Volkswagen New Beetle. Manual - part 2445

 

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Volkswagen New Beetle. Manual - part 2445

 

 

Fig. 42: Locating Outer Diameter Concave Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Engage two gears before tightening 5th gear synchro-hub and gear wheel securing bolts (arrows). See 
Fig. 22 .  

z

Install 5th gear selector fork. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 43: Tightening 5th Gear Synchro-Hub And Gear Wheel Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Adjusting 5th gear: 

z

Engage 5th gear. Loosen bolt -1-. Press locking collar and selector fork jaws in direction of (arrow), then 
tighten bolt -1- to 25 N.m. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 44: Adjusting 5th Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar 

 

2003 Volkswagen New Beetle GLS 

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

  

and gearwheel. If necessary repeat adjustment. 

z

Disengage 5th gear. Locking collar must now be in neutral position. Synchro-ring must move freely.  

z

Select all gears.  

z

Install transmission housing cover  

z

Install flange shafts along with springs, thrust washers and tapered rings. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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