Volkswagen New Beetle. Manual - part 2535

 

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Volkswagen New Beetle. Manual - part 2535

 

 

With introduction of the modified 1st gear synchronizer the shoulder has the same width on both sides of 
synchro-hub. 

The shoulder has a chamfer on one side (arrow B). 

After assembly the shoulder of the synchro-hub and the outer splines of the locking collar (arrow A) face same 
direction. 

Recesses for locking pieces on synchro-hub and locking collar (arrow C) must align one over another. 

Installation position of locking collar/synchro-hub 1st and 2nd gear 

The locking collar splines (arrow) point to splines for 3rd/4th gear synchro-hub -A-. 

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Remove the 1st gear synchro-hub as described and install again. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 142: Identifying Installation Position Of Locking Collar/Synchro-Hub 1st And 2nd Gear 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

OUTPUT SHAFT, ADJUSTING 

(Determining shim for output shaft) 

Special tools and equipment 

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VW 387 Universal dial gauge bracket  

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VW 385/17 End measuring plate  

 

2003 Volkswagen New Beetle GLS 

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

  

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VW512 Press disk3114/2 Straightening tool  

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VW 407 Press tool  

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V.A.G1331 Torque wrench  

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Measuring dial gauge 

Fig. 143: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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1 - Kukko 21/6 Internal extractor  

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4 - Kukko 22/2 Retainer 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 144: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

It is necessary to readjust the output shaft when the following components are replaced: 

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Final drive  

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Clutch housing 

or 

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Tapered roller bearing 

Adjustment overview. See Adjustment overview 

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Press small tapered roller bearing outer race together with a 0.65 mm thick shim into clutch housing. See 
Output shaft, disassembling and assembling .  

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Insert output shaft and tighten nuts for bearing support to 25 N.m, then turn 90°.  

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Mount dial gauge (3 mm measuring range) and set to "0" with 1 mm preload. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  2533  2534  2535  2536   ..