The output shaft is disassembled as follows: 

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Position separating device under 2nd gear wheel (item 19) and press 
off as described in Pressing off 3rd and 4th gear synchro-hub/locking 
collar, 2nd, 3rd and 4th gear wheels with transmission housing 
needle roller bearing sleeve .  

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Remove circlip (item 15).  

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Position two-arm puller under bearing support (item 9 ) and pull off 
locking collar with 1st and 2nd gear synchro-hub as described in. 
See Pulling off locking collar with synchro-hub and bearing support . 

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

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Both tapered roller bearings must be replaced as a set.  

NOTE:

The following list refers to items in Fig. 109 .

 

2003 Volkswagen New Beetle GLS 

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

  

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Only change outer race with large tapered roller bearing and bearing support  

10. Thrust washer 

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Shoulder on thrust washer faces tapered roller bearing  

11. 1st gear wheel 

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From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed. See 
CHANGED SPRINGS FOR 5TH GEAR SYNCHRONIZER FROM TRANSMISSION 
MANUFACTURE DATE NOVEMBER 11 01  

12. Needle roller bearing 

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For 1st gear  

13. 1st gear synchro-ring 

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Checking for wear. See Checking synchro-ring for wear  

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Identification Identifying 1st and 2nd gear synchro-rings  

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From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed. See 
CHANGED SPRINGS FOR 5TH GEAR SYNCHRONIZER FROM TRANSMISSION 
MANUFACTURE DATE NOVEMBER 11 01  

14. 1st and 2nd gear locking collar with synchro-hub 

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Pull off with bearing support after removing circlip (item 15). See Pulling off locking collar with 
synchro-hub and bearing support  

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Disassembling Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub

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Assembling locking collar/synchro hub. See Disassembling and assembling 1st and 2nd gear 
locking collar and synchro-hub and Assembling 1st and 2nd gear locking collar/synchro-hub  

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Installation position. See Installation position 1st and 2nd gear locking collar/synchro-hub  

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Pressing on Pressing on 1st and 2nd gear locking collar/synchro-hub  

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From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed. See 
CHANGED SPRINGS FOR 5TH GEAR SYNCHRONIZER FROM TRANSMISSION 
MANUFACTURE DATE NOVEMBER 11 01  

15. Securing clip  

16. 2nd gear synchro-ring 

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Identification Identifying 1st and 2nd gear synchro-rings  

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Checking for wear. See Checking 2nd gear synchro-ring for wear  

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Assemble so that recesses locate in locking collar (item 14) locking pieces  

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From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed. See 
CHANGED SPRINGS FOR 5TH GEAR SYNCHRONIZER FROM TRANSMISSION 
MANUFACTURE DATE NOVEMBER 11 01  

17. Outer ring 

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Insert in synchro-ring (item 16). Installation position. See Installation position outer-ring  

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Replace if scored or worn  

18. Synchro-ring 

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(Inner ring)  

 

2003 Volkswagen New Beetle GLS 

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