Volkswagen New Beetle. Manual - part 2375

 

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Volkswagen New Beetle. Manual - part 2375

 

 

I - 1st gear  

II - 2nd gear  

III - 3rd gear  

IV - 4th gear  

V - 5th gear  

VI - 6th gear  

R - Reverse gear  

Final drive  

T - Speedometer drive  

Arrows point in direction of travel 

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Fig. 4: Identifying Gear Location 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

CALCULATING OVERALL RATIO "I" 

Example: 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

CALCULATING OVERALL RATIO (EXAMPLE)

i

 = Z

2

 / Z

1

 (Z

1

 = No. of teeth driving gear, Z

2

 = No. of teeth driven gear)

 

i

G

 = Gear ratio = ZG

2

 : ZG

1

 = 32 : 33 = 0.970

 

i

A

 = Axle ratio = ZA

2

 : ZA

1

 = 62 : 20 = 3.100

 

overall ratio = total ratio = I

G

 x I

A

 = 0.970 x 3.100 3.007

 

GENERAL REPAIR INSTRUCTIONS 

The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful 
transmission repairs. The usual basic safety precautions also apply when performing vehicle repairs. 

A number of generally valid instructions applicable for the various repair procedures - which were previously 
repeated a number of times at numerous places in the Repair Manual - are summarized here. They apply to this 
Repair Manual. 

Transmission 

z

When installing ensure that the dowel sleeves between the engine and the transmission are correctly 
located.  

z

When assembling mounting brackets as well as other waxed components the contacts surfaces must be 
cleaned. Contact surfaces must be free of grease and wax.  

z

When changing a transmission fill it with gear oil to the lower edge of the filler hole.  

z

Capacities and specifications. See CODE LETTERS, APPLICATION, RATIOS, CAPACITIES .  

Gaskets, sealing rings 

z

Before installing oil seal, fill space between sealing lips with grease G 052 128 A1 -arrows-. 

Gear

6th gear

Final drive

Drive gear

ZG

1

 = 33

ZA

1

 = 20

Driven gear

ZG

2

 = 32

ZA

2

 = 62

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

Fig. 5: Identifying Gaskets, Sealing Rings 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

After installing, check oil level. See CHECKING FLUID LEVEL .  

z

Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.  

z

Apply sealant uniformly but not too thick.  

z

Replace "O-rings".  

Locking devices 

z

Replace circlips.  

z

Do not overstretch circlips.  

z

Circlips must locate properly in the groove.  

z

Replace spring pins installation position: Slot longitudinal to line of force. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 & 6 Spd. Manual Transmission 02M - New Beetle

  

 

 

 

 

 

 

 

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