Volkswagen New Beetle. Manual - part 2459

 

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Volkswagen New Beetle. Manual - part 2459

 

 

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3-Kukko 17/1 Separating device 

Fig. 83: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

1. Clutch housing  

2. Tapered roller bearing outer race 

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Removing. See Pressing out tapered roller bearing outer race  

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Pressing in. See Pressing in tapered roller bearing outer race  

3. Tapered roller bearing inner race 

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Pressing off. See Pressing off tapered roller bearing inner race .  

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Pressing on Pressing on tapered roller bearing inner race .  

4. Input shaft 

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Adjusting. See INPUT SHAFT, ADJUSTING  

5. 3rd gear wheel 

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Shoulder points to 4th gear  

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Pressing off. See Pressing off 4th gear wheel with tapered roller bearing and sleeve  

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Pressing on Pressing on 3rd gear wheel  

6. Circlip 

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Always replace  

7. 4th gear wheel 

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Press off with tapered roller bearing inner race and sleeve. See Pressing off 4th gear wheel with 
tapered roller bearing and sleeve
  

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Pressing on Pressing on 4th gear wheel  

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Collar faces to 3rd gear  

8. Tapered roller bearing inner race 

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Pressing off with 4th gear wheel and sleeve. See Pressing off 4th gear wheel with tapered roller 
bearing and sleeve
  

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Pressing on Pressing on tapered roller bearing inner race  

9. Thrust washer  

10. Tapered roller bearing outer race 

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Pressing out Pressing out tapered roller bearing outer race  

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Pressing in. See Pressing in tapered roller bearing outer race  

11. Shim 

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Determining thickness adjusting input shaft. See INPUT SHAFT, ADJUSTING  

NOTE:

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When installing new gear wheels, consult technical data. See Code letters, 
transmission application, ratios, capacities .  

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If the position of the tapered roller bearings is affected when exchanging 
parts, the input shaft must be readjusted. See adjustment overview. See 
Adjustment overview .  

NOTE:

The following list refers to items in Fig. 84 .

 

2003 Volkswagen New Beetle GLS 

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

  

12. Transmission housing  

13. Sleeve 

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For needle roller bearing  

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Press off with 4th gear wheel and tapered roller bearing inner race. See Pressing off 4th gear 
wheel with tapered roller bearing and sleeve
  

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Pressing on Pressing on tapered roller bearing inner race  

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Place thrust washer on before installing (item 9)  

14. Needle roller bearing  

15. 5th gear wheel 

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Pull off together with 5th gear synchro-hub. See Assembly sequence  

16. 5th gear synchro-ring 

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

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Check for wear. See Checking 5th gear synchro-ring  

17. Spring 

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Installation position. See Assembling 5th gear locking collar/synchro-hub  

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From transmission manufacture date November 05 01 the spring was changed. See CHANGED 
SPRINGS FOR 5TH GEAR SYNCHRONIZER FROM TRANSMISSION MANUFACTURE 
DATE NOVEMBER 11 01
  

18. Lock pieces (Qty. 3) 

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Installation position. See 5th gear synchronizer  

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From transmission manufacture date March 05 01 are lock pieces installed, which are inner hollow 

19. 5th gear synchro-hub 

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Removing and installing. See Assembly sequence  

20. 5th gear locking collar 

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Removing and installing. See Assembly sequence  

21. Dished washer 

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

22. Torx socket head bolt M 10, 80 N.m 

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Installed piece on bolt head locates dished spring. See Installation position of dished spring for 
gear wheel and 5th gear synchro-hub securing bolts:

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 84: Disassembling Input Shaft Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pressing out tapered roller bearing outer race 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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