Volkswagen New Beetle. Manual - part 2526

 

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Volkswagen New Beetle. Manual - part 2526

 

 

z

Checking for wear. See Installation position 1st and 2nd gear locking collar/synchro-hub .  

z

Check lugs for scoring  

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Installation position. See Installation position synchro-ring (inner-ring)  

19. 2nd gear wheel 

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Installation position. See Installation position 2nd gear wheel  

20. Needle roller bearing 

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For 2nd gear  

21. Thrust washer  

22. Sleeve for 3rd gear needle roller bearing 

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Pressing off with 2nd gear wheel. See Pressing off 3rd and 4th gear synchro-hub/locking collar, 
2nd, 3rd and 4th gear wheels with transmission housing needle roller bearing sleeve
  

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Pressing on Pressing on needle roller bearing sleeve for 3rd gear  

23. Needle roller bearing 

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For 3rd gear  

24. 3rd gear wheel  

25. 3rd gear synchro-ring 

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Checking for wear. See Checking synchro-ring for wear  

26. Locking collar with 3rd and 4th gear synchro-hub 

z

Press off with 2nd gear wheel (item 19) and 3rd gear wheel (item 24). See Pressing off 3rd and 
4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with transmission housing 
needle roller bearing sleeve
  

z

Disassembling. See Disassembling and assembling 3rd and 4th gear locking collar and 
synchro-hub
  

z

Installation position locking collar/synchro-hub. See Installation position 3rd and 4th gear 
locking collar/synchro-hub
  

z

Assembling locking collar/synchro-hub. See Disassembling and assembling 3rd and 4th gear 
locking collar and synchro-hub
 and Assembling 3rd and 4th gear locking collar/synchro-hub  

z

Pressing on Pressing on 3rd and 4th gear synchro-hub with locking collar  

27. Sleeve 

z

For needle roller bearing  

z

Press off with locking collar and 3rd and 4th gear synchro-hub (item 26). See Pressing off 3rd and 
4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with transmission housing 
needle roller bearing sleeve
  

z

Pressing on Pressing on sleeve for 4th gear needle roller bearing  

28. Needle roller bearing 

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For 4th gear  

29. 4th gear synchro-ring 

z

Checking for wear. See Checking synchro-ring for wear  

30. 4th gear wheel  

 

2003 Volkswagen New Beetle GLS 

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

  

31. Thrust washer  

32. Needle roller bearing 

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For output shaft  

z

Removing and installing. See Driving out needle roller bearing  

33. Transmission housing  

34. Sleeve 

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For output shaft needle roller bearing  

z

Pressing off. See Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th 
gear wheels with transmission housing needle roller bearing sleeve
  

z

Pressing on Pressing on sleeve for output shaft needle roller bearing  

35. 5th gear wheel 

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Removing and installing. See Assembly sequence  

36. Saucer spring washer 

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

37. Torx socket head bolt M10, 80 N.m 

z

Installed portion on bolt head holds saucer spring washer in position 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 109: Disassembled View Of Output Shaft 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pulling out small tapered roller bearing outer race

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 110: Pulling Out Small Tapered Roller Bearing Outer Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

A. Internal extractor 37 ... 46 mm, e.g. Kukko 21/6  

B. Counter support, e.g. Kukko 22/2  

Pressing in small tapered roller bearing outer race 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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