Volkswagen New Beetle. Manual - part 2497

 

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Volkswagen New Beetle. Manual - part 2497

 

 

z

Remove transmission housing cover (arrow). 

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 15: Removing Transmission Housing Cover
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Remove 5th gear selector fork (arrow) 

Fig. 16: Removing 5th Gear Selector Fork 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove spring for locking piece.  

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Remove locking collar and take off locking piece.  

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Slide locking collar, without selector fork, over synchro-hub again.  

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Remove bolts -A- for synchro-hub and 5th gear, to do this select 5th (arrow -1-) and 1st gear (arrows -2- 
and -3-). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 17: Removing Synchro-Hub And 5th Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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After engaging both gears input shaft and output shaft are locked, synchro-hub and gear wheel cannot 
turn. Both bolts can now be loosened.  

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Take off locking collar.  

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Pull off synchro-hub and 5th gear wheel and remove together with needle roller bearing. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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