Volkswagen New Beetle. Manual - part 2577

 

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Volkswagen New Beetle. Manual - part 2577

 

 

ADJUSTMENTS 

GEARSHIFT LINKAGE 

012 Transaxle 

1. Shift transaxle to Neutral. Pry cover off of center console. Remove shift knob with cover. Remove shift 

selector lever housing rubber cover. Measure dimension "E" between body and gear selector mechanism. 
See Fig. 9 . Dimension "E" should be 1.46" (37 mm) if shift selector lever must be pressed down to 
engage Reverse, or 1.61" (41 mm) if shift selector lever is not pressed down to engage Reverse. If 
dimension "E" is not as specified, loosen push rod bolt "C". Move selector lever to obtain specification. 
Tighten bolt "C" to 18 ft. lbs. (25 N.m).  

2. Loosen ball housing nuts "A" and "B". Set ball housing horizontal to mounting surface. Tighten nuts to 

18 ft. lbs. (25 N.m).  

3. Loosen selector rod bolt "D". Align shift selector lever slightly rearward. Adjust distance "A" to equal 

dimensions. See Fig. 10 . Tighten selector rod bolt to 18 ft. lbs. (25 N.m). Ensure shift selector lever rests 
in the 3rd/4th gear plane when in Neutral. Move shift selector lever through all gear positions. Gears must 
engage smoothly and without jamming. Reinstall shift knob and cover.  

4. If gearshift does not function as specified, loosen ball housing nuts "A" and "B". Press shift selector lever 

to right to transaxle stop. While pressing shift selector lever, push ball housing to left against selector 
lever. Hold this position and tighten nuts. Install shift knob and cover.  

5. Perform functional check. Shift selector lever must move from 5th/Reverse gear gate into 3rd/4th gear 

gate on its own. It must only be possible to select Reverse when shift selector lever is in Neutral position 
in the 3rd/4th gear gate. It must not be possible to shift directly from 5th gear to Reverse.  

6. If it is possible to shift directly from 5th gear to Reverse, or if only 5th gear and Reverse cannot be 

engaged, the 5th and reverse gear locking unit must be inspected and replaced (if necessary). For 
removal, inspection and installation procedure, see LOCKING UNIT under REMOVAL & 
INSTALLATION.  

NOTE:

Prior to servicing selector mechanism, disconnect ground cable at battery. 

CAUTION: When battery is disconnected, vehicle computer and memory systems 

may lose memory data. Driveability problems may exist until computer 
systems have completed a relearn cycle. See COMPUTER RELEARN 
PROCEDURES article in GENERAL INFORMATION before disconnecting 
battery. 

CAUTION: Radio/cassette or radio/CD player is equipped with an anti-theft protection 

circuit. Whenever battery is disconnected, radio will go into anti-theft 
mode. When battery is reconnected, radio will display CODE, and will be 
inoperative until proper code number is entered. Obtain security code 
before disconnecting battery. 

 

2003 Volkswagen New Beetle GLS 

2001-03 MANUAL TRANSMISSIONS Servicing - Volkswagen

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:07:22 AM

Page 9 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 9: Identifying Gear Selector Lever Adjustments (012 Transaxle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

2001-03 MANUAL TRANSMISSIONS Servicing - Volkswagen

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:07:22 AM

Page 10 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 10: Identifying Dimension "A" (012 Transaxle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

020 Transaxle 

1. Shift transaxle into Neutral. Loosen clamp bolt. See Fig. 11 . Ensure joint between selector rod and shift 

selector lever moves easily. Remove shift knob, boot and frame.  

2. Insert Gauge (3104) at shift rod. See Fig. 12 . Ensure gauge does not jam. Align selector rod and shift 

selector lever. Ensure transaxle is in Neutral. Tighten clamp bolt.  

3.  

Ensure shift selector lever is resting in 3rd/4th gear plane with transaxle in Neutral. Shift transaxle 
through all gears. Ensure gears engage smoothly and do not hang up. Ensure Reverse lockout operates 
properly.  

CAUTION: Do not put components under stress. 

 

2003 Volkswagen New Beetle GLS 

2001-03 MANUAL TRANSMISSIONS Servicing - Volkswagen

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:07:22 AM

Page 11 

© 2004 Mitchell Repair Information Company, LLC. 

4. If gears fail to engage smoothly during repeated shifting, engage 1st gear. Remove play from shift linkage 

by pressing shift selector lever gently to left at shift knob threads while 1st gear is engaged. Measure 
distance between shift selector lever and selector lever housing travel stop (distance "a"). See Fig. 13 . 
Distance must be .039-.059" (1.00-1.50 mm).  

5.  

To perform final adjustment, turn eccentric adjuster "A" as follows: Loosen clamp bolt "B". See Fig. 13 . 
Turn eccentric adjuster "A" until dimension "a" is correct. Tighten clamp bolt to 18 INCH lbs. (2 N.m). 
Install frame, shift boot and shift knob.  

Fig. 11: Locating Clamp Bolt (020 Transaxle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

To achieve correct adjustment, shift selector lever and linkage 
components must be in good condition. Shift linkage must operate 
smoothly without excessive resistance. Transaxle, clutch and clutch 
release mechanism must be in good condition. 

 

2003 Volkswagen New Beetle GLS 

2001-03 MANUAL TRANSMISSIONS Servicing - Volkswagen

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 9:07:22 AM

Page 12 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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