Volkswagen New Beetle. Manual - part 2414

 

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Volkswagen New Beetle. Manual - part 2414

 

 

1. Clutch housing  

2. Shim 

z

Always 0.65 mm thick  

3. 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 .  

4. 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 .  

5. Output shaft 

z

For 5th, 6th and reverse gear  

z

Adjusting. See OUTPUT SHAFT FOR 5TH, 6TH AND REVERSE GEAR, ADJUSTING .  

6. Reverse gear synchro-hub 

z

Pressing off. See Pressing off reverse gear synchro-hub .  

z

Installation position. See Installation position of reverse gear synchro-hub .  

z

Pressing on Pressing on reverse gear synchro-hub .  

7. Securing clip  

8. Reverse gear locking collar 

z

Securing clip  

9. Needle roller bearing 

z

For reverse gear  

10. Reverse sliding gear  

11. Sleeve 

z

Press off with reverse gear. See Pressing off sleeve -A- over reverse gear wheel .  

z

Installation position: wide shoulder of sleeve faces toward reverse gear  

z

Pressing on sleeve -A-  

12. Securing clip  

13. Needle roller bearing 

z

For 6th gear  

z

Not in 5-speed manual transmissions  

14. 6th gear 

z

Not in 5-speed manual transmissions  

15. 6th gear synchro-ring 

perform output shaft adjustment. See OUTPUT SHAFT FOR 5TH, 6TH AND 
REVERSE GEAR, ADJUSTING .  

NOTE:

The following list refers to items in Fig. 128 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Not in 5-speed manual transmissions  

z

Checking for wear. See Checking synchro-ring for wear .  

16. Spacer sleeve 

z

For 5-speed manual transmission  

z

Pull off together with 5th gear locking collar/synchro-hub after removing securing clip (item -18-). 
See Pressing off 5th gear synchro-hub/locking collar with spacer sleeve .  

z

Position toward 5th gear locking collar/synchro-hub. See Positioning spacer sleeve toward 5th 
gear locking collar/synchro-hub
 .  

z

Press on together with 5th gear locking collar/synchro-hub. See Pressing on 5th gear locking 
collar/synchro-hub together with spacer sleeve
 .  

17. 5th and 6th gear locking collar with synchro-hub 

z

After removing securing clip, press off together with 6th gear (item -18-). See Pressing off 5th and 
6th gear synchro-hub/locking collar with 6th gear
 or for 5-speed manual transmission, with 
spacer sleeve. See Pressing off 5th gear synchro-hub/locking collar with spacer sleeve .  

z

Disassembling. See Disassembling and assembling 5th and 6th gear locking collar and 
synchro-hub
 .  

z

Assembling locking collar/synchro hub. See Disassembling and assembling 5th and 6th gear 
locking collar and synchro-hub
 .  

z

Pressing off in 6-speed manual transmission. See Pressing on 5th and 6th gear locking 
collar/synchro-hub
 .  

z

Pressing off in 5-speed manual transmission. See Pressing on 5th gear locking collar/synchro-
hub together with spacer sleeve
 .  

18. Securing clip  

19. Needle roller bearing 

z

For 5th gear  

20. 5th gear synchro-ring 

z

Check for wear. See Checking synchro-ring for wear .  

21. Selector gear for 5th gear  

22. Tapered roller bearing inner race 

z

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

z

Pressing on tapered roller bearing inner race .  

23. Securing clip 

z

Redetermine if tapered roller bearing (item -22 -) or output shaft (item - 5 -) are replaced. See 
Determining thickness of circlip .  

24. 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 .  

25. Shim 

z

Determining thickness. See OUTPUT SHAFT FOR 5TH, 6TH AND REVERSE GEAR, 
ADJUSTING
 .  

 

2003 Volkswagen New Beetle GLS 

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

  

26. Transmission housing  

27. Spring 

z

Installation position. See Assembling 5th and 6th gear locking collar/synchro-hub .  

28. Locking collar  

29. Synchro-hub  

30. Locking pieces (Qty. 3) 

z

Installation position. See Disassembling and assembling 5th and 6th gear locking collar and 
synchro-hub
 .  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 128: Disassembling And Assembling Output Shaft For 5th, 6th And Reverse Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pulling tapered roller bearing outer race out from transmission housing 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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