Volkswagen New Beetle. Manual - part 2435

 

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Volkswagen New Beetle. Manual - part 2435

 

 

Fig. 6: Identifying Oil Seal Lip 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

After installation: 

Check transmission oil; if necessary top-off to lower edge of oil filler hole, specification. See CODE 
LETTERS, TRANSMISSION APPLICATION, RATIOS, CAPACITIES
 . 

Locking devices 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Replace circlips.  

z

Do not overstretch circlips.  

z

Circlips must be install properly in the groove.  

z

Replace spring pins. Installation position: Slot longitudinal to line of force. 

Fig. 7: Replacing Circlips 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Bolts and nuts 

z

Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.  

z

Delicate parts, must not be distorted, such as clutch pressure plates. Loosen and tighten nuts and bolts in 

 

2003 Volkswagen New Beetle GLS 

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

  

stages in a diagonal sequence.  

z

Tightening torques as specified are for unoiled bolts and nuts.  

z

Replace self-locking bolts and nuts.  

z

Make sure with threaded connections that the areas of the contact surfaces as well as the visible surfaces 
of nuts and bolts are rewaxed after assembly.  

Bearings 

z

Install new tapered roller bearings as supplied and do not lubricate.  

z

Install needle bearings with lettered side (thicker metal) toward installing tool.  

z

Tapered roller bearings installed to one shaft must be replaced as a set. Use same make of bearings.  

z

Heat inner races to approx. 100 °C before installing.  

Shims 

z

Measure shims at several points with a micrometer. Tolerance variations make it possible to find the 
exact shim thickness required.  

z

Check for burrs and damage.  

z

Only install perfect shims.  

Synchronizer rings 

z

Do not interchange. When reusing always install to the same gear.  

z

Check for wear and replace if necessary.  

z

Coat with gear oil before installing.  

Gear wheels 

z

Before installing clean and heat on a hot plate to approx. 100° C.  

z

Temperature can be checked with temperature tester V.A.G 1558.  

MANUAL TRANSMISSION - CONTROLS, HOUSING 

TRANSMISSION, DISASSEMBLING AND ASSEMBLING 

Transmission overview 

1. 1st gear  

2. 2nd gear  

3. 3rd gear  

4. 4th gear  

NOTE:

The following list refers to items in Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

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

  

5. 5th gear  

6. Transmission housing 

z

Servicing. See TRANSMISSION HOUSING AND CLUTCH HOUSING, SERVICING  

7. Selector mechanism 

z

(Selector forks)  

z

Disassembling and assembling. See SELECTOR FORKS, DISASSEMBLING AND 
ASSEMBLING
  

8. Input gear for 1st and reverse gear  

9. Input shaft 

z

Disassembling and assembling. See INPUT SHAFT, DISASSEMBLING AND ASSEMBLING  

10. Output shaft 

z

Disassembling and assembling. See Output shaft, disassembling and assembling  

11. Differential 

z

Disassembling and assembling. See Differential, disassembling and assembling  

12. Clutch housing 

z

Servicing. See TRANSMISSION HOUSING AND CLUTCH HOUSING, SERVICING

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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