Volkswagen New Beetle. Manual - part 2346

Fig. 43: Removing Cross Support & Heat Shield 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

7. To install, reverse removal procedure. Cable locks have holes for securing onto gear selector lever or 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

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relay lever. Holes in cable locks have various diameters. See Fig. 44 . Cable locks no longer need to be 
replaced following disassembling. 

Fig. 44: Identifying Cable Lock Allocation 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

8. Spread a small quantity of Polyurea grease (G 000 450 02) on pins (arrows) of gear change lever (1) and 

relay lever (2). See Fig. 45 . Always replace securing clips (3 and 4) after disassembling. Secure gear 
selector cable with securing clip (3) and gate selector cable with securing clip (4). 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

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Fig. 45: Installing Gear & Gate Selector Cable Clips 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

9. Adjust selector mechanism. See SELECTOR MECHANISM under ADJUSTMENTS. Tighten bolts 

and nuts to specification. See TORQUE SPECIFICATIONS .  

TRANSMISSION 

Removal 

1. Remove engine cover. Turn ignition switch to OFF position. Disconnect negative battery cable. See 

BATTERY DISCONNECT PRECAUTIONS . 

CAUTION: Turn ignition switch to OFF position. Before disconnecting negative 

battery terminal, obtain anti-theft radio security code. Disconnect negative 
battery terminal. After reconnecting battery, re-code and check operation 
of anti-theft radio. 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

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2. Remove battery and battery carrier. Remove intake hose (1), connector (2) and vacuum hose (3) from 

mass air flow sensor. See Fig. 17 . Remove complete air cleaner assembly housing by removing bolts (4 
and 5). Remove intake hose (1).  

3. Remove cable support bracket from transmission (arrow). See Fig. 46 . 

Fig. 46: Removing Cable Support Bracket 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

4. Pull lock washer (arrow 1) from gate selector cable relay lever (A). See Fig. 47 . Remove gear selector 

cable (B) with transmission selector lever, by removing nut (arrow 2). Remove power steering pipe 
(arrow 3). If necessary, use puller, such as Kukko 20-10. 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:54 AM

Page 48 

© 2004 Mitchell Repair Information Company, LLC.