Volkswagen New Beetle. Manual - part 2444

 

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Volkswagen New Beetle. Manual - part 2444

 

 

Fig. 38: Measuring Synchro-Ring And Gear Gap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

5TH GEAR SYNCHRO-RING GAP AND WEAR LIMIT 

z

Install 5th gear wheel with needle roller bearing  

z

Place 5th gear synchro-ring on gear wheel  

z

Assembly 5th gear synchro-hub/locking collar before installing. See Assembling 5th gear locking 
collar/synchro-hub
 .  

Installation position 5th gear synchro-hub/locking collar 

Gap -a-

New

Wear limit

5th gear

1.1... 1.7 mm

0.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 39: Identifying Installation Position 5th Gear Synchro-Hub/Locking Collar 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The pointed teeth of the locking collar (arrow -1-) and the high shoulder of the synchro-hub (arrow -2-) face the 
transmission housing. 

The mountings (arrow -3-) of the syncro-hub are inline with the cast locking pieces of the syncro-ring (arrows 
in 5th gear synchro-ring with cast locking pieces (arrows) ). 

5th gear synchro-ring with cast locking pieces (arrows) 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 40: Identifying 5th Gear Synchro-Ring With Cast Locking Pieces 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Drive on 5th gear synchro-hub 

NOTE:

When driving make sure synchro-ring is free to move.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 41: Installing 5th Gear Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Screw-in securing bolts for synchro-hub and 5th gear wheel.  

Installation position of dished spring for gear wheel and 5th gear synchro-hub securing bolts: 

The outer diameter (concave side -arrows-) faces 5th gear.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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