Volkswagen New Beetle. Manual - part 2290

 

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Volkswagen New Beetle. Manual - part 2290

 

 

could have effects on gearshift function and quality.

GEAR CHANGE POINT VARIATIONS FOR HILLS 

An additional gear change map automatically selects gear changes for hills dependent upon accelerator pedal 
position and driving speed.  

z

Gear change map for extreme uphill stretches, is matched to engine output.  

z

Gear change map for extreme downhill stretches, is matched to braking effect of the engine.  

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By selecting a gear directly via Tiptronic the engine braking effect can be exploited also with a specific 
gear selected, such as when you have gradients in the trailer mode.  

LUBRICATION & ADJUSTMENTS 

For lubrication and adjustments, see SERVICING - A/T (02E) article in TRANSMISSION SERVICING. 

ON-VEHICLE SERVICE 

AXLE SHAFTS 

For information on axle shaft, see AXLE SHAFTS article in DRIVELINE/AXLES. 

TRANSMISSION COMPONENTS 

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T 
(02E)
 article. 

APPLY & BRAKE CLUTCH APPLICATION 

Manufacturer does not provide specific information for apply and brake clutch application. 

REPAIR INSTRUCTIONS 

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful 
transmission repairs. The usual basic safety precautions naturally also apply when performing servicing work. 

A number of generally valid instructions for various repair procedures, which are mentioned at various points in 
the Repair Manual; are summarized here. 

BATTERY DISCONNECTING & RECONNECTING 

CAUTION: Before beginning repairs on the electrical system: 

z

Obtain anti-theft radio security code.  

 

2003 Volkswagen New Beetle GLS 

2003-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 02E

  

For work steps required after reconnecting battery, see Fig. 3 .

z

Switch off all electrical consumers.  

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Switch ignition off and remove ignition key.  

z

Do not loosen or remove ground strap from body. Disconnect 
terminal from battery only.  

 

2003 Volkswagen New Beetle GLS 

2003-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 02E

  

Fig. 3: Reconnecting Battery Work Steps 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

NOTE:

If desired, print this page and use the table above as a checklist.

 

2003 Volkswagen New Beetle GLS 

2003-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 02E

  

RULES FOR CLEANLINESS WHEN WORKING ON TRANSMISSION

z

Do not run engine or tow vehicle with oil pan removed or without gear oil.  

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Carefully clean all joints and adjacent areas before disconnecting.  

z

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

z

Place parts that have been removed on a clean surface and cover so that they are not soiled. Use sheeting 
and paper. Do not use fluffy cloths!  

z

Only install clean components: Unpack replacement parts immediately prior to installation.  

z

Carefully cover opened components or seal if repairs cannot be carried out immediately.  

O-RINGS, OIL SEALS, GASKETS 

z

Always replace O-rings, oil seals and gaskets.  

z

After removing seals/gaskets, examine the contact surfaces on housings or shafts for burrs and signs of 
damage and repair before reinstalling.  

z

Before installing a radial shaft seal lubricate the outside diameter with gear oil and fill the space between 
the sealing lips (arrow) halfway with G 052 128 A1.  

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The open side of an oil seal faces towards the oil.  

z

Always use transmission oil. Other lubricants will cause the hydraulics to malfunction.  

z

Check gear oil level after installing and if necessary top off. See SERVICING - A/T (02E) article.  

NUTS, BOLTS 

z

Loosen and tighten nuts, bolts/screws for securing covers and housings in a diagonal sequence.  

z

Do not tilt the very sensitive parts and also loosen and tighten in a diagonal sequence.  

z

The torque settings indicated refer to non-lubricated screws and bolts:  

z

Threads of bolts/screws that are secured by locking fluid are to be cleaned with a wire brush. Then insert 
bolts/screws with AMV 185 100 A1.  

z

All threaded holes where locking fluid is applied must be cleaned with a thread tap to remove remnants of 
locking fluid. Otherwise there is a danger that a bolt/screw will shear when reinstalling.  

z

Replace self-locking nuts.  

OVERHAUL 

Manufacturer does not provide overhaul procedures or specifications. For fluid capacities and types, adjustment 
or servicing procedures, seeSERVICING - A/T (02E) article. For removal and installation procedures, see 
REMOVAL & INSTALLATION - A/T (02E) article.

 

2003 Volkswagen New Beetle GLS 

2003-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 02E

  

 

 

 

 

 

 

 

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