Volkswagen New Beetle. Manual - part 2458

 

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Volkswagen New Beetle. Manual - part 2458

 

 

Fig. 80: Pressing Inner Race In Selector Fork Onto Stop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The hollow in press piece 3290/1 points to bearing. 

Selector Fork With Selector Segments Installed 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 81: Installing Selector Fork With Selector Segments 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Selector Fork Measurements 

Application

(1)

 Dim. -a-

(mm)

1st/2nd gear selector fork

87.2 ... 87.9

 

2003 Volkswagen New Beetle GLS 

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

  

Selector segment assignment. See Identifying Selector Segments . 

MANUAL TRANSMISSION - GEARS, SHAFTS 

INPUT SHAFT, DISASSEMBLING AND ASSEMBLING 

Special tools and equipment 

z

VW 407 H Press tool  

z

VW 447 H Press plate  

z

VW412 Press tool  

z

VW 422 Tube  

z

VW 401 Press plate  

z

VW 408 A Press tool 

1st and 2nd gear selector segments with changed synchronization. See Changed springs 
for 5th gear synchronizer from transmission manufacture date November 11 01

88.4 ... 89.1

3rd/4th gear selector forks

96.0 ... 96.7

(1)

For dimension a, see Fig. 81 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 82: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VW 421 Tube  

z

VW 454 Press piece  

z

VW 447 i Thrust plate  

z

VW510 Press piece  

z

41-501 Drift sleeve  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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