Volkswagen New Beetle. Manual - part 2293

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  2291  2292  2293  2294   ..

 

 

Volkswagen New Beetle. Manual - part 2293

 

 

z

Model year  

z

Variant  

z

Engine code  

Confirm data as entered: 

Using "Go to" key, select "Function/component selection" 

Follow instructions on screen to start functions desired. 

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 also apply when performing vehicle repairs. 

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned 
at various points in the repair manual; are summarized here. 

BATTERY DISCONNECTING & RECONNECTING 

For work steps required after reconnecting battery, see Fig. 6 .

NOTE:

Wait until the tester has read all the available control modules.

CAUTION: Before beginning repairs on the electrical system: 

z

Obtain anti-theft radio security code.  

z

Switch off all electrical consumers.  

z

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 

2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

  

Fig. 6: 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 

2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

  

TRANSMISSION 

z

When an automatic transmission is replaced the following fluid levels must be checked: 

ATF in planetary gearbox and final drive. See SERVICING - A/T (09G) article. 

Capacities and specifications. See SERVICING - A/T (09G) article. 

z

Do not run engine or tow vehicle with oil pan removed or when there is no ATF in transmission.  

z

Secure torque converter against falling out when transmission is removed.  

z

Clean joints and connecting points thoroughly before loosening.  

z

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

z

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

z

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

z

Carefully cover opened components or seal if the repair cannot be performed immediately.  

z

Replace transmission if any of the selector elements are scorched/burned.  

z

A basic (default) setting must be performed each time the transmission is reinstalled.  

GASKETS, SEALS 

z

Always replace O-rings, seals and gaskets.  

z

After removing seals/gaskets etc. always check contact surfaces on housings or shafts for burrs and 
damage and correct before reinstalling.  

z

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

z

Before installing an oil seal moisten the outer surfaces and the sealing lip sparingly with ATF.  

z

Moisten O-rings with ATF to prevent damage to the O-ring when installing.  

z

Only use ATF in the areas normally lubricated by ATF. Other lubricants will cause the hydraulic 
elements to malfunction.  

z

After installing, check ATF level in planetary gearbox/final drive and correct levels as necessary. 

ATF in planetary gearbox and final drive. See SERVICING - A/T (09G) article. 

Capacities and specifications. See SERVICING - A/T (09G) article. 

BOLTS, NUTS 

z

Loosen and tighten the screws and bolts for securing the covers and housings in a diagonal sequence.  

z

Do not cant particularly sensitive parts, e.g. valve body, and loosen and tighten in stages using diagonal 
sequence.  

z

Prescribed torque specifications apply to unoiled nuts, screws/bolts. 

 

2003 Volkswagen New Beetle GLS 

2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

  

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 employed 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 and bolts/screws.  

VALVE BODY 

z

The valve body is allocated according to transmission code. See CODE LETTERS, TRANSMISSION 
APPLICATION, RATIOS, EQUIPMENT
 .  

GUIDED FAULT FINDING, VEHICLE SELF-DIAGNOSIS AND MEASURING TECHNOLOGY 

Before servicing the automatic transmission, determine the cause of the malfunction as precisely as possible 
with Vehicle Diagnosis, Test and Information System VAS 5051 with the aid of "Guided fault finding", 
"Vehicle self-diagnosis" and "Measuring technology". 

TORQUE CONVERTER 

ASSEMBLY OVERVIEW 

 

2003 Volkswagen New Beetle GLS 

2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

  

 

 

 

 

 

 

 

Content   ..  2291  2292  2293  2294   ..