Volkswagen New Beetle. Manual - part 2436

 

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Volkswagen New Beetle. Manual - part 2436

 

 

Fig. 8: Sectional View Of O2J Transmission 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Assembly overview 

I. Removing and installing cover for transmission housing and 5th gear. See COVER FOR 

TRANSMISSION HOUSING AND 5TH GEAR, REMOVING AND INSTALLING  

II. Disassembling and assembling transmission housing and shift mechanism. See TRANSMISSION 

HOUSING AND SELECTOR MECHANISM, REMOVING AND INSTALLING  

III. Disassembling and assembling input shaft, output shaft, differential and selector forks. See INPUT 

NOTE:

The following list refers to items in Fig. 9 .

 

2003 Volkswagen New Beetle GLS 

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

  

SHAFT, OUTPUT SHAFT (PINION SHAFT), DIFFERENTIAL AND SELECTOR FORKS, 
REMOVING AND INSTALLING
 

Fig. 9: Identifying Assembly Overview 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Cover for transmission housing and 5th gear, removing and installing 

1. Hex bolt, 10 N.m 

z

For transmission housing cover  

2. Transmission housing cover 

NOTE:

The following list refers to items in Fig. 10 .

 

2003 Volkswagen New Beetle GLS 

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

  

3. Gasket  

4. 5Torx socket head bolt M10, 80 N.m 

z

Install piece on bolt head holds saucer spring washer in position  

5. Dished spring 

z

Installing. See INSTALLATION POSITION OF DISHED SPRING FOR GEAR WHEEL 
AND 5TH GEAR SYNCHRO-HUB SECURING BOLTS:
  

6. Socket head bolt, 25 N.m 

z

For pivot pin to transmission housing  

7. Pivot pin  

8. 5th gear selector fork 

z

Disassembling and assembling. See SELECTOR FORKS, DISASSEMBLING AND 
ASSEMBLING
  

z

Adjusting. See ADJUSTING 5TH GEAR:  

9. 5th gear locking collar 

z

Installation position. See CHECKING 5TH GEAR SYNCHRO-RING  

z

Adjusting. See ADJUSTING 5TH GEAR:  

10. Synchro-hub with 5th gear and synchronizing ring 

z

Disassembling and assembling. See 5th gear synchronizer  

11. Needle roller bearing  

12. 5th speed gear wheel 

z

Installation position. See INSTALLATION POSITION 5TH GEAR WHEEL  

NOTE:

If the transmission cover is installed with the transmission installed, check 
oil level as follows: 

z

Fill with oil to lower edge of filler hole and install filler plug.  

z

Start engine, engage gear and allow transmission to turn for approx. 
2 minutes.  

z

Switch off engine and top off transmission oil to lower edge of filler 
hole again.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 10: Exploded View Of Transmission Housing Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Transmission housing and selector mechanism, removing and installing 

1. Cone head bolt, 25 N.m  

2. Flange shaft with spring 

z

Removing and installing. See ASSEMBLY SEQUENCE  

z

Complement. See item 19 Flange Shaft  

3. Torx socket head bolt, 30 N.m 

z

For reverse shaft support  

NOTE:

The following list refers to items in Fig. 11 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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