Volkswagen New Beetle. Manual - part 2530

 

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Volkswagen New Beetle. Manual - part 2530

 

 

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Identifying 1st and 2nd gear synchro-rings 

Fig. 123: Identifying 1st And 2nd Gear Synchro-Rings 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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1st gear synchro-ring: 3 x 1/2 ground-down half teeth (arrow)  

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2nd gear synchro-ring: 3x1/2 ground down half teeth (arrow) or 2 ground-down half teeth 

Only the version with 2x1/2 ground-down half teeth is available as a spare part for the 2nd gear synchro-
ring. 

Distinguishing 1st and 2nd gear synchro-rings 

NOTE:

Before pressing on, place 1st gear synchro-ring on 1st gear wheel.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 124: Distinguishing 1st And 2nd Gear Synchro-Rings 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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1st gear synchro-ring - no recesses  

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2nd gear synchro-ring - three recesses (arrows)  

Checking 2nd gear synchro-ring for wear 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 125: Checking 2nd Gear Synchro-Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

2ND GEAR SYNCHRO-RING GAP DIMENSIONS WEAR LIMIT 

Gap "a"

New dimension

Wear limit

2nd gear

1.2 ... 1.8 mm

0.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Installation position outer-ring 

Fig. 126: Installation position outer-ring 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The lugs (arrows) face to 1st gear -A- 

Checking inner ring for wear 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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