Volkswagen New Beetle. Manual - part 2494

 

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Volkswagen New Beetle. Manual - part 2494

 

 

stages in a diagonal sequence.  

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Tightening torques as specified are for unoiled bolts and nuts.  

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Replace self-locking bolts and nuts.  

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Make sure with threaded connections that the areas of the contact surfaces as well as the visible surfaces 
of nuts and bolts are rewaxed after assembly.  

Bearings 

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Install new tapered roller bearings as supplied and do not lubricate.  

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Install needle bearings with lettered side (thicker metal) toward installing tool.  

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Tapered roller bearings installed to one shaft must be replaced as a set. Use same make of bearings.  

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Heat inner races to approx. 100 °C before installing.  

Shims 

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Measure shims at several points with a micrometer. Tolerance variations make it possible to find the 
exact shim thickness required.  

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Check for burrs and damage.  

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Only install perfect shims.  

Synchronizer rings 

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Do not interchange. When reusing always install to the same gear.  

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Check for wear and replace if necessary.  

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Coat with gear oil before installing.  

Gear wheels 

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Before installing clean and heat on a hot plate to approx. 100° C.  

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Temperature can be checked with temperature tester V.A.G 1558.  

MANUAL TRANSMISSION - CONTROLS, HOUSING 

TRANSMISSION, DISASSEMBLING AND ASSEMBLING 

Transmission overview 

1. 1st gear  

2. 2nd gear  

3. 3rd gear  

4. 4th gear  

NOTE:

The following list refers to items in Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

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

  

5. 5th gear  

6. Transmission housing 

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Servicing. See TRANSMISSION HOUSING AND CLUTCH HOUSING, SERVICING  

7. Selector mechanism 

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(Selector forks)  

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Disassembling and assembling. See SELECTOR FORKS, DISASSEMBLING AND 
ASSEMBLING
  

8. Input gear for 1st and reverse gear  

9. Input shaft 

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Disassembling and assembling. See INPUT SHAFT, DISASSEMBLING AND ASSEMBLING  

10. Output shaft 

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Disassembling and assembling. See Output shaft, disassembling and assembling  

11. Differential 

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Disassembling and assembling. See Differential, disassembling and assembling  

12. Clutch housing 

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Servicing. See TRANSMISSION HOUSING AND CLUTCH HOUSING, SERVICING

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 8: Sectional View Of O2J Transmission 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Assembly overview 

I. Removing and installing cover for transmission housing and 5th gear. See COVER FOR 

TRANSMISSION HOUSING AND 5TH GEAR, REMOVING AND INSTALLING  

II. Disassembling and assembling transmission housing and shift mechanism. See TRANSMISSION 

HOUSING AND SELECTOR MECHANISM, REMOVING AND INSTALLING  

III. Disassembling and assembling input shaft, output shaft, differential and selector forks. See INPUT 

NOTE:

The following list refers to items in Fig. 9 .

 

2003 Volkswagen New Beetle GLS 

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

  

SHAFT, OUTPUT SHAFT (PINION SHAFT), DIFFERENTIAL AND SELECTOR FORKS, 
REMOVING AND INSTALLING
 

Fig. 9: Identifying Assembly Overview 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Cover for transmission housing and 5th gear, removing and installing 

1. Hex bolt, 10 N.m 

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For transmission housing cover  

2. Transmission housing cover 

NOTE:

The following list refers to items in Fig. 10 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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