Volkswagen New Beetle. Manual - part 2335

 

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Volkswagen New Beetle. Manual - part 2335

 

 

2002-04 CLUTCHES 

Clutches - New Beetle (5 & 6 Speed, 02M) 

IDENTIFICATION 

On 02M transmission model, identification tag is located on transmission, identifying code letters and date of 
manufacture. See Fig. 1 .  

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:52 AM

Page 1 

© 2004 Mitchell Repair Information Company, LLC. 

Helpmelearn Repair Manuals 

 

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

DESCRIPTION & OPERATION 

Clutch is a single-disc type, using a diaphragm spring to engage pressure plate. Clutch is hydraulically 
controlled by master cylinder, slave cylinder, release lever and pre-lubricated release bearing. Clutch release 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:52 AM

Page 2 

© 2004 Mitchell Repair Information Company, LLC. 

bearing and slave cylinder are an integral unit, and must be replace together. Clutch master cylinder is supplied 
fluid from brake master cylinder fluid reservoir. Flywheel on some models was changed from a single piece 
solid flywheel to a dual mass flywheel. Note changes in torque specifications for pressure plate.  

BLEEDING 

1. Connect brake filler/bleeder unit (VAG 5234), or equivalent. Connect bleed hose to brake bleeding 

collector bottle. Attach hose (arrow) to bleeder (arrow) fitting located on clutch master cylinder, next to 
hydraulic line 

Fig. 2: Locating Bleeder Valve 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

2. Open bleed valve. See Fig. 2 . Turn bleed unit on. After finishing bleeding process, depress clutch pedal 

several times.  

NOTE:

Fill brake master cylinder reservoir with DOT 4 brake fluid. 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:53 AM

Page 3 

© 2004 Mitchell Repair Information Company, LLC. 

ADJUSTMENTS 

CLUTCH 

BRAKE LIGHT SWITCH 

For servicing purposes, they will be referred to as "old style" and "new style". It is important to identify which 
style of switch is installed, prior to servicing, as each requires specific removal and installation (replacement) 
procedures. See Fig. 3 .  

"Old style" switch is identified by a large (approximately 10 mm) plunger tip button, and a square plunger shaft. 
"New style" switch is identified by a small (approximately 4 mm) plunger tip without a button, and round 
plunger shaft. "Old style" switches can be removed and reinstalled/adjusted. "New style" switch must NOT be 
reused after removal. Always replace.  

Should a brake light switch require replacement, only a specific "new style" switch is available (supersedes all 
previous part number versions). This switch requires critical procedures be followed, prior to and during 
installation.  

NOTE:

Hydraulic clutch systems are automatically adjusted and require no manual 
adjustment. 

NOTE:

Two different styles of brake light switch were used in production. 

 

2003 Volkswagen New Beetle GLS 

2002-04 CLUTCHES Clutches - New Beetle (5 & 6 Speed, 02M)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:05:53 AM

Page 4 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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