Volkswagen New Beetle. Manual - part 96

 

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Volkswagen New Beetle. Manual - part 96

 

 

FLYWHEELS 

Flywheels 

NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic 
system which DOES NOT affect the rubber parts, the required service is to flush and fill 
with the correct hydraulic fluid. (Code B) 

Exceeding service interval 

3 

Suggest replacement. 

Hydraulic fluid incorrect 

B 

Require service. See note below. 

NOTE: If a fluid other than specification hydraulic fluid is present in the hydraulic 
system, the required service is to flush and fill with the correct hydraulic fluid. 

Level incorrect 

B 

Require correction of fluid level. 

Near service interval 

3 

Suggest replacement. 

Rubber master cylinder cover gasket distorted 
and gummy 

A 

Require service. See note below. 

NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic 
system which DOES affect the rubber parts, the required service is to: 1) remove all 
components having rubber parts from the system, 2) flush lines with denatured alcohol 
or hydraulic cleaner, 3) repair or replace all components having rubber parts, and 4) 
bleed and flush with correct hydraulic fluid. 

Varnished 

Further inspection required. See 

note below. 

Note: Fluid that is varnished may indicate a serious problem. Determine and correct the 
cause. 

NOTE:

Clutch disc replacement does not necessitate flywheel reconditioning, unless 
other conditions justify the reason to do so. 

Condition 

Code 

Procedure 

Attaching hardware broken 

A 

Require repair or replacement of 

hardware. 

Attaching hardware missing 

C 

Require replacement of hardware. 

Attaching hardware not functioning 

A 

Require repair or replacement of 

hardware. 

Cracked (other than mounting area) 

A 

Require resurfacing or 

replacement. See note below. 

NOTE: Some manufacturers allow slight surface cracking in the friction surface. 

Cracks in mounting area 

B 

Require replacement. 

Hard spots 

B 

Require repair or replacement. 

Ring gear broken 

A 

Require replacement of ring gear . 

Ring gear teeth worn, affecting performance 

A 

Require replacement of ring gear. 

Runout exceeds specifications 

B 

Require repair or replacement. 

Scored 

B 

Require repair or replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards DRIVE TRAIN AND TRANSMISSION

  

FORCE MOTORS 

See Actuators (Electrical).  

GUIDES 

See Dowel Pins, Guides, and Pilot Holes.  

HALF SHAFTS 

See Drive Shafts and Half Shafts  

HOSES, LINES, AND TUBES 

Hoses, Lines, and Tubes 

Surface cracks after resurfacing to 
manufacturer's minimum specifications 

B 

Require replacement. 

Wear exceeds specifications 

B 

Require replacement. 

Worn, not affecting performance, but close to 
the end of its useful life 

1 

Suggest repair or replacement. 

Worn, affecting performance 

A 

Require repair or replacement. 

Threads damaged 

A 

Require repair or replacement. 

Threads stripped (threads missing) 

A 

Require replacement. 

Condition 

Code 

Procedure 

Application incorrect 

B 

Require replacement. 

Connected incorrectly 

A 

Require repair. 

Corroded, not reusable 

1 

Suggest replacement. 

Cracked line or tube 

A 

Require replacement. 

Surface cracked (weather-checked) 

1 

Suggest repair or 

replacement. 

Hard hose 

1 

Suggest replacement. 

Inner fabric (webbing) damaged 

A 

Require replacement. 

Insufficient clamping force, allowing hose to leak 

A 

Require repair or 

replacement. 

Leaking 

A 

Require repair or 

replacement. 

Maintenance intervals 

3 

Suggest replacement. 

Melted 

1 

Suggest repair or 

replacement. 

Missing 

C 

Require replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards DRIVE TRAIN AND TRANSMISSION

  

HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY) 

Housings (Bell, Case, Tail (Extension) and Auxiliary) 

INTERMEDIATE SHAFT SUPPORT BEARINGS 

Intermediate Shaft Support Bearings 

Outer covering damaged 

1 

Suggest replacement. 

Outer covering damaged to the extent that the inner 
fabric is visible 

A 

Require replacement. 

Protective sleeves damaged 

2 

Suggest replacement of 

sleeves. 

Protective sleeves missing 

2 

Suggest replacement of 

sleeves. 

Restricted, affecting performance 

A 

Require repair or 

replacement. 

Restricted, not affecting performance 

2 

Suggest repair or 

replacement. 

Routed incorrectly 

2 

Suggest replacement. 

Safety clip missing 

C 

Require replacement. 

Spongy 

1 

Suggest repair or 

replacement. 

Stripped 

A 

Require replacement. 

Swollen 

B 

Require replacement. 

Threads damaged 

A 

Require repair or 

replacement. 

Threads stripped (threads missing) 

A 

Require replacement. 

Type incorrect 

1 

Suggest repair or 

replacement. 

Condition 

Code 

Procedure 

Bearing race loose in bore 

A 

Require repair or replacement. 

Broken, affecting performance 

A 

Require repair or replacement. 

Cracked 

A 

Require repair or replacement. 

Dowel pin holes worn, affecting performance 

See Dowel Pins, Guides, and Pilot 

Holes. 

Machined surfaces damaged, affecting 
performance 

A 

Require repair or replacement. 

Threads damaged 

A 

Require repair or replacement. 

Threads stripped (threads missing) 

A 

Require replacement. 

Worn, affecting performance 

A 

Require repair or replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards DRIVE TRAIN AND TRANSMISSION

  

KEY INTERLOCK SYSTEMS 

See Shift Interlock Systems (Selector and Key Interlock Systems). 

Condition 

Code 

Procedure 

Attaching hardware broken 

A 

Require repair or 

replacement of hardware. 

Attaching hardware missing 

C 

Require replacement of 

hardware. 

Attaching hardware not functioning 

A 

Require repair or 

replacement of hardware. 

Bearing rollers, balls or races are worn, pitted, noisy, 
or feel rough when rotated as an assembly 

A 

Require replacement of 

bearing assembly. 

Bracket bent, affecting performance 

A 

Require repair or 

replacement. 

Bracket bent, not affecting performance 

No service suggested or 

required. 

Bracket broken, affecting performance 

A 

Require replacement. 

Bracket broken, not affecting performance 

2 

Suggest repair or 

replacement of bracket. 

Bracket corroded, affecting performance 

A 

Require repair or 

replacement. 

Bracket corroded, not affecting performance 

2 

Suggest repair or 

replacement. 

Bracket cracked, affecting performance 

A 

Require repair or 

replacement. 

Bracket cracked, not affecting performance 

1 

Suggest repair or 

replacement. 

Bracket holes elongated, affecting performance 

A 

Require repair or 

replacement. 

Bracket holes elongated, not affecting performances) 

No service suggested or 

required. 

Bracket loose, affecting performance 

A 

Require repair or 

replacement. 

Bracket loose, not affecting performance 

1 

Suggest repair or 

replacement. 

Bracket missing 

C 

Require replacement. 

Cracked 

A 

Require replacement. 

Rough (brinelling, spalling) 

A 

Require replacement. 

Rubber deteriorated, affecting performance 

A 

Require replacement. 

Seized 

A 

Require replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards DRIVE TRAIN AND TRANSMISSION

  

 

 

 

 

 

 

 

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