Volkswagen New Beetle. Manual - part 2359

 

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Volkswagen New Beetle. Manual - part 2359

 

 

Fig. 23: Exploded View Of Clutch Assembly 
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. 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. 24 . 

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 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:02 AM

Page 25 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 24: Inspecting Pressure Plate Diaphragm Spring 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3. 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. Inspect flywheel ring gear 
teeth for wear and damage. 

4. Inspect flywheel for wear, cracks and burned condition. Ensure centering pins are a tight fit. Contact 

surface for clutch lining must be free of grooves, oil and grease.  

Installation 

NOTE:

Replace clutch plates and pressure plates that have damaged or loose 
rivets. 

NOTE:

Before installing transmission, press clutch release lever toward transmission 
housing and secure it with an assembly pin, assembly bolt or a M8 x 35 bolt. 
Remove pin or bolt after transmission has been installed. Hole will then be 
sealed by 3rd cable support bracket securing bolt. See Fig. 25 . 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:02 AM

Page 26 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 25: Securing Clutch Release Lever 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

1. To install, reverse removal procedure. Clean input shaft splines and on used clutch plates, the 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. Excess grease must be 
removed.  

2. 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.  

3. Apply grease to ball stud and inner surface of release bearing.  

4. Install pressure plate bolts finger tight. Using clutch centering tool (3190A), align clutch disc and pilot 

bushing holes. See Fig. 26 . Pressure plate contact surface and clutch plate must make full contact with 

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:02 AM

Page 27 

© 2004 Mitchell Repair Information Company, LLC. 

flywheel. Tighten bolts diagonally and evenly to prevent damage to the centering holes in the pressure 
plate housing and the centering pins in the flywheel. See TORQUE SPECIFICATIONS 

Fig. 26: Aligning Clutch Disc 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5. Using flywheel lock (3067) or similar device, hold crankshaft from turning. Tighten flywheel bolts to 

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

CLUTCH MASTER CYLINDER 

1. Remove intake hose (1), connector (2) and vacuum hose (3) from mass air flow sensor. See Fig. 9 . 

Remove complete air cleaner assembly housing by removing 2 bolts. On vehicles with 2.0L engine, 
remove protective housing for relays from cable channel.  

2. Pull off supply hose (A) to brake fluid reservoir and plug hose. See Fig. 27 . Pry clip (B) for line/hose 

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 CLUTCHES New Beetle (5-Speed, 02J)

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:02 AM

Page 28 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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