Volkswagen New Beetle. Manual - part 2534

 

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Volkswagen New Beetle. Manual - part 2534

 

 

Fig. 138: Identifying Installation Position Of Inner Ring, Outer Ring And Synchro-Ring 1st Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Check inner ring 1st gear for wear 

z

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

INNER RING 1ST GEAR GAP DIMENSIONS WEAR LIMIT 

Gap "a"

New dimension

Wear limit

1st gear

0.75 ... 1.25 mm

0.3 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 139: Checking Inner Ring 1st Gear For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Check synchro-ring 1st gear and outer ring for wear 

z

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

SYNCHRO-RING 1ST GEAR AND OUTER RING GAP DIMENSIONS WEAR LIMIT 

Gap "a"

New dimension

Wear limit

1st gear

1.2 ... 1.8 mm

0.5 mm

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 140: Checking Synchro-Ring 1st Gear And Outer Ring For Wear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Assembling locking collar and locking pieces with 1st and 2nd gear synchro-hub

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 141: Assembling Locking Collar And Locking Pieces With 1st And 2nd Gear Synchro-Hub 
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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