Volkswagen New Beetle. Manual - part 2339

 

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Volkswagen New Beetle. Manual - part 2339

 

 

Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Inspection 

1. Inspect pressure plate surface for wear, cracks, burning or warpage. Inspect clutch release bearing for 

smooth operation and looseness. Replace bearing if noisy, with slave cylinder. DO NOT wash release 
bearing in solvent.  

2.  

Inspect pressure plate diaphragm springs. Wear up to half thickness of diaphragm spring is permitted. See 
Fig. 15 . Inspect clutch disc lining for excessive wear and burned or oil-soaked condition. Inspect clutch 
disc for loose rivets and torsion dampers. Measure clutch disc and flywheel runout. 

Fig. 15: Inspecting Pressure Plate Diaphragm Spring 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3. On flywheel, ensure centering pins are a tight fit. Contact surface for clutch lining must be free of 

NOTE:

Pressure plate has a protective grease coating. Remove contact surface 
grease only. Service life will be shortened if remaining portions of 
pressure plate protective grease are removed. 

 

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 17 

© 2004 Mitchell Repair Information Company, LLC. 

grooves, oil and grease. Inspect flywheel ring gear teeth for wear and damage. Inspect flywheel for wear, 
cracks and burned condition.  

Installation 

1. To install, reverse removal procedure. Apply grease to ball stud and inner surface of release bearing.  

2. Clean input shaft splines and, on used clutch plates, hub splines, remove corrosion and apply only a very 

thin coating of grease, Part No: G 000 100, to input shaft splines. Then move clutch plate back and forth 
on input shaft until hub moves freely on shaft. Excess grease must be removed.  

3. On models with dual mass flywheel, installed position of clutch disc have a shorter hub end pointing 

toward pressure plate. On models with single piece flywheel, installed position of clutch disc spring cage 
faces pressure plate.  

4. Install pressure plate bolts finger tight. Using clutch centering tool (T10097), align clutch disc and pilot 

bushing holes. See Fig. 16 . Using a crosswise pattern, tighten pressure plate bolts to specification. See 
TORQUE SPECIFICATIONS 

 

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 18 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 16: Aligning Clutch Disc 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5. Using flywheel lock (3067) or similar device, hold crankshaft from turning. If removed, tighten flywheel 

bolts to specification. See TORQUE SPECIFICATIONS . Ensure transmission oil level is correct.  

CLUTCH MASTER CYLINDER 

Removal & Installation 

1. Remove intake hose (1), connector (2) and vacuum hose (3) from mass air flow sensor. See Fig. 17 . 

Remove complete air cleaner assembly housing by removing 2 bolts. 

Fig. 17: Removing Air Cleaner Housing 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

2. Pull off supply hose (A) to brake fluid reservoir and plug hose. See Fig. 18 . Pry clip (B) for line/hose 

assembly out of clutch master cylinder. Pull line/hose assembly (C) out of clutch master cylinder and plug 

 

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 19 

© 2004 Mitchell Repair Information Company, LLC. 

to prevent fluid leakage. 

Fig. 18: Removing Supply Hose, Clip & Line/Hose Assembly 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

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 20 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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