New Beetle L4-2.0L (AZG) (2003)
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Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.
Fig. 12 Installation position of outer ring, inner ring and 2nd gear synchro ring
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Place inner ring -A- on 2nd gear wheel.
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Angled lugs (arrow -1-) point toward outer ring -B-.
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Fit outer ring -B-.
Lugs (arrow -2-) engage in gear wheel recesses (arrow 3).
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Fit synchro-ring -C-.
The recesses (arrow -4-) engage in lugs (arrow -1-) of inner ring -A-.
Fig. 13 Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub
1- Spring
2- Locking piece
3- Locking collar
4- Synchro-hub
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Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub and locking collar must align.