Volkswagen New Beetle. Manual - part 2476

 

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Volkswagen New Beetle. Manual - part 2476

 

 

Fig. 140: Checking Synchro-Ring 1st Gear And Outer Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 141: Assembling Locking Collar And Locking Pieces With 1st And 2nd Gear Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

With introduction of the modified 1st gear synchronizer the shoulder has the same width on both sides of 
synchro-hub. 

The shoulder has a chamfer on one side (arrow B). 

After assembly the shoulder of the synchro-hub and the outer splines of the locking collar (arrow A) face same 
direction. 

Recesses for locking pieces on synchro-hub and locking collar (arrow C) must align one over another. 

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

The locking collar splines (arrow) point to splines for 3rd/4th gear synchro-hub -A-. 

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Remove the 1st gear synchro-hub as described and install again. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 142: Identifying Installation Position Of Locking Collar/Synchro-Hub 1st And 2nd Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

OUTPUT SHAFT, ADJUSTING 

(Determining shim for output shaft) 

Special tools and equipment 

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VW 387 Universal dial gauge bracket  

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VW 385/17 End measuring plate  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2474  2475  2476  2477   ..