Volkswagen New Beetle. Manual - part 2402

 

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Volkswagen New Beetle. Manual - part 2402

 

 

z

Pulling out. See Pulling Dished Washer Out Of Output Shaft .  

z

Pressing in. See Pressing Dished Washer Into Output Shaft Onto Stop .  

4. Outer race/tapered roller bearing 

z

Pulling out. See Pulling Tapered Roller Bearing Outer Race Out Of Transmission Housing .  

z

Pressing in. See Pressing Tapered Roller Bearing Outer Race Into Transmission Housing .  

5. Tapered roller bearing inner race 

z

Pressing off. See Pulling Off Tapered Roller Bearing Inner Race .  

z

Pressing on. See Pressing On Tapered Roller Bearing Inner Race .  

6. Output shaft 

z

For 1st-4th gear  

z

Adjusting. See OUTPUT SHAFT FOR 1ST-4TH GEARS, ADJUSTING .  

7. Needle roller bearing 

z

For 2nd gear  

8. 2nd gear  

9. Synchro-ring 

z

(Inner ring for 2nd gear)  

z

Checking for wear. See Checking Inner Ring For 1st, 2nd And 3 Gear For Wear .  

z

Check lugs for scoring  

z

Installation position. See Installation Position Of Outer Ring, Inner Ring And 2nd Gear 
Synchro Ring
 .  

10. 2nd gear outer ring 

z

Insert in the synchro-ring (item - 9 -)  

z

Replace if scored  

z

Installation position. See Installation Position Of Outer Ring, Inner Ring And 2nd Gear 
Synchro Ring
 .  

11. 2nd gear synchro-ring 

z

Checking for wear. See Checking 1st, 2nd And 3rd Gear Synchro-Rings For Wear .  

z

Installation position. See Installation Position Of Outer Ring, Inner Ring And 2nd Gear 
Synchro Ring
 .  

12. 1st and 2nd gear locking collar with synchro-hub 

z

Pull off over bearing support after removing securing clip (item 13). See Pressing Off 1st And 2nd 
Gear Locking Collar And Synchro-Hub
 .  

z

Disassembling. See Disassembling And Assembling 1st And 2nd Gear Locking Collar And 
Synchro-Hub
 .  

z

Assembling locking collar/synchro hub. See Disassembling And Assembling 1st And 2nd Gear 
Locking Collar And Synchro-Hub
 and see Assembling 1st And 2nd Gear Locking 
Collar/Synchro-Hub
 .  

z

Installation position. See Installation Position Of 1st And 2nd gear Locking Collar/Synchro-
Hub
 .  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Pressing on Pressing On 1st and 2nd Gear Locking Collar/Synchro-Hub .  

13. Securing clip  

14. 1st gear synchro-ring 

z

Checking for wear. See Checking 1st, 2nd And 3rd Gear Synchro-Rings For Wear .  

z

Assemble so that recesses locate in locking collar (item-12-) locking pieces  

15. 1st gear outer ring 

z

Insert in the synchro-ring (item -11 -), installation position. See Installation Position For 1st or 
3rd Gear Outer Ring
 .  

z

Replace if scored  

16. Synchro-ring 

z

(1st gear inner ring)  

z

Checking for wear. See Checking Inner Ring For 1st, 2nd And 3 Gear For Wear .  

z

Check lugs for scoring  

z

Installation position. See Installation Position Synchro-Ring (Inner Ring) .  

17. Needle roller bearing 

z

For 1st gear  

18. 1st selector gear 

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Installation position. See Identifying Installation Position 1st And 3rd Gear Wheel .  

19. Thrust washer 

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For 1st and 4th gear  

z

Insert lugs on thrust washer in holes on output shaft  

20. Shim 

z

Holds thrust washer (-item 19-) in position on output shaft  

21. Needle roller bearing 

z

For 4th gear  

22. Selector gear for 4th gear  

23. 4th gear synchro-ring 

z

Checking for wear. See Checking Synchro-Ring For Wear .  

24. Locking collar with 3rd and 4th gear synchro-hub 

z

Pull off by pulling off 4th gear wheel after removing the circlip (item - 25 -). See Pulling Off 3rd 
And 4th Gear Synchro-Hub/Locking Collar Over 4th Gear Wheel
 .  

z

Disassembling. See Disassembling And Assembling 1st And 2nd Gear Locking Collar And 
Synchro-Hub
 .  

z

Installation position locking collar/synchro-hub. See Identifying Installation Position 3rd And 
4th Gear Locking Collar/Synchro-Hub
 .  

z

Assembling locking collar/synchro hub. See Disassembling And Assembling 1st And 2nd Gear 
Locking Collar And Synchro-Hub
 and see Assembling 1st And 2nd Gear Locking 
Collar/Synchro-Hub
 .  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Pressing On 3rd And 4th Gear Synchro-Hub With Locking Collar  

25. Securing clip  

26. 3rd gear synchro-ring 

z

Checking for wear. See Checking 1st, 2nd And 3rd Gear Synchro-Rings For Wear .  

27. Outer ring for 3rd gear 

z

Insert in the synchro-ring (item - 26 -), installation position. See Installation Position For 1st or 
3rd Gear Outer Ring
 .  

z

Replace if scored  

28. Synchro-ring 

z

(3rd gear inner ring)  

z

Checking for wear. See Checking Inner Ring For 1st, 2nd And 3 Gear For Wear .  

z

Check lugs for scoring  

z

Installation position. See Installation Position Synchro-Ring (Inner Ring) .  

29. Needle roller bearing 

z

For 3rd gear  

30. Selector gear for 3rd gear 

z

Installation position. See Identifying Installation Position 1st And 3rd Gear Wheel .  

31. Tapered roller bearing inner race 

z

Pulling off. See Pulling Off Tapered Roller Bearing Inner Race .  

z

Pressing on Pressing On Tapered Roller Bearing Inner Race .  

32. Securing clip 

z

Redetermine thickness if tapered roller bearing (-item 6 -) or output shaft (-item 31 -) are replaced. 
See Determining Thickness Of Circlip .  

33. Outer race/tapered roller bearing 

z

Pulling out. See Pulling Tapered Roller Bearing Outer Race Out From Transmission 
Housing
 .  

z

Pressing in. See Pressing Tapered Roller Bearing Outer Race Into Transmission Housing .  

34. Shim 

z

Determining thickness. See OUTPUT SHAFT FOR 1ST-4TH GEARS, ADJUSTING .  

35. Transmission housing  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 89: Disassembling And Assembling Output Shaft, 1st-4th Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pulling Dished Washer Out Of Output Shaft 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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