Volkswagen New Beetle. Manual - part 2309

 

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Volkswagen New Beetle. Manual - part 2309

 

 

Fig. 18: Removing & Installing Left Sound Insulation 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

2001-04 AUTOMATIC TRANSMISSIONS Removal & Installation - 01M

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:58:18 AM

Page 20 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 19: Removing ATF Oil Pan Protective Plate 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

8. Remove bracket (1) for power steering pressure line from lower starter bolt (arrow). See Fig. 20 . 

Remove lower bolt at starter. Remove starter (2). Remove right hand inner constant velocity joint 
protective cover from engine, if installed. Disconnect drive axles at transaxle flanges. Raise right drive 
axle and secure to the side. Remove pendulum support (arrows). See Fig. 21 .  

9. Unclip cap for torque converter nut cover. Remove nut (arrow) from torque converter using Special 

Socket (V 175). See Fig. 22 . Turn crankshaft 120 degrees further for each nut. Turn steering to left lock. 
Mark installation position of ball joint bolts on left hand control arm and remove 3 bolts.  

10. Disconnect left coupling rod (1) from control arm and turn rod upward. Swing wheel bearing housing 

outward. Guide left drive axle (2) out between subframe and transaxle. Lift drive axle and secure to 
suspension strut with wire. See Fig. 23 .  

11. Remove left assembly mounting (2) hex bolts (arrows) from left mount (1). See Fig. 24 . Carefully tilt 

engine and transaxle by lowering left hand spindle about 2.36" (60 mm) on Support Bar (10-222 A).  

12.  

 

2003 Volkswagen New Beetle GLS 

2001-04 AUTOMATIC TRANSMISSIONS Removal & Installation - 01M

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:58:18 AM

Page 21 

© 2004 Mitchell Repair Information Company, LLC. 

Remove left mount (1) from transaxle (arrows). See Fig. 25 . Separate exhaust system at down pipe. 
Using 2 bolts (M 8 x 25), bolt Support Rail (VW 457/1) to both pendulum support securing holes (A) on 
subframe. Insert spacers totalling .24" (6 mm) between subframe and Support Rail (VW 457/1). Install 
Support Device (3300 A) and tighten with bolt (B). See Fig. 27 .  

13. Repair Manual, Engine Mechanical, Repair Group 26; Removing and installing parts of exhaust system.  

14. Tilt engine and transaxle forward with Support Device (3300 A). Set up Transaxle Support (3282). 

Transaxle Support (3282) must be set up with Adjusting Plate (3282/2) for removing transaxle. See Fig. 
7
 . The symbols on the adjusting plate indicate the supports required. Move Transaxle Jack (VAG 1383 
A) with Transaxle Support (3282) under transaxle and support transaxle. See Fig. 8 .  

15. Place safety support pin on oil pan and secure to transaxle housing (arrow). See Fig. 9 . On vehicles with 

triple roller drive axle, turn transaxle flange to right so that flat (arrow) is vertical. See Fig. 28 . Remove 
lower engine/transaxle connecting bolt. Press transaxle off engine, while pressing torque converter out of 
drive plate. Press torque converter against ATF pump.  

16. Lower transaxle slightly. Guide power steering pressure line past transaxle. Tilt transaxle using transaxle 

jack spindle, and while lowering, ensure cover (wheel housing side) is guided closely past wheel housing. 
Swivel transaxle and carefully lower transaxle. Ensure that the right joint flange does not contact the 
engine or the Support Device (3300 A), and that the multifunction TR switch does not contact the 
subframe. Secure torque converter to prevent it from falling out.  

17. To install transaxle, reverse removal procedure. When installing the torque converter, ensure that both 

drive pins engage in the ATF pump inner wheel recesses. Before installing, ensure that dowel sleeves are 
correctly located. When installing transaxle, observe torque converter contact impression on drive plate. 
Replace selector cable anchorage locking washer. Check selector lever cable adjustment, and adjust if 
necessary. Check and top off ATF level. See SERVICING - 01M & 01V article. See TORQUE 
SPECIFICATIONS 

NOTE:

In the following step, to secure support rail to subframe, a NEW hole must 
be drilled in support rail. Drill a .335" (8.50 mm) diameter hole (arrow) at 
recessed section of support rail. See Fig. 26 . 

 

2003 Volkswagen New Beetle GLS 

2001-04 AUTOMATIC TRANSMISSIONS Removal & Installation - 01M

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:58:18 AM

Page 22 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 20: Removing Bracket & Starter 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

2001-04 AUTOMATIC TRANSMISSIONS Removal & Installation - 01M

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:58:18 AM

Page 23 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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