Volkswagen New Beetle. Manual - part 2528

 

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Volkswagen New Beetle. Manual - part 2528

 

 

Fig. 115: Pulling Off Locking Collar With Synchro-Hub And Bearing Support 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

First remove the circlip -arrow-.  

Pulling off large tapered roller bearing inner race 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 116: Pulling Off Large Tapered Roller Bearing Inner Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

A. Vice clamps 

 

2003 Volkswagen New Beetle GLS 

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

  

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Before installing puller insert a M 10 x 20 hex bolt in output shaft drilling.  

Pressing on large tapered roller bearing inner race 

Fig. 117: Pressing On Large Tapered Roller Bearing Inner Race 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

A. Thrust washer 

 

2003 Volkswagen New Beetle GLS 

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

  

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Install thrust washer before pressing on inner race. Shoulder faces inner race.  

Checking synchro-ring for wear 

Fig. 118: Checking Synchro-Ring For Wear (Output Shaft) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Press synchro-ring onto gear wheel cone and measure gap "a" with feeler gauge. 

SYNCHRO-RING GAP DIMENSIONS WEAR LIMIT (OUTPUT SHAFT) 

Gap "a"

New dimension

Wear limit

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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