Volkswagen New Beetle. Manual - part 2472

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  2470  2471  2472  2473   ..

 

 

Volkswagen New Beetle. Manual - part 2472

 

 

Fig. 125: Checking 2nd Gear Synchro-Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

2ND GEAR SYNCHRO-RING GAP DIMENSIONS WEAR LIMIT 

Gap "a"

New dimension

Wear limit

2nd gear

1.2 ... 1.8 mm

0.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Installation position outer-ring 

Fig. 126: Installation position outer-ring 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The lugs (arrows) face to 1st gear -A- 

Checking inner ring for wear 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 127: Checking 2nd Gear Synchro-Ring Inner Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press inner ring onto 2nd gear wheel cone and measure gap "a" with a feeler gauge. 

2ND GEAR SYNCHRO INNER RING GAP DIMENSIONS WEAR LIMIT 

Installation position synchro-ring (inner-ring) 

Gap "a"

New dimension

Wear limit

2nd gear

0.75 ... 1.25 mm

0.3 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 128: Identifying Installation Position Synchro-Ring (Inner-Ring) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The lugs (arrow -1-) locate in the recesses (arrow -2-) in the synchro-ring -B-. 

Installation position 2nd gear wheel 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2470  2471  2472  2473   ..