Volkswagen New Beetle. Manual - part 2529

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

1st gear

1.0 ... 1.7 mm

0.5 mm

3rd gear

1.0 ... 1.7 mm

4th gear

1.0 ... 1.7 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 119: Disassembling And Assembling 1st And 2nd Gear Locking Collar And Synchro-Hub
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1. Spring  

2. Locking collar  

3. Synchro-hub  

4. Locking piece 

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Slide locking collar over synchro-hub. 

The wide shoulder of the synchro-hub (arrow -A-) and the outer splines of the locking collar (arrow 
-B-) face opposite directions after assembly. Recesses for locking pieces on synchro-hub and 
locking collar must align. 

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

Fig. 120: Assembling 1st And 2nd Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Locking collar is pushed over synchro-hub. 

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Insert locking pieces and install springs 120° off-set. The angled end of spring must locate in 
hollow locking piece.  

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

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 121: Identifying Installation Position 1st And 2nd Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The locking collar splines (arrow -1-) point to splines for 3rd/4th gear synchro-hub -A-. 

The wide shoulder of the synchro-hub (arrow -2-) then faces to 1st gear -B-.

 

2003 Volkswagen New Beetle GLS 

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

  

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

Fig. 122: Pressing On 1st And 2nd Gear Locking Collar/Synchro-Hub

 

2003 Volkswagen New Beetle GLS 

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