Volkswagen New Beetle. Manual - part 2442

 

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Volkswagen New Beetle. Manual - part 2442

 

 

Fig. 30: Installing Sealing Rings To Output Shaft Bearing Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install input shaft, output shaft and reverse shaft together.  

z

Tighten nuts for output shaft bearing support.  

z

Clean locking fluid remnants from threads in reverse shaft support. See INSTALLATION POSITION 
5TH GEAR WHEEL
 . Remnants can be removed using a tap.  

z

Install reverse shaft support.  

z

Install selector mechanism/reverse gear. 

Installation position reverse gear 

NOTE:

The illustration only shows 3 of the 4 sealing rings.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 31: Installation Position Reverse Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Install selector forks together with selector plates.  

z

Screw M 8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after installing 
transmission housing. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 32: Identifying Reverse Shaft Into Transmission Housing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Align selector plates. 

z

Install transmission housing.  

Install reverse shaft support bolts (arrow) as follows: 

z

Insert bolt -a-, remove stud (see Illustration V34-2s008), insert bolt -b- and hand tighten. 

NOTE:

The selector segments must be positioned in the grooves on the locking 
collars.

 

2003 Volkswagen New Beetle GLS 

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

  

Tightening sequence: 

1. Bolt -a- 30 N.m  

2. Bolt -b- 30 N.m  

Fig. 33: Sectional View Of Gear Assembly

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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