Volkswagen New Beetle. Manual - part 2301

 

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Volkswagen New Beetle. Manual - part 2301

 

 

TRANSMISSION 

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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. 

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

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Secure torque converter against falling out when transmission is removed.  

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Clean joints and connecting points thoroughly before loosening.  

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

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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!  

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

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

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

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

GASKETS, SEALS 

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Always replace O-rings, seals and gaskets.  

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

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

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

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

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

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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 

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

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

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

 

2003 Volkswagen New Beetle GLS 

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

  

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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.  

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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.  

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Replace self locking nuts and bolts/screws.  

VALVE BODY 

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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

  

Fig. 7: Overview Of Torque Converter Assembly 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

TORQUE CONVERTER, IDENTIFICATION 

There are various torque converters. Identification is via code letters (arrows). See Fig. 8 . 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 8: Locating Torque Converter Code 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Allocating torque converter to transmission, see CODE LETTERS, TRANSMISSION APPLICATION, 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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