Volkswagen New Beetle. Manual - part 2298

 

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Volkswagen New Beetle. Manual - part 2298

 

 

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.  

z

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.  

z

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

  

2002-04 AUTOMATIC TRANSMISSION

Overhaul - New Beetle, 09G 

APPLICATION 

TRANSMISSION APPLICATION 

IDENTIFICATION 

Transmission code letters are given on type plate (arrow). See Fig. 1 . Transmission code letters are also given 
on vehicle data plate. 

Application

Transmission Model

1.8L (2002-2004)

09G, 6-Speed

2.0L (2003-2004)

09G, 6-Speed

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

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

CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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