New Beetle L4-2.0L (AZG) (2003)
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Pressing off, Refer to Fig 8
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Pressing on, Refer to Fig 9
6- Output shaft
7- Needle roller bearing
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For 2nd gear
8- 2nd gear
9- Synchro-ring
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(Inner ring for 2nd gear)
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Checking for wear, Refer to Fig. 10
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Check lugs for scoring
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Installation position, Refer to Fig. 12
10- 2nd gear outer ring
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Insert in the synchro-ring (item -9-)
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Replace if scored
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Installation position, Refer to Fig. 12
11- 2nd gear synchro-ring
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Checking for wear, Refer to Fig. 11
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Installation position - Fig. 12
12- 1st and 2nd gear locking collar with synchro-hub
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Pull off over bearing support after removing securing clip (item 13)
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Disassembling, Refer to Fig. 13
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Assembling locking collar/synchro hub, Refer to Fig. 13 and - Fig. 14
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Installation position, Refer to Fig. 15
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Pressing on, Refer to Fig. 16
13- Securing clip
14- 1st gear synchro-ring
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Checking for wear, Refer to Fig. 11
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Assemble so that recesses locate in locking collar (item -12 -) locking pieces
15
-1st gear outer ring
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Insert in the synchro-ring (item -11-), installation position , Refer to Fig. 17
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Replace if scored
16- Synchro-ring
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(1st gear inner ring)
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Checking for wear, Refer to Fig. 10
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Check lugs for scoring
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Installation position, Refer to Fig. 18
17- Needle roller bearing
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For1st gear
18- 1st selector gear
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Installation position, Refer to Fig. 19
19- Thrust washer
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For 1st and 4th gear
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Insert lugs on thrust washer in holes on output shaft
20- Shim
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Holds thrust washer (-item 19 -) in position on output shaft
21- Needle roller bearing
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For 4th gear
22- Selector gear for 4th gear
23- 4th gear synchro-ring
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Checking for wear, Refer to Fig. 22
24- Locking collar with 3rd and 4th gear synchro-hub
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Pull off by pulling off 4th gear wheel after removing the circlip (item -25-)
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Disassembling, Refer to Fig. 13
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Installation position locking
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collar/synchrohub, Refer to Fig. 20
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Assembling locking collar/synchro hub, Refer to Fig. 13 and Fig. 14
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Pressing on, Refer to Fig. 21
25- Securing clip
26- 3rd gear synchro-ring
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Checking for wear, Refer to Fig. 11
27- Outer ring for 3rd gear
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Insert in the synchro-ring (item - 26 -), installation position, Refer to Fig. 17
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Replace if scored
28- Synchro-ring
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(3rd gear inner ring)
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Checking for wear, Refer to Fig. 10
