Volkswagen New Beetle. Manual - part 2434

Fig. 4: Identifying Transmission Layout (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Gear ratios 

I - 1st gear  

NOTE:

The following list refers to items in Fig. 5 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

II - 2nd gear  

III - 3rd gear  

IV - 4th gear  

V - 5th gear  

R - Reverse gear  

A - Final drive  

T - Speedometer drive  

Arrows point in direction of travel 

Fig. 5: Identifying Transmission Layout (2 Of 2)

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

CALCULATING OVERALL RATIO "I" 

Example: 

CALCULATING OVERALL RATIO "i" (EXAMPLE) 

i= Z

2

 "DIVIDE" Z

1

1

 )

 

I

G

 =Gear ratio = ZG

2

 / ZG

1

 =36 / 43 = 0.837

 

I

A

 = Final drive ratio = ZA

2

 / ZA

1

 = 72 / 17 = 4.235

 

i = Total ratio 

= I

G

 x I

A

 = 0.837 x 4.235 = 3.545

 

1)

 Z

1

 = No. of teeth driving gear, Z

2

 = No. of teeth driven gear

 

GENERAL REPAIR INSTRUCTIONS 

To ensure perfect transmission repairs, the greatest care and cleanliness as well as the use of good and proper 
tools is essential. Obviously, the basis rules for safety are also applicable during repair work. 

A number of generally valid instructions applicable for the various repair procedures - which were previously 
repeated a number of times at numerous places in the Repair Manual - are summarized here. They apply to this 
Repair Manual. 

Transmission 

z

When installing make sure that the dowel sleeves between the engine and transmission are correctly 
located.  

z

When changing a transmission fill with gear oil to the lower edge of the filler hole.  

z

Capacities and specifications. See CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, 
CAPACITIES .  

Gear

5th gear

Final drive

Driving gear

ZG

1

 = 43

ZA

1

 = 17

Driven gear

ZG

2

 = 36

ZA

2

 = 72

NOTE:

z

If the oil level is topped off with the transmission installed, carry out oil 
level check as follows:  

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Gaskets, sealing rings 

z

Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.  

z

Apply sealant uniformly but not too thick.  

z

Replace "O-rings".  

z

Radial shaft oil seals.  

Before installation: 

z

Lightly oil outer edge, fill space between sealing lips -arrow-with grease G 052 128 A1. 

z

Fill with oil to the lower edge of the filler hole and install filler plug. Start 
the engine, engage a gear and allow transmission to turn for approx. 2 
minutes. Switch off engine and again top off oil to lower edge of filler hole. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle