Volkswagen New Beetle. Manual - part 2515

 

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Volkswagen New Beetle. Manual - part 2515

 

 

Fig. 74: Disassembling Selector Fork Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Identifying Selector Segments 

Fig. 75: Identifying Selector Segments 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

1. 1st and 2nd gear selector segments = 12.1 mm 

1st and 2nd gear selector segments with changed synchronization = 11.4 mm. See Changed springs for 
5th gear synchronizer from transmission manufacture date November 11 01
 

The shorter selector segments can be installed in previous transmissions. 

2. 3rd and 4th gear selector segments = 7.7 mm  

3. 5th gear selector segments = 12.1 mm  

Removing circlip 

Fig. 76: Removing Circlip 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Tighten selector fork into screwed stick with the vice clamps -B-.  

z

Pry circlip in direction of arrow -A-.  

Installing circlip 

Fig. 77: Installing Circlip 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press circlip into selector segment groove with socket.  

A. Socket driver, 10 mm A/F  

B. Vice clamps  

Removing bearing inner race 

NOTE:

After installing the circlip the selector segment must rotate freely.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2513  2514  2515  2516   ..