Beetle L4-2.0L (AEG) (2000)
13
1st: gear synchronizer ring
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Checking for wear refer to Fig. 9
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Identification refer to Fig. 14
14
1st and 2nd gear operating sleeve with synchronizer hub
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Pull off with bearing support after removing circlip (item 15) Fig. 6
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Disassembling refer to Fig. 10
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Assembling operating sleeve/ synchronizer hub refer to Fig. 10 and Fig. 11
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Installation position refer to Fig. 12
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Pressing on refer to Fig. 13
15
Circlip
16
2nd gear synchronizer ring
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Identification refer to Fig. 14
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Checking for wear refer to Fig. 16
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Assemble so that the recesses locate in the operating sleeve (item 14) locking pieces
17
Outer ring
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Insert in synchronizer ring (item 16), installation position refer to Fig. 17
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Replace if scored
18
Synchronizer ring
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(Inner ring)
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Checking for wear refer to Fig. 18
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Check lugs for scoring
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Installation position refer to Fig. 19
19
2nd gear
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Installation position refer to Fig. 20
20
Needle roller bearing
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For 2nd gear
21
Thrust washer
22
Sleeve for 3rd gear needle roller bearing
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Pressing off with 2nd gear refer to Fig. 5
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Pressing on refer to Fig. 21
23
Needle roller bearing
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For 3rd gear
24
3rd gear
25
3rd gear synchronizer ring
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Checking for wear refer to Fig. 9
26
Operating sleeve with 3rd and 4th gear synchronizer hub
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Press off with 2nd gear (item 19) and 3rd gear (item 24) refer to Fig. 5
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Disassembling refer to Fig. 22
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Installation position of operating sleeve/synchronizer hub Fig. 24
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Assembling operating sleeve/ synchronizer hub refer to Fig. 22 and Fig. 23
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Pressing on refer to Fig. 25
27
Sleeve
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For needle roller bearing
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Press off with operating sleeve and 3rd and 4th gear synchronizer hub (item 26) refer to Fig. 5
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Pressing on refer to Fig. 26
28
Needle roller bearing
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For 4th gear
29
4th gear synchronizer ring
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Checking for wear refer to Fig. 9
30
4th gear
31
Thrust washer
32
Needle roller bearing
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For output shaft
33
Transmission housing
34
Sleeve
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For output shaft needle roller bearing
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Pressing off refer to Fig. 5
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Pressing on refer to Fig. 27
35
5th gear
36
Dished washer
37
Torx socket-head bolt
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80 Nm (59 ft. lbs.)
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M10
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Bolt head holds dished washer in position
Fig. 1 Pulling out small tapered roller bearing outer race