Volkswagen New Beetle. Manual - part 2470

 

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Volkswagen New Beetle. Manual - part 2470

 

 

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Before installing puller insert a M 10 x 20 hex bolt in output shaft drilling.  

Pressing on large tapered roller bearing inner race 

Fig. 117: Pressing On Large Tapered Roller Bearing Inner Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

A. Thrust washer 

 

2003 Volkswagen New Beetle GLS 

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

  

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Install thrust washer before pressing on inner race. Shoulder faces inner race.  

Checking synchro-ring for wear 

Fig. 118: Checking Synchro-Ring For Wear (Output Shaft) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press synchro-ring onto gear wheel cone and measure gap "a" with feeler gauge. 

SYNCHRO-RING GAP DIMENSIONS WEAR LIMIT (OUTPUT SHAFT) 

Gap "a"

New dimension

Wear limit

 

2003 Volkswagen New Beetle GLS 

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

  

Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub 

1st gear

1.0 ... 1.7 mm

0.5 mm

3rd gear

1.0 ... 1.7 mm

4th gear

1.0 ... 1.7 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 119: Disassembling And Assembling 1st And 2nd Gear Locking Collar And Synchro-Hub
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

1. Spring  

2. Locking collar  

3. Synchro-hub  

4. Locking piece 

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Slide locking collar over synchro-hub. 

The wide shoulder of the synchro-hub (arrow -A-) and the outer splines of the locking collar (arrow 
-B-) face opposite directions after assembly. Recesses for locking pieces on synchro-hub and 
locking collar must align. 

Assembling 1st and 2nd gear locking collar/synchro-hub 

Fig. 120: Assembling 1st And 2nd Gear Locking Collar/Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Locking collar is pushed over synchro-hub. 

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Insert locking pieces and install springs 120° off-set. The angled end of spring must locate in 
hollow locking piece.  

Installation position 1st and 2nd gear locking collar/synchro-hub 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2468  2469  2470  2471   ..