Volkswagen New Beetle. Manual - part 2382

 

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Volkswagen New Beetle. Manual - part 2382

 

 

Fig. 21: Removing 1st-4th Gear Output Shaft With Selector Rods In Right Hand 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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With left hand, lift differential slightly.  

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At same time, have a second mechanic slightly lift 5th, 6th and reverse gear output shaft together with 
reverse shaft -4-.  

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Insert 1st-4th gear output shaft in direction of arrow. 

Toothing of output shafts and final drive gear/differential must mesh. 

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Together with second mechanic, place shafts in their bearing seats.  

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Set input shaft in clutch housing and swing in -arrow-. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Fig. 22: Setting Input Shaft In Clutch Housing And Swing In 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Fit transmission housing.  

Install selector shaft as follows: 

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Bring selector rods -A- into neutral.  

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Insert selector shaft -1-. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Fig. 23: Inserting Selector Shaft 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Position selector shaft so that shift fingers are inserted in selector rods, see Installation position of 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

complete selector mechanism in transmission 

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When doing this, align lower selector shaft bearing -arrow- through drilling for cover plate.  

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Bolt cover plate -A- to lower selector shaft bearing -1- with bolt -2-, M8 x 60 mm.  

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Hand tighten cover plate -A- by alternately tightening (1/2turn) bolts -arrows-.  

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Remove bolt -2- and hand tighten original bolt in its place.  

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Install selector shaft cover -B- and tighten hex bolts to torque.  

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Tighten cover plate hex bolts.  

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Insert locking bolt -3- for selector shaft gate with locking fluid D 000 600 A2. 

Fig. 24: Tightening Cover Plate -A- By Alternately Tightening (1/2Turn) Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

 

 

 

 

 

 

 

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