Volkswagen New Beetle. Manual - part 2498

 

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Volkswagen New Beetle. Manual - part 2498

 

 

A. Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.  

B. Hex bolt M10 x 20  

Fig. 18: Removing Synchro-Hub And 5th Gear Wheel With Needle Roller Bearing 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Pull off 5th gear wheel 

A. Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.  

B. Hex bolt M10 x 20  

Sequence for removing: 

z

Install two arm puller and centralize by turning screw (arrow).  

z

Heat gear wheel with hot air blower VAG 1416 and pull off. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 19: Removing 5th Gear Wheel 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove both flange shafts. 

NOTE:

When pulling off the gear wheel make sure that the hooks do not bend 
outward, if necessary tighten screw (arrow). After 5th gear wheel has been 
removed check for damage.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 20: Removing Flange Shafts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Take out flange shafts along with springs, thrust washers and tapered rings.  

z

Remove both reverse shaft support bracket bolts (arrows). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 21: Removing Reverse Shaft Support Bracket 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Transmissions up to 05.99 

z

Remove selector shaft with selector mechanism cover; to do this place selector shaft in neutral position. 
Then remove bolts (arrows) and pull selector shaft out of transmission housing.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2496  2497  2498  2499   ..