Volkswagen New Beetle. Manual - part 2353

1998-2004 CLUTCHES 

New Beetle (5-Speed, 02J) 

IDENTIFICATION 

On 02J transmission identification tag is located on transmission, identifying code letters and date of 
manufacture (1), and transmission model (2). See Fig. 1 .  

Fig. 1: Locating Identification Tag 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

DESCRIPTION & OPERATION

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

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Clutch is a single-disc type, using a diaphragm spring to engage pressure plate. Clutch is hydraulically 
controlled by master cylinder, slave cylinder, release lever and pre-lubricated release bearing. Clutch master 
cylinder is supplied fluid from brake master cylinder fluid reservoir. On some models, a dual mass flywheel is 
used. Note changes in torque specifications for pressure plate.  

BLEEDING 

Connect brake filler/bleeder unit (VAG 5234), or equivalent. Attach hose (A) to bleeder fitting located on clutch 
slave cylinder (B), next to hydraulic line. See Fig. 2 . Open bleed valve. Turn bleed unit on. Depress clutch 
pedal several times, after completion of bleeding process.  

Fig. 2: Connecting Bleed Hose To Bleeder Valve 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Fill brake master cylinder reservoir with DOT 4 brake fluid. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

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© 2004 Mitchell Repair Information Company, LLC. 

ADJUSTMENTS 

BRAKE LIGHT SWITCH 

For servicing purposes, they will be referred to as "old style" and "new style". It is important to identify which 
style of switch is installed, prior to servicing, as each requires specific removal and installation (replacement) 
procedures. See Fig. 3 .  

"Old style" switch is identified by a large (approximately 10 mm) plunger tip button, and a square plunger shaft. 
"New style" switch is identified by a small (approximately 4 mm) plunger tip without a button, and round 
plunger shaft. "Old style" switches can be removed and reinstalled/adjusted. "New style" switch must NOT be 
reused after removal. Always replace. Should a brake light switch require replacement, only a specific "new 
style" switch is available (supersedes all previous part number versions). This switch requires critical 
procedures be followed, prior to and during installation.  

NOTE:

Two different styles of brake light switch were used in production. 

NOTE:

On diesel and gasoline models equipped with cruise control, brake switch and 
brake pedal switch are integrated. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:01 AM

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© 2004 Mitchell Repair Information Company, LLC. 

Fig. 3: Identifying "New Style" & "Old Style" Brake Switches 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Brake Light Switch (Old Style) 

1. Remove driver's side lower instrument panel cover. Disconnect brake light switch harness connector. 

Turn switch counterclockwise 90 degrees. Pull switch out from retainer mounting hole. See Fig. 4 .  

2. Pull plunger out completely. Depress and hold brake pedal in down position. Note orientation of retainer 

tabs on switch, and carefully insert switch into retainer mounting hole. Secure switch, by turning 
clockwise 90 degrees. Slowly release brake pedal to stop. Connect brake light switch harness connector. 
Check function of brake light switch. 

NOTE:

The following applies only to an existing, functional "old style" switch that is 
removed, reinstalled/adjusted. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:01 AM

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© 2004 Mitchell Repair Information Company, LLC.