Volkswagen New Beetle. Manual - part 2503

 

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Volkswagen New Beetle. Manual - part 2503

 

 

Fig. 40: Identifying 5th Gear Synchro-Ring With Cast Locking Pieces 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Drive on 5th gear synchro-hub 

NOTE:

When driving make sure synchro-ring is free to move.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 41: Installing 5th Gear Synchro-Hub 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Screw-in securing bolts for synchro-hub and 5th gear wheel.  

Installation position of dished spring for gear wheel and 5th gear synchro-hub securing bolts: 

The outer diameter (concave side -arrows-) faces 5th gear.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 42: Locating Outer Diameter Concave Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Engage two gears before tightening 5th gear synchro-hub and gear wheel securing bolts (arrows). See 
Fig. 22 .  

z

Install 5th gear selector fork. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 43: Tightening 5th Gear Synchro-Hub And Gear Wheel Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Adjusting 5th gear: 

z

Engage 5th gear. Loosen bolt -1-. Press locking collar and selector fork jaws in direction of (arrow), then 
tighten bolt -1- to 25 N.m. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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