Volkswagen New Beetle. Manual - part 2368

 

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Volkswagen New Beetle. Manual - part 2368

 

 

Fig. 54: Installing Gear Selector Cable-To-Transmission Selector Lever (Vehicles Built From June 
1999)
 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

8. Adjust selector mechanism. See SELECTOR MECHANISM under ADJUSTMENTS.  

TRANSMISSION 

Removal 

1. Remove engine cover. Obtain radio code. Turn ignition switch to OFF position. Disconnect negative 

battery cable. See BATTERY DISCONNECT PRECAUTIONS .  

2. Remove power steering reservoir from battery carrier. DO NOT open/loosen hoses. Wire reservoir to lock 

carrier. Remove battery and battery carrier.  

3. 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 bolts (4 and 5).  

4.  

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:03 AM

Page 61 

© 2004 Mitchell Repair Information Company, LLC. 

On vehicles built up to May 1999, disconnect reverse light harness connector (arrow 2). See Fig. 55 . Pull 
connector off vehicle speed sensor (arrow 1). Disconnect vehicle speed sensor (arrow 1) and back-up 
light switch (arrow 2) harness connectors. 

Fig. 55: Disconnect Speed Sensor & Back-Up Light Connectors 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

5. Remove balance weight (A) and gear selector cable (B) from gear selector lever. See Fig. 46 . Remove 

gear selector cable with washer and square nut (self-locking). Lift tab in direction of arrow, and pull gate 
selector cable off actuating arm/relay lever (C).  

6. Remove cable support bracket from transmission (arrows). See Fig. 47 . If necessary, unclip hose at cable 

support bracket first. 

NOTE:

On vehicles built, FROM June 1999, go to step 7 . 

NOTE:

Continue transmission removal procedure at step 10 . 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:03 AM

Page 62 

© 2004 Mitchell Repair Information Company, LLC. 

7. On vehicles built from June 1999, remove cable support bracket from transmission (arrows), if necessary 

unclip hose (A) at cable support bracket first. See Fig. 51 .  

8. Remove circlip and pull off gate selector cable (A) with relay lever. See Fig. 71 . Remove nut (arrow) and 

remove gear selector cable (B) with transmission selector lever. Tie selector cable with transmission 
selector lever and gate selector cable with relay lever up.  

9. Disconnect vehicle speed sensor (arrow 1) and reverse light switch (arrow 2) harness connectors. See Fig. 

56 . 

Fig. 56: Disconnecting Speed Sensor & Back-Up Light Switch 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

10. On all models, remove slave cylinder, and wire aside. See Fig. 57 . DO NOT disconnect lines. DO NOT 

depress clutch pedal. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:03 AM

Page 63 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 57: Removing Slave Cylinder 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

11. Remove cable retainer (arrow 1) on starter. See Fig. 58 . Remove upper securing bolt (arrow 2) on starter. 

Remove ground strap at engine/transmission upper securing bolt. Remove engine/transmission upper 
securing bolts. 

 

2003 Volkswagen New Beetle GLS 

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

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:04:03 AM

Page 64 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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