Volkswagen New Beetle. Manual - part 2504

 

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Volkswagen New Beetle. Manual - part 2504

 

 

Fig. 44: Adjusting 5th Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar 

 

2003 Volkswagen New Beetle GLS 

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

  

and gearwheel. If necessary repeat adjustment. 

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Disengage 5th gear. Locking collar must now be in neutral position. Synchro-ring must move freely.  

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Select all gears.  

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Install transmission housing cover  

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

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 45: Installing Flange Shafts 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

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Install release bearing guide sleeve. See CLUTCH RELEASE BEARING .  

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Install clutch release lever and release bearing. See CLUTCH RELEASE BEARING .  

TRANSMISSION HOUSING AND CLUTCH HOUSING, SERVICING 

Special Tools And Equipment 

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VW 295 Drift  

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VW 295a Adapter  

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VW 447 H Press plate  

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VW512 Press disk  

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2040 Tube  

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VW 454 Press piece 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2502  2503  2504  2505   ..