Volkswagen New Beetle. Manual - part 2475

 

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Volkswagen New Beetle. Manual - part 2475

 

 

Fig. 137: Pressing On Sleeve For Output Shaft Needle Roller Bearing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The following components have been added or modified:

 

2003 Volkswagen New Beetle GLS 

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

  

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A- Inner ring  

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B- Outer ring  

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C- Synchro-ring 

with additional recesses -4- for the lugs -1- of inner ring -A-. 

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1st gear wheel  

with additional recesses -3- for the lugs -2- of outer ring -B-. 

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If the components should not be replaced, ensure they are reallocated to the original gear .  

Installation position of inner ring, outer ring and synchro-ring 1st gear: 

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Place inner ring -A- on 1st gear wheel. 

Angled lugs (arrow 1) point toward outer ring -B-. 

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Install outer ring -B-. 

Lugs (arrow 2) engage in gear wheel recesses (arrow 3). 

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Install synchro-ring -C-. 

The recesses (arrow 4) engage in lugs (arrow 1) of inner ring -A-.

NOTE:

For the 2nd gear the same inner ring, outer ring and synchro ring are installed.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 138: Identifying Installation Position Of Inner Ring, Outer Ring And Synchro-Ring 1st Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Check inner ring 1st gear for wear 

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

INNER RING 1ST GEAR GAP DIMENSIONS WEAR LIMIT 

Gap "a"

New dimension

Wear limit

1st 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. 139: Checking Inner Ring 1st Gear For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Check synchro-ring 1st gear and outer ring for wear 

z

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

SYNCHRO-RING 1ST GEAR AND OUTER RING GAP DIMENSIONS WEAR LIMIT 

Gap "a"

New dimension

Wear limit

1st gear

1.2 ... 1.8 mm

0.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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