Volkswagen New Beetle. Manual - part 2362

CLUTCH RELEASE BEARING 

Removal & Installation 

Removal information not available from manufacturer. Use Fig. 35 as an aid for procedure. If damaged, replace 
guide sleeve and O-ring together. Lubricate guide sleeve in area of release bearing with MoS2 grease. Lubricate 
surfaces which contact release lever with MoS2 grease. Grease end of slave cylinder plunger with MoS2 grease. 

CAUTION: DO NOT wash out bearing. Replace noisy bearing. 

NOTE:

Inspect clutch release bearing for smooth operation and looseness. Replace 
bearing if noisy. DO NOT wash release bearing in solvent. 

 

2003 Volkswagen New Beetle GLS 

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

  

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Fig. 35: Identifying Clutch Release Components 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

CLUTCH SLAVE CYLINDER 

Removal & Installation 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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

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© 2004 Mitchell Repair Information Company, LLC. 

Full removal and installation procedure is not available from manufacturer. See Fig. 35 for location.  

Before removing slave cylinder, remove gear selector cable from gear selector lever. Remove relay lever and 
actuating arm for gate selector cable. After installing adjust gear selector mechanism. See SELECTOR 
MECHANISM under ADJUSTMENTS.  

OVERCENTER SPRING 

Removal & Installation 

1. Remove driver's side lower cover. Install Assembly Clamp (T10111) from right side, onto overcenter 

spring. See Fig. 36 . Ensure assembly clamp is correctly seated. Clamp must be positioned on rear part of 
overcenter spring so claws fit over web (1). Press clutch pedal lightly toward bulkhead. Hook tab (2) of 
assembly clamp into cutout of overcenter spring. 

Fig. 36: Installing Assembly Clamp 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

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

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© 2004 Mitchell Repair Information Company, LLC. 

2. Press clutch pedal as far as possible toward bulkhead until overcenter spring can be removed downward 

out of mountings on bearing bracket and clutch pedal. Bring clutch pedal to rest position. Turn overcenter 
spring together with assembly clamp in direction of arrow (A) and take out downward in direction of 
arrow (B). See Fig. 37 . 

Fig. 37: Turning Overcenter Spring & Clamp 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3. To install, pull clutch pedal into passenger compartment. Insert overcenter spring with assembly clamp 

(T10111) upward in direction of arrow (A) into bearing bracket, and then turn in direction of arrow (B). 
See Fig. 38 . 

 

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 40 

© 2004 Mitchell Repair Information Company, LLC.