Volkswagen New Beetle. Manual - part 2456

 

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Volkswagen New Beetle. Manual - part 2456

 

 

Fig. 73: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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80-200 Removal lever  

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10-508 Assembly mandrel  

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2070 Tensioning device  

1. Selector segment 5th gear 

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Identification. See Identifying Selector Segments  

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After installing circlip selector segment must rotate freely 

NOTE:

The selector fork group (item 7) does not need disassembling and assembling 
the selector segments to disassemble the bearings and the circlips.

NOTE:

The following list refers to items in Fig. 74 .

 

2003 Volkswagen New Beetle GLS 

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

  

2. Circlip 

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Always replace  

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Removing. See Installing circlip  

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Installing. See Installing circlip  

3. 5th gear selector fork 

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Adjusting. See ADJUSTING 5TH GEAR:  

4. Bolt, 25 N.m  

5. 5th gear selector jaw  

6. Bearing 

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4 Pieces  

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Removing. See Removing bearing inner race  

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Pressing inner ring into outer ring. See Pressing Bearing Inner Ring Into Outer Ring  

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Pressing in. See Pressing Inner Race In Selector Fork Onto Stop  

7. Selector fork group with selector rails  

8. Selector segment 1st/2nd gear 

z

Identification. See Identifying Selector Segments  

z

After installing the circlip the segment must rotate freely  

9. Selector segment 3rd/4th gear 

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Identification. See Identifying Selector Segments  

z

After installing the circlip the segment must rotate freely  

10. Domed sliding piece  

11. Spring  

12. Reverse gear selector fork  

13. Support for reverse gear selector fork  

14. Circlip  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 74: Disassembling Selector Fork Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Identifying Selector Segments 

Fig. 75: Identifying Selector Segments 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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