2003 Volkswagen New Beetle GLS

1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

1998-2004 AUTOMATIC TRANSMISSIONS

Overhaul - New Beetle, 01M

APPLICATION
TRANSMISSION APPLICATION
Application Transaxle Model
New Beetle 01M, 4-Speed

IDENTIFICATION
Transmission type and code letters are cast into transmission case. See Fig. 1 . The code letters of the
transmission are also given on the vehicle data plates. For further identification, see CODE LETTERS,
TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Fig. 1: Identification Of Transmission Type & Code Letters

Courtesy of VOLKSWAGEN UNITED STATES, INC.

GEAR RATIOS

For gear ratios, see CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT

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Fig. 2: Transmission Codes DYQ, ECN & ECP (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 3: Transmission Codes DYQ, ECN & ECP (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 4: Transmission Codes EFB, ECV & FDB (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 5: Transmission Codes EFB, ECV & FDB (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 6: Transmission Codes ELU, ELT & ELY (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 7: Transmission Codes ELU, ELT & ELY (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 8: Transmission Codes ELZ, EPB & EPC (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 9: Transmission Codes ELZ, EPB & EPC (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 10: Transmission Codes FDC, FDF & FDG (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 11: Transmission Codes FDC, FDF & FDG (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 12: Transmission Codes EPG, EPH & EPP (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 13: Transmission Codes EPG, EPH & EPP (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

DESCRIPTION & OPERATION

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Fig. 14: Cross-Sectional View Of Transmission Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 15: Identifying Transmission Control Module (TCM) & Shift Lock Electrical Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

TRANSMISSION

The 4-speed automatic transmission 01M is equipped with 4 hydraulically activated forward gears. When the
lock-up clutch is closed these forward gears become mechanically driven gears by cutting-out the torque
converter slip.

TORQUE CONVERTER

The torque converter is equipped with a lock-up clutch. The lock-up clutch is closed dependent on load and
speed and drives 1st, 2nd, 3rd and 4th gears mechanically independent of slip.

In some cases, it may be necessary for installation of a new converter to remove the sleeve bearing from the
turbine shaft.

ON BOARD DIAGNOSTIC (OBD)

It is recommended that the OBD be performed before and after each repair. See DIAGNOSIS - 01M article.

TRANSMISSION CONTROL MODULE

With Driving Situation Gear Changes (Fuzzy Logic)

Determining the driving situation and driving resistance dependent gear change point happens automatically.

Advantages:

z Gear changes will be consumption orientated

z Maximum engine output is always available
z Individual adaption of gear change points in all driving situations
z Gear change points are infinitely variable

Gear Change Point Variations For Hills

An additional gear change map automatically selects gear changes for hills dependent upon accelerator pedal
position and driving speed.

Gear change map for extreme uphill stretches is matched to engine output.

Gear change map for extreme downhill stretches is matched to the braking effect of the engine.

LUBRICATION & ADJUSTMENTS

For lubrication and adjustments, see SERVICING - A/T (01M) article in TRANSMISSION SERVICING.
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ON-VEHICLE SERVICE
AXLE SHAFTS

For information on axle shaft, see AXLE SHAFTS article in DRIVELINE/AXLES.

TRANSMISSION COMPONENTS

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T
(01M) article.

FINAL DRIVE, CHECKING OIL LEVEL

For final drive fluid level checking, see SERVICING - A/T (01M) article.

APPLY & BRAKE CLUTCH APPLICATION

NOTE: Before starting repairs to the transmission, first perform the On Board
Diagnostic (OBD). See DIAGNOSIS - 01M article.

Fig. 16: Locating Selector Elements Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

POSITION OF SELECTOR ELEMENTS

Fig. 17 shows which selector elements are operated in the individual gears to help deal with complaints
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 2003 Volkswagen New Beetle GLS
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regarding poor acceleration and speed performance or generally with drive train questions. The table makes it
possible to determine which selector elements may not be operating properly.

All gears will be shifted hydraulically. All forward gears are driven mechanically at a predetermined load and
speed via the torque converter lock-up clutch.

Fig. 17: Position Of Selector Elements

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 2003 Volkswagen New Beetle GLS
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Courtesy of VOLKSWAGEN UNITED STATES, INC.

TRANSMISSION CHECKING
All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the new
tester VAS 5051 in the vehicle self-diagnosis operating mode.

VEHICLE DIAGNOSIS, TESTING AND INFORMATION SYSTEM VAS 5051 CONNECTING

Special Tools And Equipment

z VAS 5051 Vehicle diagnosis, testing and information system

Connecting VAS 5051

With ignition switched off, connect tester VAS 5051 to diagnosis connection using diagnosis cable VAS 5051/1
or VAS 5051/3. See Fig. 18 .

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Fig. 18: Connecting Diagnostic Cable To DLC

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Switch on tester -arrow-. See Fig. 19 . The tester requires approx. 3 minutes to warm up.

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Fig. 19: Identifying Tester (VAS 5051)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Switch ignition on.

Select zone "Vehicle self-diagnosis" on touch screen.

NOTE: The automatic transmission is only to be checked AFTER having first

completed the self-diagnosis and the cause of damage cannot be located and
corrected. See DIAGNOSIS - 01M article.
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MAIN PRESSURE CHECKING

Conditions For Performing Check

z Diagnostic Trouble Code (DTC) memory checked

When the DTC memory is checked, the following display should appear: "No DTC recognized!"

z ATF level OK

Special Tools And Equipment

z VAG 1702 Pressure tester

Fig. 20: Identifying Pressure Tester

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Main Pressure Checking

Remove bolt -arrow- for main pressure port. Always replace bolt. See Fig. 21 .

Fig. 21: Locating Main Pressure Port Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect pressure tester VAG 1702 and tighten thumb screw.

Start engine.

Bleed pressure tester VAG 1702 by loosening thumb screw and tighten when bleeding is complete.

If V.A.G 1551 is used: With ignition switched off, connect V.A.G 1551 Scan Tool with diagnosis cable V.A.G
1551/3A. See Fig. 22 .

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Fig. 22: Connecting Diagnostic Cable (VAG 1551/3A)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Indicated on display:

z VAG - ON BOARD DIAGNOSTIC HELP

z 1 - Rapid data transfer (appears alternately)
z 2 - Blink code output (appears alternately)

Start engine.

Press key 1 for "Rapid data transfer" mode.

Indicated on display:

z Rapid data transfer HELP

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z Enter address word XX

Press keys 0 and 2 to select address word "Transmission electronics".

Indicated on display:

z Rapid data transfer Q

z 02 - Transmission electronics

Confirm entry with key Q.

Indicated on display:

z Rapid data transfer HELP

z Select function XX

Press keys 0 and 8 to select function "Read measured value block".

Indicated on display:

z Rapid data transfer Q

z 08 - Read measured value block

Confirm entry with key Q.

Indicated on display:

z Read measured value block

z Enter display group number XXX

Press keys 0 0 5 to select "Display group number 005".

Confirm entry with key Q.

Indicated on display (values shown are for example):

z Read measured value block 5 "right arrow"

z 30° C 0011011 0 900 RPM

The first display zone shows the ATF temperature.

Allow ATF temperature to rise to 60° C.

For main pressure specifications at idle, see Fig. 23 .

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Fig. 23: Identifying Main Pressure Specifications At Idle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If there are deviations from prescribed values, the following could be the cause: See Fig. 24 .

Fig. 24: Possible Causes & Remedies Of Deviations At Idle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Switch engine off.

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Press fuse together and pull off solenoid valve connector. See Fig. 25 .

Fig. 25: Identifying Solenoid Valve Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Start engine.

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Fig. 26: Identifying Main Pressure Specifications At 2000 RPM

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If possible, main pressure test should be performed on a rolling road.

If there are deviations from the prescribed values, the following could be the cause. See Fig. 27 .

Fig. 27: Identifying Causes & Remedies Of Deviations At 2000 RPM

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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After test: Disconnect pressure tester VAG 1702.

Install new bolt for main pressure port and tighten to 15 Nm.

Install solenoid valve connector.

Once connector has been fitted, check and erase DTC memory.

If necessary, install sound insulation.

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

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned
at various points in the overhaul are summarized here.

BATTERY DISCONNECTING & RECONNECTING

CAUTION: Before beginning repairs on the electrical system:

z Obtain anti-theft radio security code.

z Switch off all electrical consumers.
z Switch ignition off and remove ignition key.
z Do not loosen or remove ground strap from body. Disconnect
terminal from battery only.

For work steps required after reconnecting battery, see Fig. 28 .

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Fig. 28: Reconnecting Battery Work Steps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: If desired, print this page and use the table above as a checklist.
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TRANSMISSION

When an automatic transmission is replaced, the ATF in the planetary gearbox, and the gear oil in the final
drive must be checked and topped off as necessary. See SERVICING - A/T (01M) article.

GASKETS, OIL SEALS

Radial shaft seals: Pack space between sealing lips with grease before installing.

Always install new O-rings.

After installing, check ATF level in planetary gearbox or gear oil in final drive, adjust to correct level if
necessary. See SERVICING - A/T (01M) article.

LOCKING ELEMENTS

Do not overstretch circlips; replace if necessary.

Circlips must be properly seated in the grooves.

Replace spring pins. Installation position: Slot must be longitudinal to line of force.

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Fig. 29: Positioning Slotted Spring Pins

Courtesy of VOLKSWAGEN UNITED STATES, INC.

SHIMS

Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact
shim thickness required.

Check for signs of burr and damage. Install only shims which are in perfect condition.

BEARINGS

Tapered roller bearings are allocated in the parts catalog according to the transmission build date and code
letters.

Always replace tapered roller bearings which are mounted on a shaft together and use bearings from a single
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manufacturer.

Install needle bearings with the inscribed side (thicker sheet metal) facing the drift.

Heat the inner races of tapered roller bearings to approx. 100° C before installing.

Do not interchange the inner and outer races of same size bearings.

NUTS, BOLTS

Nuts and bolts for attaching covers and housings must be loosened and tightened in a crosswise pattern.

Do not distort particularly sensitive parts (e.g. valve body), and loosen or tighten diagonally in stages.

The tightening torques stated apply to unoiled nuts and bolts.

Threads of bolts that are secured by locking fluid are to be cleaned with a wire brush. Then insert bolts with
AMV 185 100 A1.

Always replace self-locking nuts.

INNER PLATES

Place new inner plates in ATF fluid for 15 minutes before installing.

VALVE BODY

Replace the valve body if any of the selector elements are scorched.

CLUTCHES

Clutches K1, K2 and K3 should be disassembled only for cleaning. If parts are faulty, replace the clutch.
Allocate clutches according to transmission code letters.

ON BOARD DIAGNOSTIC (OBD)

Before repair work on the automatic transmission, the cause of the malfunction should be determined as
precisely as possible with the aid of On Board Diagnostic (OBD). See DIAGNOSIS - 01M article.

TRANSMISSION

For removal and installation procedure, see REMOVAL & INSTALLATION - A/T (01M) article.

For transmission repairs, an exchange component is available for the shift elements, which is often more cost
effective.

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When installing a transmission, make sure that the dowel sleeves are installed correctly.

TORQUE CONVERTER
The ATF pump is driven via the torque converter.

When installing the torque converter, ensure that both drive pins engage in the recesses in the ATF pump inner
wheel.

There are different types of torque converter, which can be identified by the code letters (arrow). See Fig. 30 .
For more information, see CODE LETTERS, TRANSMISSION APPLICATION, RATIOS,
EQUIPMENT .

Fig. 30: Locating Torque Converter ID

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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TORQUE CONVERTER IDENTIFICATION

There are different types of torque converter. Current torque converter with sleeve bearing in turbine shaft of
transmission. New torque converter with integrated needle bearing. Identification is by means of the code
letters. See CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

The current torque converter may only be installed in a transmission with a sleeve bearing in the turbine shaft. It
can be identified by the fourth letter, which is either a B, C, R, T or V. See Fig. 31 .

Fig. 31: Identifying Current Torque Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Example (arrow) is a "C". See Fig. 31 .

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The new torque converter may only be installed in a transmission without a sleeve bearing in the turbine shaft.
It can be identified by the fourth letter, which is either a D, H, or J. See Fig. 32 . Example (arrow) is a "D".

Fig. 32: Identifying New Torque Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: If a new torque converter with an integrated needle bearing is installed in a

transmission with a sleeve bearing in the turbine shaft, the sleeve bearing must
be removed.

TORQUE CONVERTER APPLICATIONS

There are two types, which are allocated according to the transmission code letters. See CODE LETTERS,
TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

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Current torque converter with sleeve bearing in the turbine shaft of the transmission (arrow). See Fig. 33 .

Fig. 33: Identifying Torque Converter with Sleeve Bear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

For the new torque converter with an integrated needle bearing, a sleeve bearing (arrow) may not be installed in
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the turbine shaft of the transmission with this type. Remove if necessary.

Removing Sleeve Bearing From Turbine Shaft

Place transmission in its installation position on transmission oil pan.

Remove torque converter.

Position holes -A- of turbine shaft in horizontal position. See Fig. 34 .

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Fig. 34: Locating Turbine Shaft Holes

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Protect transmission by carefully taping around turbine shaft and over holes. See Fig. 35 .

Fig. 35: Taping Around Turbine Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Saw through sleeve bearing using a saw blade. Do NOT saw at thrust point of sleeve bearing (arrow). See Fig.
36 .

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Fig. 36: Sawing Through Sleeve Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Make sure that no filings enter the transmission.

Without damaging turbine shaft, carefully pry up split sleeve bearing using a screwdriver. See Fig. 37 .

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Fig. 37: Prying Sleeve Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove filings and sticky tape.

Replace torque converter seal.

TORQUE CONVERTER OIL SEAL, REMOVING AND INSTALLING

Special Tools And Equipment

z VW 681 Extractor lever

z 3158 Drift sleeve

Removing & Installing Torque Converter Oil Seal

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Fig. 38: Identifying Extractor Lever

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 39: Identifying Drift Sleeve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 40: Removing Torque Converter Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 41: Driving In Torque Converter Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

TORQUE CONVERTER, DRAINING

Special Tools And Equipment

z VAG 1358 A Oil extractor

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Fig. 42: Identifying Oil Extractor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If the torque converter has become fouled by abrasion or if performing a major overhaul of the transmission,
drain the torque converter as follows:

Extract ATF from torque converter using VAG 1358 A and probe VAG 1358 A/1. See Fig. 43 .

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Fig. 43: Extracting ATF From Torque Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

TRANSMISSION DISASSEMBLY AND ASSEMBLY

ATF COOLER AND ATF FILLER TUBE, REMOVING AND INSTALLING

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Fig. 44: Removing & Installing ATF Cooler & ATF Filler
Courtesy of VOLKSWAGEN UNITED STATES, INC.

TRANSMISSION, DISASSEMBLING AND ASSEMBLING -OVERVIEW-

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Fig. 45: Exploded Views Of Transmission Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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ATF PUMP TO SUPPORTING TUBE, REMOVING AND INSTALLING

Number of inner and outer plates varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 46: Removing & Installing ATF Pump To Supporting Tube

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Courtesy of VOLKSWAGEN UNITED STATES, INC.

REVERSE GEAR CLUTCH -K2- TO LARGE SUN GEAR, REMOVING AND INSTALLING

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 47: Removing & Installing Reverse Gear Clutch To Large Sun Gear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

FREEWHEEL AND REVERSE GEAR BRAKE -B1-, REMOVING AND INSTALLING

Number of inner and outer plates varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

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Fig. 48: Removing & Installing Freewheel & Reverse Gear Brake
Courtesy of VOLKSWAGEN UNITED STATES, INC.

PLANET CARRIER AND TRANSMISSION HOUSING WITH INPUT GEAR AND COVER

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 49: Exploded View Of Planet Carrier & Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

TRANSMISSION DISASSEMBLING AND ASSEMBLING

Special Tools And Equipment

z VW 309 Holding plate

z VW 313 Support clamp
z VW 353 Transmission support
z VW 402 Thrust plate
z VW 412 Press tool
z VW 415 A Tube
z VW 418 A Tube
z 3110 Tube
z 3267 Assembly ring
z 3336 Transmission lifting beam
z VAG 1331 Torque wrench

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Fig. 50: Identifying Assembly & Disassembly Special Tools (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 51: Identifying Assembly & Disassembly Special Tools ( 2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disassembling Transmission

Ensure transmission is attached to transmission support device. See Fig. 51 . Place container under
transmission.

Remove sealing plug -1- and ATF overflow pipe -2-. See Fig. 52 . Drain ATF.

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Fig. 52: Identifying ATF Pipe & Plugs

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Seal ATF cooler connections. Remove torque converter.

Secure transmission to assembly support with bolts -1- and -2- (M10). See Fig. 53 . Remove transmission
support device 3336.

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Fig. 53: Identifying Transmission Assembly Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove transmission housing cover with gasket (arrow). See Fig. 85 . Remove transmission oil pan. Remove
ATF screen.

Remove valve body with conductor strip. See VALVE BODY, REMOVING AND INSTALLING under
COMPONENT DISASSEMBLY & REASSEMBLY.

Pull out sealing plugs for -B1- (arrow). See Fig. 54 . Remove ATF pump bolts (arrows). See Fig. 55 .

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Fig. 54: Locating Sealing Plugs (B1)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 55: Locating ATF Pump Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Screw bolts -A- (M8) into tapped holes of ATF pump. See Fig. 56 . Press ATF pump off transmission by
turning bolts -A- evenly.

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Fig. 56: Removing Oil Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove strainer if installed. See Fig. 57 . The strainer is installed in ATF cooler line.

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Fig. 57: Removing Strainer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove all clutches with supporting tube, -B2- plates, springs and spring caps together. See Fig. 58 . The
clutches -K1- and -K3- are pressed together. Clutch -K1- must only be pressed off -K3- if one of the clutches is
to be disassembled or replaced. See Pressing Clutch -K1- Off -K3- .

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Fig. 58: Removing Clutches W/ Supporting Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert screwdriver through hole of large sun gear to loosen and tighten bolt for small input shaft. See Fig. 59 .

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Fig. 59: Locking Small Sun Gear Drive Shell

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen small input shaft bolt -arrow-. See Fig. 60 . Remove small input shaft bolt, washer and shim. Planet
carrier axial needle bearing remains in transmission/input gear. Remove small input shaft.

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Fig. 60: Locating Small Input Shaft Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove large input shaft (arrow). See Fig. 61 .

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Fig. 61: Removing Large Input Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove large sun gear (arrow). See Fig. 62 . Remove transmission vehicle speed sensor (VSS) -G38-. See
TRANSMISSION VEHICLE SPEED SENSOR -G38- in DIAGNOSIS - 01M article.

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Fig. 62: Removing Large Sun Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Freewheel circlip is also referred to as "one way clutch clip".

Remove supporting tube circlip and freewheel circlip. See Fig. 63 . Take freewheel out of transmission housing
by pulling on freewheel retaining wedge with pliers.

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Fig. 63: Removing Support Tube & One-Way Clutch Circlips & One-Way Clutch
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: It is not necessary to remove input gear to disassemble planetary transmission.

Remove planet carrier with dished spring. See Fig. 64 . Remove reverse gear brake -B1- plates.

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Fig. 64: Removing Planet Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing Clutch -K1- Off -K3-

The clutches -K1- and -K3- are pressed together.

Clutch -K1- must only be pressed off -K3- if one of the clutches is to be disassembled or replaced.

Make sure tool press surface is flat and not damaged. The pin of tube 3110 faces to plate VW 402. Hold turbine
shaft when pressing off. See Fig. 65 .

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Fig. 65: Pressing Clutch -K1- Off -K3-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing Clutch -K1- Onto -K3-

Insert new O-ring in recess turbine shaft (arrow). See Fig. 66 .

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 66: Locating Turbine Shaft "O" Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Moisten O-ring with ATF.

Clip (2) axial needle bearing (1) with washer to 3rd and 4th gear clutch -K3-. See Fig. 67 .

Fig. 67: Identifying Axial Needle Bearing & Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Make sure tool press surface is flat and not damaged.

Prepare -K1- and -K3- for pressing as illustrated. See Fig. 68 .

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Fig. 68: Preparing -K1- & -K3- For Pressing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before pressing on, align VW 418 A centrally onto surface for axial needle bearing (this illustration shows -K3-
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 2003 Volkswagen New Beetle GLS
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from below). See Fig. 69 .

Fig. 69: Aligning VW 418 A Onto Axial Bearing Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press clutch -K1- on carefully until stop is perceptible.

NOTE: Do not exert further pressure onto clutches!

Assembling Transmission

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Install O-ring into planet carrier. See Fig. 70 .

Fig. 70: Locating Planet Carrier "O" Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: After replacing planet carrier. See PLANET CARRIER, ADJUSTING .

Insert axial needle bearing with washers and planet carrier in input gear. See Assembling Transmission .

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z 1 - Input gear is installed in transmission housing. See TRANSMISSION, DISASSEMBLING AND

ASSEMBLING -OVERVIEW- .
z 2 - Axial needle bearing washer, insert smooth side into input gear.
z 3 - Axial needle bearing.
z 4 - Axial needle bearing washer.
z 5 - Install planet carrier with seal installed.

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Fig. 71: Installing Planet Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place washer and axial needle bearing on "small sun gear" in planet carrier. See Fig. 72 .

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Fig. 72: Installing Washer & Axial Needle Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Centralize washer and axial needle bearing on small sun gear. See Fig. 72 .

Insert inner and outer -B1- plates. See Fig. 72 .

Insert pressure plate with flat side facing plates. See Fig. 72 .

Thickness of pressure plate varies according to number of plates. Replacement part is assigned according to
transmission code letters. See Fig. 72 .

Insert dished washer with convex facing freewheel. See Fig. 73 .

Fig. 73: Installing Dished Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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NOTE: When replacing: Transmission housing, freewheel, piston for reverse gear
brake -B1- or plates, then adjust -B1-. See REVERSE GEAR BRAKE -B1-,
ADJUSTING .

Preload freewheel rollers with assembly ring 3267 and insert free wheel. See Fig. 74 .

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Fig. 74: Installing Freewheel Roller W/Assembly Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Install circlip for freewheel -b- and circlip for supporting tube -a-. See Fig. 63 .

Insert circlip gaps over freewheel retaining wedge.

Install transmission vehicle speed sensor -G38-. See TRANSMISSION VEHICLE SPEED SENSOR -G38-
in DIAGNOSIS - 01M article.

Perform measurement check of -B1-. See REVERSE GEAR BRAKE -B1-, ADJUSTING .

Insert components into transmission housing starting with large sun wheel down to small input shaft. See Fig.
75 .

z 1 - Large sun wheel

z 2 - Needle bearing washer (collar faces large sun wheel)
z 3 - Axial needle bearing
z 4 - Large input shaft
z 5 - Axial needle bearing
z 6 - Needle bearing
z 7 - Small input shaft

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Fig. 75: Installing Components Into Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install small drive shaft bolt -1- with washer -2- and shim -3-. Tightening torque 30 Nm. See Fig. 76 .
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Fig. 76: Installing Small Drive Shaft Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: z Insert shim -3- onto small input shaft shoulder (arrow).
z Determining shim thickness, adjusting planet carrier. See PLANET
CARRIER, ADJUSTING .

Perform planet carrier check measurement. See Planet Carrier Check Measurement .

Clip axial needle bearing with thrust washer to 3rd and 4th gear clutch -K3-. See Fig. 77 .

z 1 - Axial needle bearing with thrust washer

z 2 - 3rd and 4th gear clutch -K3-

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Fig. 77: Installing Axial Needle Bearing With Thrust Washer

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Make sure piston rings seat correctly on -K3-. See Fig. 78 .

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Fig. 78: Locating Piston Rings On -K3-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Make sure that ends of piston rings are hooked together.

Insert 1st to 3rd gear clutches -K1- with 3rd and 4th gear clutch -K3-. See Fig. 79 .

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Fig. 79: Install 1st-3rd Gear Clutches -K1- W/ 3rd & 4th Gear Clutch -K3-
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert shims -arrow- in -K1-. See Fig. 80 .

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Fig. 80: Installing Shims in -K1-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Remeasure shim when replacing -K1-, -K2- or ATF pump, adjusting clutch play
between -K1- and -K2. See CLUTCH PLAY BETWEEN -K1- AND -K2-,
ADJUSTING . 1 or 2 shims can be installed.

Insert reverse gear clutch -K2-. See Fig. 81 . Insert supporting tube for -B2- plate set (arrow) so that supporting
tube groove engages in freewheel wedge.

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Insert reverse gear clutch -K2-. See Fig. 81 .

Fig. 81: Installing Reverse Gear Clutch -K2-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert supporting tube for -B2- plate set (arrow) so that supporting tube groove engages in freewheel wedge. See
Fig. 82 .

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Fig. 82: Installing Supporting Tube For -B2- Plate Set

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install -B2- plates as follows:

z First insert a 3 mm thick outer plate.

z Insert three spring caps in outer plate.
z Insert compression springs (arrows).
z Insert all but last outer plate.
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z Insert three spring caps onto compression springs.

z Insert last outer plate -3 mm thick-.

Determine shim thickness. See 2ND AND 4TH GEAR BRAKE -B2-, ADJUSTMENT .

Install shim -a-. See Fig. 83 .

Insert retaining ring -b- onto shim. Smooth side facing shim. See Fig. 83 .

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Fig. 83: Installing Shim & Retaining Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When replacing the following component, then the 2nd and 4th gear brakes -B2- are to be adjusted. See 2ND
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AND 4TH GEAR BRAKE -B2-, ADJUSTMENT :

z the transmission housing

z Supporting tube
z the ATF pump
z retaining ring
z or the plates

NOTE: These components are assigned as replacement parts according to

transmission code letters.

Clean strainer.

Install strainer. See Fig. 57 .

Strainer is located in ATF cooler pipe.

Install ATF pump seal. Install O-ring on ATF pump. Tighten bolts evenly, in a diagonal pattern. See Fig. 84 .
Turn bolts 90° further after initial tightening torque. Turning further can be done in several stages.

NOTE: Make sure that the O-ring is not damaged. Initial tightening torque: 8 Nm.

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Fig. 84: Installing ATF Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carry out check measurement of clutch play. See Check Measurement (Clutch Play) .

Insert sealing plugs with O-rings -arrow-. See Fig. 54 . Installation position: Lug engages in oil channel.

Install valve body with conductor strip. See CONDUCTOR STRIP WITH INTEGRATED
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TRANSMISSION FLUID TEMPERATURE SENSOR -G93- in DIAGNOSIS - 01M article.

Install transmission oil pan. See VALVE BODY, REMOVING AND INSTALLING .

Install cover (arrow) with gasket and spacer bushings. See Fig. 85 . Tightening torque: 8 Nm.

Fig. 85: Locating Transmission Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thread in ATF overflow pipe -1- and sealing plug -2- with new seal hand tight. See Fig. 86 .

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Fig. 86: Locating Plug & Overflow Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install torque converter.

Install transmission. See REMOVAL & INSTALLATION - A/T (01M) article.

Fill with 3 liters of ATF and check ATF level and top off. See SERVICING - A/T (01M) .

OVERVIEW OF ALL PLANETARY TRANSMISSION ADJUSTMENTS

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Fig. 87: Overview Of All Planetary Transmission Adjustments

Courtesy of VOLKSWAGEN UNITED STATES, INC.

PLANET CARRIER, ADJUSTING

Special Tools And Equipment

z VW 309 Holding plate

z VW 313 Support clamp
z VW 353 Transmission support
z VW 382 Measuring device
z Dial gauge

Fig. 88: Planet Carrier Adjusting Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview Of Components To Adjust Planet Carrier

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Fig. 89: Overview Of Components To Adjust Planet Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Determining shim -A- (Planet Carrier)

See Fig. 90 .

Fig. 90: View Of Planetary Carrier Shim (A) End Play

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Install all components (items - 2 - to - 16 -) to adjust planet carrier into transmission housing. See Fig. 89 .

Insert screwdriver through hole of large sun gear to loosen and tighten bolt for small input shaft. See Fig. 59 .

Install small input shaft bolt -1- with washer -2- but without shim. See Fig. 91 . Tightening torque: 30 Nm.

Fig. 91: Installing Small Planetary Driveshaft Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install dial gauge in VW 382/7.

Set up dial gauge so that top of gauge is positioned on bolt head center with 1 mm preload. See Fig. 92 . Zero
dial gauge. Move small input shaft up and take reading.

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Fig. 92: Adjusting Planetary Carrier End Play

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Example: Reading 2.00 mm. Determine thickness of shim using table and find Part No. in parts catalog. See
PLANET CARRIER SHIMS .

PLANET CARRIER SHIMS

Gauge Reading (mm) Shims (mm)
1.26-1.35 1.0
1.36-1.45 1.1
1.46-1.55 1.2
1.56-1.65 1.3
1.66-1.75 1.4
1.76-1.85 1.5
1.86-1.95 1.6
1.96-2.05 1.7
2.06-2.15 1.8
2.16-2.25 1.9
2.26-2.35 2.0
2.36-2.45 2.1
2.46-2.55 2.2
2.56-2.65 2.3

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2.66-2.75 2.4
2.76-2.85 2.5
2.86-2.95 2.6
2.96-3.05 2.7
3.06-3.15 2.8
3.16-3.25 2.9

Example: Measured value 2.00 mm = Insert 1.7 mm thick shim.

Remove small input shaft bolt.

Insert correct shim -3- on small input shaft -arrow-. See Fig. 91 .

Tighten small input shaft bolt -1- with washer -2-. Tightening torque 30 Nm.

Carry out planet carrier check measurement. See Planet Carrier Check Measurement .

Planet Carrier Check Measurement

Insert dial gauge in VW 382/7 and place tip on bolt of small input shaft. See Fig. 92 .

Move small input shaft up and down and take reading of play on dial gauge.

Play: Min. = 0.23 mm. Max. = 0.37 mm

NOTE: If the planet carrier has been adjusted with reverse gear brake -B1- and free
wheel removed then before installing planet carrier install reverse gear brake -
B1-. See Assembling Transmission .

REVERSE GEAR BRAKE -B1-, ADJUSTING

Number of inner and outer plates varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 309 Holding plate

z VW 313 Support clamp
z VW 353 Transmission support
z VW 402 Thrust plate
z Depth gauge
z Straightedge
z Feeler gauges

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Fig. 93: Identifying Reverse Gear Adjustment Special Tools (Reverse Gear Brake -B1-)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview Of Components To Adjust Reverse Gear Brake -B1-

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Fig. 94: Overview Of Components To Adjust Reverse Gear Brake -B1-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Determining Shim -A- Thickness (Reverse Gear Brake -B1-)

For the measuring sequence the transmission housing must be clamped into the assembly stand so that the input
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gear is facing downward, as illustrated. See Fig. 94 .

For explanation of callouts in Fig. 94 , see the following:

z A = Shim
z x = Gap
z I = Position of piston in freewheel
z m = Height of plate set including pressure plate
z K = Constant = 26.9 mm

"K" is determined by installation height in transmission housing and is not adjustable

Shim thickness is determined by gap "x" and selected from table. See Table Of Shims (Reverse Gear Brake -
B1-) .

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Fig. 95: Identifying Shim Measurements (Reverse Gear Brake -B1-)

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Calculating "I" (Reverse Gear Brake -B1-)

Press piston in direction of arrow as far as stop. See Fig. 96 .

Fig. 96: Calculating "I" (Reverse Gear Brake -B1-)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place straightedge "A" onto outer race of freewheel.

Measure to inner edge of piston with depth gauge "B".

Example:

z "start" Reading = 51.8 mm

z "minus" Straightedge = 48.2 mm
z "equals" Calculated size l = 3.6 mm

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Calculating "M" (Reverse Gear Brake -B1-)

Place straightedge "A" on thrust plate. See .

Fig. 97: Calculating "M" (Reverse Gear Brake -B1-)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Compress set of plates including pressure plate in direction of arrow and measure the thickness of plate set with
depth gauge "B".

Example:

z "start" Reading = 73.5 mm

z "minus" Straightedge = 48.2 mm
z "equals" Calculated size l = 25.3 mm

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Determine Gap "X" (Reverse Gear Brake -B1-)

A sample calculation would be:

z x = k + 1 / 2 -m
z x = 26.9 + 3.6 / 2 - 25.3 = 3.4 mm

Determine size of shims according to table: See REVERSE GEAR BRAKE SHIMS .

Calculate thickness of shims according to table and determine Part No. from parts catalog.

After determining shim for -B1- carry out Reverse Gear Brake -B1- Check Measurement .

Table Of Shims (Reverse Gear Brake -B1-)

REVERSE GEAR BRAKE -B1- SHIMS

Gap (mm) Shim - mm
2.36-2.45 1.0
2.46-2.55 1.1
2.56-2.65 1.2
2.66-2.75 1.3
2.76-2.85 1.4
2.86-2.95 1.5
2.96-3.05 1.6
3.06-3.15 1.7
3.16-3.25 1.8
3.26-3.35 1.9
3.36-3.45 1.0+1.0
3.46-3.55 1.0+1.1
3.56-3.65 1.1+1.1
3.66-3.75 1.1+1.2
3.76-3.85 1.2+1.2
3.86-3.95 1.2+1.3
3.96-4.05 1.3+1.3
4.06-4.15 1.3+1.4
4.16-4.25 1.4+1.4

Reverse Gear Brake -B1- Check Measurement

Install parts up to freewheel and secure with circlip. See Assembling Transmission .

Measure play between plates with feeler gauge "A". See Fig. 98 .

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Fig. 98: Reverse Gear Brake -B1- Check Measurement

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Play:

z Min. = 1.25 mm
z Max. = 1.55 mm

CLUTCH PLAY BETWEEN -K1- AND -K2-, ADJUSTING

Special Tools And Equipment

z VW 309 Holding plate

z VW 313 Support clamp
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z VW 353 Transmission support

z VW 387 Universal dial gauge bracket
z Depth gauge
z Straightedge
z Dial gauge

Fig. 99: Clutch Play Between -K1- & -K2- Adjusting Special Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 100: Overview Of Clutch Play Between -K1- & -K2-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Conditions

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z Planet carrier installed and adjusted. See Assembling Transmission .

z For the measuring sequence the transmission housing must be clamped into the assembly stand so that the
input gear is facing downward. See Fig. 100 .

Determining Shim -A- (-K1- & -K2-)

Calculating thickness of shim. Determine gap "x" and calculate shim thickness. See Fig. 101 .

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Fig. 101: Determining Shim -A- (-K1- & -K2-)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Gap x = a - b
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Calculating "a"(-K1- & -K2-)

For the measuring sequence the transmission housing must be clamped into assembly stand so that the input
gear is facing downward. See Fig. 100 .

Place straightedge "A" onto transmission housing. See Fig. 102 .

Fig. 102: Placing Straightedge "A" Onto Transmission Housing (-K1- & -K2-)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press -K1- together with -K3- down in direction of arrow and measure distance into -K1- with depth gauge "B".

Example: Reading 1 = 88.5 mm

Measure with depth gauge "B" to pump flange on transmission housing. See Fig. 103 .

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Fig. 103: Calculating "a" (-K1- & -K2-)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Example: Reading 2 = 34.3 mm

z "start" Reading 1= 88.5 mm

z "minus" Reading 2 = 34.3 mm
z "equals" Calculated size a = 54.2 mm

Size measured from pump flange/transmission housing into -K1-.

Calculating "b" (-K1- & -K2-)

Place new paper gasket onto ATF pump.

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Place straightedge -B- onto stator support (arrow) and measure with depth gauge -A- to gasket of pump flange.
See Fig. 104 .

Fig. 104: Calculating "b" (-K1- & -K2-)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Example calculation:

z "start" Reading = 70.5 mm

z "minus" Straightedge = 19.5 mm
z "equals" Calculated size b = 51.0 mm
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Gap x = a - b

Gap = 54.2 mm - 51.0 mm = 3.2 mm

Determine size of shim according to table. See CLUTCH PLAY BETWEEN -K1- AND -K2- SHIMS .

Calculate thickness of shims according to table and determine Part No. from parts catalog.

Carry out Check Measurement (Clutch Play) after installing ATF pump.

Table Of Shims (-K1- & -K2-)

CLUTCH PLAY BETWEEN -K1- AND -K2- SHIMS

Gap "x" (mm) Shims (mm)
0-2.54 1.4
2.55-3.09 1+1
3.10-3.49 1.2 + 1.2
3.50-3.89 1.4 + 1.4
3.90-4.29 1.6 + 1.6
4.30-4.69 1.8 +1.8
4.70-5.04 1.2 + 1.2 + 1.6
5.05-5.25 1.2 + 1.2 + 1.8

Check Measurement (Clutch Play)

The clutch play cannot be measured until the ATF pump has been installed.

Attach dial gauge holder to transmission housing and place dial gauge on turbine shaft with a preload of 1 mm.
See Fig. 105 .

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Fig. 105: Check Clutch Play Measurement

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Move turbine shaft up and down and read of play on dial gauge.

Play: Min. = 0.5 mm.; Max. = 1.2 mm

2ND AND 4TH GEAR BRAKE -B2-, ADJUSTMENT

Number of inner and outer plates varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 309 Holding plate

z VW 313 Support clamp
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z VW 353 Transmission support

z 3459 Adjustment tool
z Depth gauge
z Straightedge

Fig. 106: 2nd & 4th Gear Brake Adjusting Special Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: To adjust, install components without shim (item -11-), without last outer plate
(item -10-) and without spring caps (item 6). See Fig. 107 .

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Fig. 107: Overview Of 2nd & 4th Gear Brake

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Determining Shim (2nd & 4th Gear Brake)

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The thickness of the shim(s) is determined by gap x. See Fig. 108 . For this the formula (Gap x = a - b - 2.65
mm) must be used. The measuring points are shown in the illustration to help understanding the formula.
Special tool 3459, which exerts a force -F- onto the plate packet via the retaining ring, is not illustrated.

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Fig. 108: Determining 2nd & 4th Gear Brake Shims

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Determining dimension a: See Calculating Dimension "a": .

Determining dimension b: See Calculating Dimension "b": .

2.65 mm: The amount for settling is taken into account by force F.

NOTE: First outer plate -arrow- and last outer plate (do not install to measure!) are
always 3 mm thick.

Calculating Dimension "a" (2nd & 4th Gear Brake)

Assemble transmission up to the last -B2- inner plate. See Assembling Transmission . The last outer plate and
shim are not installed.

Place retaining ring with smooth side onto last inner plate. See Fig. 109 .

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Fig. 109: Calculating Dimension "a" For 2nd & 4th Gear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place retaining ring with smooth side onto last inner plate.
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Place 3459 onto retaining ring and turn so that 3 clips align with 3 holes for ATF pump.

Bolt 3459 to flange for ATF pump with 5 Nm.

The plate packet for -B2- is now pressed together for the measurements.

Measure from pump flange/transmission housing -arrow- to 3459 with depth gauge. See Fig. 110 .

Fig. 110: Measuring From Pump Flange-To-Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimension a = Height of 3459 in mm - measured value

Example calculation:

z "start" Height of 3459 = 60.0 mm

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z "minus" Measured value = 32.7 mm

z "equals" Calculated value a = 27.3 mm

Note calculated value a.

Remove 3459.

Remove retaining ring.

Calculating Dimension "b" (2nd & 4th Gear Brake)

Push piston into ATF pump onto stop.

Place new paper gasket onto ATF pump.

Place straightedge "B" onto stator support (arrow) and measure with depth gauge "A" to gasket of pump flange.
See Fig. 111 .

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Fig. 111: Calculating Dimension "b" (2nd & 4th Gear Brake)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Example calculation:

z "start" Measured value = 39.8 mm

z "minus" Straightedge = 19.5 mm
z "equals" Calculated value b = 20.3 mm

Note calculated value b.

Gap x = a - b - 2.65 mm
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Gap x = 27.3 - 20.3 - 2.65 mm = 4.35 mm

Determine size of shim(s) according to table: See 2ND & 4th Gear Brake Shims .

Calculate thickness of shim(s) according to table and determine Part No. from parts catalog.

In this example two shims must be installed (each 1.00 mm thick).

Insert three spring caps onto compression springs.

Insert last outer plate (3 mm thick).

Install correct shim(s) -a-. See Fig. 112 .

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Fig. 112: Installing Shim & Retaining Ring (2nd & 4th Gear Brake)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place retaining ring -b- onto shim(s). Smooth side facing shim.

Further installation instructions are described in Assembling Transmission .

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Table Of Shims (2nd & 4th Gear Brake)

2ND & 4TH GEAR BRAKE SHIMS

Gap "x" (mm) Shims (mm)
3.25-3.50 1.00
3.51-3.75 1.25
3.76-4.00 1.50
4.01-4.25 1.75
4.26-4.50 1.00 + 1.00
4.51-4.75 1.00 + 1.25
4.76-5.00 1.25 + 1.25
5.01-5.25 1.25 + 1.50
5.26-5.50 1.50 + 1.50
5.51-5.75 1.50 + 1.75
5.76-6.00 1.75 + 7.75

ATF PUMP

Replacement ATF pump parts and the ATF pump are assigned according to transmission code.

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Fig. 113: Exploded View Of ATF Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disassembling And Assembling

Make sure that ends of piston rings are hooked together. See Fig. 114 .

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Fig. 114: Checking ATF Pump Piston Rings Are Located Correctly
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place piston ring in groove. See Fig. 115 .

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Fig. 115: Installing ATF Pump Piston Rings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hook ends together by pressing sides of ring in and guiding ends over one another.

NOTE: Do not twist piston ring out of groove on one side.

FREEWHEEL WITH -B1- PISTON

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Fig. 116: Identifying Freewheel W/Piston Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disassembling And Assembling

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Insert springs so that spring (arrow) engages in cage. See Fig. 117 .

Fig. 117: Installing Rollers & Springs (-B1- Piston)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install with large lugs (arrow) facing up. See Fig. 118 .

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Fig. 118: Inserting Cage W/Springs & Rollers (-B1- Piston)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure cage by turning in direction of arrow as far as stop. See Fig. 119 .

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Fig. 119: Securing Cage (-B1- Piston)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert piston -A- as shown. See Fig. 120 .

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Fig. 120: Identifying Installation Position Of Piston (-B1- Piston)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1ST TO 3RD GEAR CLUTCH -K1-

Number of inner and outer plates varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 401 Thrust plate

z VW 402 Thrust plate
z VW 412 Press tool
z VW 442 Thrust pad
z 40-203/ 1 Tube, split

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Fig. 121: Identifying 1st-3rd Gear Clutch Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disassembling And Assembling

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Fig. 122: Identifying 1st-3rd Gear Clutch Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Press piston cap with intermediate spring ring down far enough for circlip (arrow) to be inserted in groove. See
Fig. 123 .

Fig. 123: Removing & Installing Circlip (1st-3rd Gear Clutch)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install thrust plate -a- with smooth side facing inner plate and stepped side towards inner plate carrier. See Fig.
124 .

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Fig. 124: Installing Thrust Plate & Plates Onto Inner Plate Carrier (1st-3rd Gear Clutch)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install 3 inner plates -b- and 2 outer plates -c-.

Clip in supporting ring with step (arrow).

NOTE: Locate locating lugs correctly.

First insert corrugated washer. See Fig. 125 .

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Fig. 125: Installing Corrugated Washer & Inner & Outer Plates In Clutch Housing (1st-3rd Gear Clutch)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert 2 mm thick outer plate.

Insert remaining inner and outer plates.

Lift inner plate carrier slightly to install circlip (arrows). See Fig. 126 .

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Fig. 126: Inserting Inner Plate Carrier & Installing Circlip (1st-3rd Gear Clutch)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

REVERSE GEAR CLUTCH -K2-

Number of inner and outer plates varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 401 Thrust plate

z VW 460 Removal device
z 3267 Assembly ring

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Fig. 127: Identifying Reverse Gear Clutch Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 128: Identifying Reverse Gear Clutch Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disassembling And Assembling

Press spring supporting plate down with 3267 just enough to be able to remove and install circlip. See Fig. 129 .
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Do not damage clutch housing ball valve.

Fig. 129: Removing & Installing Circlip (Reverse Gear Clutch)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Circlip (arrow) must be seated in the groove of clutch housing. Spring supporting plate must be centered
relative to hub. See Fig. 130 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 130: Installation Position Of Spring Supporting Plate (Reverse Gear Clutch)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

3RD AND 4TH GEAR CLUTCH -K3- WITH TURBINE SHAFT

Number of inner and outer plates varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 401 Thrust plate

z VW 402 Thrust plate
z VW 407 Press tool
z 3292/1 From assembly tool 3292

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 131: Identifying 3rd & 4th Gear Clutch Special Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 132: Identifying 3rd & 4th Gear Clutch Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disassembling And Assembling

Press down carefully on piston cap until circlip can be installed. See Fig. 133 .

Fig. 133: Removing & Installing Circlip (3rd & 4th Gear Clutch)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A piston ring is installed on the pump shaft inside the clutch housing (arrow). See Fig. 134 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 134: Checking Seating Of Piston Rings (3rd & 4th Gear Clutch)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Make sure that ends of piston rings are hooked together.

Place piston ring in groove. See Fig. 115 .

Hook ends together by pressing sides of ring in and guiding ends over one another.
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

NOTE: Do not twist piston ring out of groove on one side.

Insert O-ring in recess in turbine shaft (arrow). See Fig. 135 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 135: Installing "O" Ring (3rd & 4th Gear Clutch)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

VALVE BODY

WARNING: DO NOT run engine or tow vehicle with oil pan removed or when there is
no ATF fluid in transmission.

NOTE: Code letters are stamped on a metal tab located on valve body for component
identification. Metal tab must remain on the valve body. See Fig. 136 .

Fig. 136: Locating Valve Body Identification Tab

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removal & Installation

Place container under transmission. Remove plug (2). See Fig. 86 . Remove overflow pipe (1), and allow ATF
to drain. Screw overflow pipe in onto stop.
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Remove oil pan bolts, oil pan, gasket and ATF screen. See Fig. 137 .

Fig. 137: Exploded View Of Valve Body Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Remove conductor strip, by placing Pry Bar (3373) onto stop under solenoid valve plug. Pull plug off, with pry
bar in direction of arrow. See Fig. 138 . Remove bolt (1), and conductor strip.

Fig. 138: Removing Conductor Strip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When removing valve body, manual selector valve (1) remains in valve body. See Fig. 139 . Remove valve
body bolts and valve body. Shift selector lever/shaft into position 1. Pull manual selector valve out, until it is
just possible to unhook operating rod (2). Secure manual selector valve so it cannot fall out.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 139: Removing Valve Body & Unhooking Operating Rod

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull sealing plug out of housing before removing and installing free wheel, otherwise sealing plug and O-ring
will be damaged. Moisten 2 NEW O-rings with ATF and install to sealing plug. Insert sealing plug in hole in
transmission housing (arrow). See Fig. 140 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 140: Inserting Sealing Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn manual selector valve (1), so shoulder faces operating rod. See Fig. 139 . Guide operating rod (2) with
manual selector valve into valve body. Install with stepped side of rod facing manual selector valve.

To adjust operating rod, move selector shaft to position "P". Push operating rod with manual selector valve into
valve body onto stop (direction of arrow). See Fig. 141 . Tighten bolt to 35 INCH lbs. (4 N.m). Ensure selector
valve is resting against stop. Counter-hold (in direction of arrow) when tightening bolt. Always replace bolt and
manual selector valve retaining clip.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 141: Adjusting Operating Rod For Manual Selector Valve

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Install valve body and bolts. Tighten the two centering bolts first by hand. Tighten bolts to 44 INCH lbs. (5
N.m). When installing conductor strip, route conductor strip as shown. See Fig. 142 . Ensure conductor strip is
not kinked or twisted.

Fig. 142: Installing Conductor Strip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing ATF filter, insert seal in valve body. Firmly press ATF filter onto valve body. See Fig. 137 .

Secure clip with bolt for conductor strip connector by connecting conductor strip connector to lower retainer.
Install upper retainer with recess (arrow) onto connector tab. See Fig. 143 . Tighten bolt to 15 ft. lbs. (20 N.m).

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 143: Installing Upper Retainer Onto Connector Tab

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install oil pan, gasket and bolts. Tighten oil pan bolts to 106 INCH lbs. (12 N.m). Check transmission fluid
level. See SERVICING - A/T (01M) article.

PARKING LOCK

Special Tools And Equipment

z VW 222 A Drift
z VW 228 B Puller
z VW 423 Tube
z VW 460/2 Mandrel
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 144: Parking Lock Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 145: Exploded View Of Parking Lock Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Disassembling And Assembling

Driving Spring Pins Out And In

Drive spring pin for engaging lever and spring pin for detent segment out only far enough to remove the
selector shaft. See Fig. 146 .

Fig. 146: Driving Spring Pins Out & In

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: If driven in further spring pin of engaging lever may drop into transmission.

Drive in spring pins until flush after inserting selector shaft, engaging lever and detent segment.

Removing And Installing Selector Shaft With Selector Segments

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

With valve body installed do not damage the conductor strip.

Remove selector segment spring -A-. See Fig. 147 .

Fig. 147: Removing & Installing Selector Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove screw with washer (arrow).

The washer prevents selector shaft movement.

Inserting Guide Plate And Supporting Plate

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 148: Inserting Guide Plate & Supporting Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Inserting Pawl With Return Spring

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 149: Inserting Pawl W/Return Spring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Out Starter Bushing

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 150: Pulling Out Starter Bushing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving In Starter Bushing

Lubricate bushing mounting before driving in.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 151: Driving In Starter Bushing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing And Installing Multi-Function TR Switch

Location: The multi-function TR switch is located on rear of the transmission.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 152: Identifying Multi-Function Transmission Range

Courtesy of AUDI OF AMERICA, INC.

Switch ignition off, open hood.

Pull connector off multi-function TR switch.

Remove bolt and retainer.

Remove multi-function TR switch.

Replace seal.

Installation is performed in the reverse order of removal.

Insert switch so that each pin rests on a slope of detent segment.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Tighten bolt to 10 Nm.

Removing And Installing Transmission Vehicle Speed Sensor -G68-

Location: The transmission speed sensor -arrow- is located on top of the transmission.

Fig. 153: Identifying Transmission Vehicle Speed Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Switch ignition off, open hood.

Disconnect white connector at sensor.

Remove bolt and pull sensor out.

Replace seal.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Installation is performed in the reverse order of removal.

Tighten bolt to 10 Nm.

Removing And Installing Vehicle Speed Sensor -G68- With Transmission Installed

Location: The vehicle speed sensor -arrow- is located on top of transmission.

When the transmission is installed, the sensor is covered by the left assembly mounting.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 154: Locating Vehicle Speed Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Obtain radio code on vehicles with coded radio.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

With ignition switched off disconnect battery Ground strap and remove battery.

Remove air cleaner.

Remove hoses and cable connections in area of engine mounting eye for support 10-222 A.

Erect support device 10-222 A with adapters 10-222 A/8. See Fig. 155 .

Fig. 155: Installing Support Device & Adapters To Vehicle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: Do not remove the bolts for the carrier until the transmission has been
supported. See Fig. 156 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 156: Identifying Transmisson-To-Body Bolt Torque Specifications

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove pendulum support -A- and -B-. See Fig. 158 .

Lower transmission approx. 60 mm -a-. See Fig. 157 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 157: Removing Vehicle Speed Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect black connector from sensor.

Remove bolt and take sensor -1- out.

Replace seal.

Installation is performed in the reverse order of removal. Tighten bolt to 10 Nm. For pendulum support bolt
torque specifications, see Fig. 158 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 158: Identifying Pendulum Support Bolt Torque Specifications

Courtesy of VOLKSWAGEN UNITED STATES, INC.

FINAL DRIVE, DISASSEMBLING AND ASSEMBLING

REPAIR OVERVIEW OF FINAL DRIVE

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 159: Overview Of Final Drive

Courtesy of VOLKSWAGEN UNITED STATES, INC.

INPUT GEAR, REMOVING AND INSTALLING

Number of input gear teeth varies based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 402 Thrust plate

z VW 407 Press tool
z VW 771 Multi-purpose tool
z 30-205 Thrust plate
z 40-21 Press tool
z 40-105 Thrust plate
z VAG 1582 Tapered roller bearing puller
z VAG 1582/3 Grip
z VAG 1576 Torque wrench

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 160: Identifying Input Gear Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: For transmissions produced from 04.98, the tool for removing the tapered roller
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

bearings in the final drive and differential is VAG 1582/8.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 161: Exploded View Of Input Gear Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Off Tapered Roller Bearing Inner Race

Place thrust plate 40-105 on input gear. See Fig. 162 .

Fig. 162: Pulling Off Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Pressing On Tapered Roller Bearing Inner Race

A press piece must be placed below the hub of the input gear to avoid damage to the gear. See Fig. 163 .

Fig. 163: Pressing On Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Inserting Tapered Roller Bearing Inner Race

Insert tapered roller bearing inner race with AMV 185 101 A1 -arrow-. See Fig. 164 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 164: Inserting Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing Input Gear

Insert socket head fastener without dished washer, shim and axial needle bearing far enough for gap size a = 3
mm to exist between socket head fastener and tapered roller bearing inner race. See Fig. 165 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 165: Removing Input Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive out input gear with VW 771 as far as stop of tapered roller bearing inner race.

Remove VW 771 and take out input gear.

DRIVE PINION, REMOVING AND INSTALLING

Number of drive pinion and output gear teeth varies based on transmission code. For correct number used, see
CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 295 Drift
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

z VW 402 Thrust plate

z VW 408 A Press tool
z VW 432 Press piece
z VW 447 i Thrust plate
z VW 454 Press piece
z VW 510 Press piece
z VW 516 Tube
z 30-204 Installing ring
z 30-555 Thrust piece
z 32-109 Tube
z 40-203/ 1 Tube, split
z 3155 Ring nut spanner
z 3183 A Castellated box spanner
z 3274 Adapter
z VAG 1582 Tapered roller bearing puller
z VAG 1582/4 Grip
z Kukko 20-10 Puller
z V/172 Removal hook

NOTE: For transmissions produced from 04.98, the tool for removing the tapered roller
bearings in the final drive and differential is VAG 1582/8.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 166: Identifying Drive Pinion Special Tools (1 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 167: Identifying Drive Pinion Special Tools ( 2 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 168: Identifying Drive Pinion Special Tools (3 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 169: Exploded View Of Drive Pinion Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Off Output Gear

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

A - Kukko 20-10 and Matra V 172 pulling hooks. See Fig. 170 .

Fig. 170: Pulling Off Output Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Off Tapered Roller Bearing Inner Race

Place press piece onto collar of output gear. See Fig. 171 .

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 171: Pulling Off Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing On Tapered Roller Bearing Inner Race

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 172: Pressing On Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing In Tapered Roller Bearing Outer Race

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 173: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing & Installing Bearing Supporting Ring

Remove locking bolt. See Fig. 174 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 174: Removing & Installing Bearing Supporting Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Torque wrench

Tighten bearing supporting ring to 200 Nm and secure with locking screw. Insert screw with AKD 456 000 01.

Bearing Supporting Ring W/Seal For Drive Pinion

Installation position of seal: See Fig. 175 .

Open side (arrow) faces tapered roller bearing outer race.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 175: Bearing Supporting Ring W/Seal For Drive Pinion

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving In Drive Pinion Oil Seal

Insert oil seal so that sealing lip faces outward to special tool 30-204. See Fig. 176 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 176: Driving In Drive Pinion Oil Seal

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing Drive Pinion

A - Ring spanner 32 mm. See Fig. 177 .

Fig. 177: Removing Drive Pinion

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving In Tapered Roller Bearing Outer Race

Insert drive pinion with tapered roller bearing inner race, then drive in outer race. See Fig. 178 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 178: Driving In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing On Tapered Roller Bearing Inner Race

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 179: Pressing On Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

DIFFERENTIAL, REMOVING AND INSTALLING

Special Tolls And Equipment

z VW 391 Drive shaft fitting appliance

z VW 681 Oil seal extractor
z 3109 Puller
z 3155 Ring nut spanner
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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

z 3319 Thrust piece

Fig. 180: Identifying Differential Special Tools

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 181: Exploded View Of Differential Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 182: Exploded View Of Differential Assembly Legend

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving In Drive Flange Oil Seal Up To Stop

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Fig. 183: Driving In Drive Flange Oil Seal Up To Stop

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Marking Adjusting Ring

If used bearings are re-installed, mark installation position (arrow) and again position on marking when
installing. See Fig. 184 .

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 2003 Volkswagen New Beetle GLS
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Fig. 184: Marking Adjusting Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing Adjusting Ring

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 2003 Volkswagen New Beetle GLS
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Fig. 185: Removing Adjusting Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Speedometer Drive

With transmission installed, check gear oil in final drive. See SERVICING - A/T (01M) article.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 186: Identifying Speedometer Drive

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Inserting Differential

Insert differential and screw in bearing body as far as stop to 150 Nm. See Fig. 187 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 187: Inserting Differential

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Inserting Circlip

Remove circlip (arrows) with two screwdrivers. See Fig. 188 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 188: Inserting Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing And Installing Securing Ring For Drive Flange

Screw spindle out of bridge -A- on puller Kukko 18-0. See Fig. 189 .

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 189: Removing & Installing Drive Flange Securing Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert spindle with nut from assembly tool 3301 instead.

Bolt puller Kukko 18-0 to flange using two 8x35 mm bolts and 8 mm diameter washers.

Remove securing ring -arrow- for drive flange

Removing And Installing Drive Flange

Removing

Bolt puller Kukko 18-0 to flange using two 8x35 mm bolts and 8 mm diameter washers. See Fig. 190 .

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Fig. 190: Removing & Installing Drive Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off drive flange.

NOTE: Drive flange for triple roller shaft with 108 mm flange diameter can also be
pulled off with assembly tool VW 391.

Installing

Secure puller 18-0 on drive flange. See Fig. 190 .

Exchange spindle -B- from Kukko 18-0 for spindle with nut from assembly tool 330. See Fig. 189 .

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 2003 Volkswagen New Beetle GLS
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Pull in drive flange.

NOTE: Drive flange can also be pulled in with VW 391.

DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING

Number of teeth on final drive gear vary based on transmission code. For correct number used, see CODE
LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT .

Special Tools And Equipment

z VW 402 Thrust plate

z VW 408 A Press tool
z VW 411 Press tool
z 30-205 Thrust plate
z 40-21 Press tool
z VAG 1582 Tapered roller bearing puller
z VW 191
z VW 472/1 Thrust piece
z VW 472/2 Thrust piece
z VW 792 Thrust piece
z 3347 Assembly tool
z 2010
z VW 433 Thrust piece
z VAG 1582/6 Grip
z VAG 1582/6A Grip
z VAG 1582/11 Grip
z Kukko 21/7 Internal puller
z Kukko 22/2 Counter-support
z VAG 1582/3 Clamping ring
z 30-555 Thrust piece

NOTE: For transmissions produced from 04.98, the tool for removing the tapered roller
bearings in the final drive and differential is VAG 1582/8.

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Fig. 191: Identifying Differential Disassembly & Assembly Special Tools (1 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 192: Identifying Differential Disassembly & Assembly Special Tools (2 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 193: Identifying Differential Disassembly & Assembly Special Tools (3 Of 3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 194: Identifying Clamping Ring (VAG 1582/3)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 195: Identifying Thrust Piece (30-555)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 196: Overview Of Differential Disassembly & Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Off Tapered Roller Bearing Inner Race

Use adapter VAG 1582/6A for larger bearings

Place press piece 30-555 on differential housing. See Fig. 197 .

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 197: Pulling Off Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: For transmissions produced from 04.98, the tool for removing the tapered roller
bearings in the final drive and differential is VAG 1582/8.

Pressing On Tapered Roller Bearing Inner Race

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Fig. 198: Pressing On Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Out Tapered Roller Bearing Outer Race

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Fig. 199: Pulling Out Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing In Tapered Roller Bearing Outer Race

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Fig. 200: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Inserting Differential Bevel Gears

Insert one-piece thrust washer with gear oil.

Insert small bevel gears, drive in shaft and secure with spring pin.

Insert large bevel gears offset 180° and swivel in direction of arrow. See Fig. 201 .

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Fig. 201: Inserting Differential Bevel Gears

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing In Tapered Roller Bearing Outer Race

With adjusting ring or bearing body heated, insert outer race and press home as far as stop. See Fig. 202 .

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Fig. 202: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Out Tapered Roller Bearing Outer Race

A - Kukko 22/2 counter-support. See Fig. 203 .

B - Kukko 21/7 internal puller

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 203: Pulling Out Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing In Tapered Roller Bearing Outer Race

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Fig. 204: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling Off Tapered Roller Bearing Inner Race

Place press piece VW 433 on bearing body.

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Fig. 205: Pulling Off Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing On Tapered Roller Bearing Inner Race

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 206: Pressing On Tapered Roller Bearing Inner Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing And Installing Differential Pinion Shaft Spring Pin

Length of spring pin 28.5 mm

Removing

Pull out spring pin with side cutting pliers. See Fig. 207 .

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Fig. 207: Removing Differential Pinion Shaft Spring Pin

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

Drive in spring pin as far as stop.

FINAL DRIVE, ADJUSTING

OVERVIEW OF ADJUSTMENTS

To prevent unnecessary adjustment work on final drive after making repairs, see ADJUSTMENTS TO BE
COMPLETED AFTER REPLACING INDIVIDUAL COMPONENTS .

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Fig. 208: Overview Of Final Drive Adjustments

Courtesy of VOLKSWAGEN UNITED STATES, INC.

ADJUSTMENTS TO BE COMPLETED AFTER REPLACING INDIVIDUAL COMPONENTS

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Fig. 209: Adjustments Table (After Replacing Individual Components)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

DRIVE PINION, ADJUSTING

Special Tools And Equipment

z VW 385/17 End dimension plate

z VW 387 Universal dial gauge bracket
z Dial gauge
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Fig. 210: Identifying End Dimension Plate (VW 385/17)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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1998-2004 AUTOMATIC TRANSMISSIONS Overhaul - New Beetle, 01M

Fig. 211: Identifying Universal Dial gauge Bracket (VW 387)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Conditions

z Supporting ring for drive pinion bearing is installed and secured.

z Parking lock mechanism and parking lock gear are installed.

Adjusting

Place two shims (each 1.5 mm thick) -arrow- onto drive pinion. See Fig. 212 .

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Fig. 212: Locating Shims On Drive Pinion

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place output gear with tapered roller bearing onto drive pinion and tighten hex nut (41 mm AF) to 250 Nm;
engage parking lock when performing this step.

Insert dial gauge -A- and zero with a preload of 1 mm. See Fig. 213 . Move drive pinion up and down. Read off
play at dial gauge and note (example 0.93 mm).

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Fig. 213: Identifying Dial Gauge Installation Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: When performing measurement, do not turn drive pinion as the bearings will
otherwise settle and give you a false measurement.

Determining Shims

The specified bearing preload is achieved if the reading (0.93 mm), the preload of the bearings 0.12 mm and the
amount for compression 0.10 mm are deducted from the 2 x 1.5 mm thick shims.

Example calculation:

z "start" Shims inserted = 3.00 mm

z "minus" Reading = 0.93 mm
z "minus" Preload = 0.12 mm

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z "minus" Amount for settlement = 0.10 mm

z "equals" Thickness of shim = 1.85 mm

Remove output gear. Determine size of shim on basis of table, and fit onto pinion. See Table Of Shims For
Drive Pinion And Input Gear .

Re-install output gear and tighten hex nut to 250 Nm. Secure with drift.

Table Of Shims For Drive Pinion And Input Gear

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Fig. 214: Drive Pinion & Input Gear Shim Table

Courtesy of VOLKSWAGEN UNITED STATES, INC.

INPUT GEAR, ADJUSTING

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Special Tools And Equipment

z VW 382 Measuring appliance

z VAG 1332 Torque wrench
z Dial gauge

Fig. 215: Identifying Measuring Appliance (VW 382)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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Fig. 216: Identifying Torque Wrench (VAG 1332)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Conditions

Tighten socket head fastener to 100 Nm without dished washer and without shim. See Fig. 217 . The parking
lock must be engaged. Remove socket head fastener.

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Fig. 217: Tightening Socket Head Fastener Without Dished Washer Or Shim
Courtesy of VOLKSWAGEN UNITED STATES, INC.

For Fig. 217 , components are:

z A - Torque wrench
z B - 22 mm socket

Measure distance between input gear and tapered roller bearing inner race. See Fig. 218 .

Insert dial gauge and zero with a preload of 3 mm. See Fig. 218 . Note reading (example 1.00 mm).

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Fig. 218: Inserting Dial Gauge For Input Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thickness of dished washer, 1.50 mm, must be added to reading to equal 2.50 mm.

Determining Shim (Input Gear)

The specified bearing preload is achieved if the bearing preload of 0.18 mm is deducted from the figure
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obtained from the measurement (dished washer + reading) of 2.50 mm.

Example calculation:

z "start" Dished washer + reading = 2.50 mm

z "minus" Bearing preload = 0.18 mm
z "equals" Thickness of shim = 2.32 mm

Determine shim on basis of table and fit onto drive shaft. See Table Of Shims For Drive Pinion And Input
Gear .

Insert axial needle bearing and tighten socket head fastener including dished washer to 250 Nm.

NOTE: Insert axial needle bearing for input shaft before tightening socket head
fastener. Installation position. See INPUT GEAR, REMOVING AND INSTALLING .

DIFFERENTIAL, ADJUSTING

Special Tools And Equipment

z 3155 Ring nut spanner

z VAG 1332 Torque Wrench

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Fig. 219: Identifying Ring Nut Spanner (3155)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjusting Differential

Tighten bearing body with 3155 to 150 Nm as far as stop and secure. See Fig. 220 .

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Fig. 220: Tightening Bearing Body with Special Tool 3155

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten adjusting ring to 50 Nm and mark.

NOTE: When performing measurement, do not turn differential otherwise the bearings
will settle and give you a false measurement.

Turn adjusting ring on by five locking lugs and secure so that preload of tapered roller bearings is set.

DEFINITIONS
These definitions are only for this assembly group: Automatic transmission 01M. They are not valid for general
use.

ATF (AUTOMATIC TRANSMISSION FLUID)

Transmission oil for automatic transmission.

ATF PUMP

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A gear type pump driven by the torque converter.

ATF LEVEL

The fill level of ATF in the transmission with engine running.

DATA BUS

Transportation of data. To do this the electrical signals are brought into a certain format (bus).

DATA BUS LOW (HIGH)

The voltage used to transport the data is low (high).

BRAKES

These hold rotating components in the transmission. The automatic transmission is fitted with plate type brakes.
In difference to the clutches, the brakes support against the transmission housing.

TORQUE CONVERTER

Transfers the engine torque to the automatic transmission and acts as a drive-away clutch. The torque converter
also includes the lock-up clutch.

ON BOARD DIAGNOSTIC (OBD)

The capability of the control module:

z to recognize malfunctions,
z to react to malfunctions,
z to store diagnostic trouble codes (DTCs),
z to register malfunctions and make them available in the Measured Value Block.

PERFORMING ON BOARD DIAGNOSTIC

Connecting the Scan Tool to be able to check the Diagnostic Trouble Code (DTC) memory.

PERFORMING ELECTRICAL CHECK

A targeted check of the electronic components by performing certain measurements.

FREEWHEEL/STATOR

Ensures the torque is increased in the torque converter when driving off.

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FREEWHEEL/TRANSMISSION

Technically simplifies the gear changes without interrupting the power and ensures a constant gear change
quality.

TRANSMISSION VEHICLE SPEED SENSOR (VSS) -G38-

The sensor records the speed of the large sun-wheel in the planetary gearbox and transmits it to the automatic
transmission control module. Further information on this can be found in Self-study program No. 172.

VEHICLE SPEED SENSOR (VSS) -G68-

The sensor records the speed of the output gear and transmits it to the automatic transmission control unit (not
to the speedometer). Further information on this can be found in Self-study program No. 172.

CLUTCHES

Together with the brakes, they engage the individual gears.

SELECTOR LEVER LOCK SOLENOID N110

Located in the selector mechanism close to the selector lever. Prevents movement (involuntary) of the selector
lever from positions "P" and "N" as long as the brake pedal is not depressed.

SOLENOID VALVES

Opens and closes the oil channels to the clutches and brakes.

MULTI FUNCTION SWITCH -F125-

Electrical switch with multiple functions. For more information refer to Self-study program No. 172.

EMERGENCY RUNNING

"Condition of the control unit" when certain malfunctions are recognized it guarantees the further driving
safety, protects the transmission against damage and at the same time impairs the driving characteristics only as
much as is necessary.

PARKING LOCK

The parking lock gear is mechanically locked when the vehicle is stationary and prevents the vehicle from
rolling (involuntarily).

PLANETARY GEARBOX

Is a mechanical component of the automatic transmission and is switched via the clutches and brakes without
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loss of power.

PENDULUM SUPPORT

Designation for a part of the assembly mounting.

VALVE BODY

Located on the bottom of the transmission and is enclosed in the ATF pan. Its valves regulates the hydraulic
pressure and distributes it via the oil channels to the switch elements (clutches and brakes).

TRANSMISSION CONTROL MODULE (TCM) -J217-

The electronic control module defines the shift points. The function of the transmission is monitored via the
self-diagnosis. If a component or sensor fails, an emergency running program ensures the vehicle can still be
driven.

TCC (TORQUE CONVERTER LOCK-UP CLUTCH)

It transfers the engine torque mechanically to the transmission.

IGNITION KEY WITHDRAWAL LOCK

Makes sure that the ignition key can only be withdrawn when Park position is selected and also mechanically
locks the selector level in this position.

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2003-04 AUTOMATIC TRANSMISSION

Overhaul - New Beetle, 02E

APPLICATION
TRANSMISSION APPLICATION
Application Transmission Model
1.9L (2003-2004) 02E, 6-Speed

IDENTIFICATION
Transmission code letters are given on bottom of transmission, near oil cooler. See Fig. 1 . Transmission code
letters are also given on vehicle data stickers.

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Fig. 1: Locating Transmission Identification Code

Courtesy of VOLKSWAGEN UNITED STATES, INC.

CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT

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Fig. 2: Transmission Code GPX

Courtesy of VOLKSWAGEN UNITED STATES, INC.

DESCRIPTION & OPERATION

TRANSMISSION

The 6 Spd. Direct Shift Automatic Transmission 02E is also called double-clutch transmission. The engine
torque is initiated via the two-mass flywheel into the transmission. The transmission is built up like a 6-speed
manual transmission. By alternating sequence of the hydraulic activation of two multi-plate wet clutches, it is
operated like an automatic transmission, that means the speeds are selected automatically or manually via
Tiptronic mode. A clutch pedal is not installed.

SAFETY FUNCTIONS OF TRANSMISSION CONTROL MODULE

If one or more components or sensors fail the Transmission Control Module (TCM) -J217- activates the
corresponding functions or emergency programs. This ensures a transmission operation without damage which
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 2003 Volkswagen New Beetle GLS
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could have effects on gearshift function and quality.

GEAR CHANGE POINT VARIATIONS FOR HILLS

An additional gear change map automatically selects gear changes for hills dependent upon accelerator pedal
position and driving speed.

z Gear change map for extreme uphill stretches, is matched to engine output.
z Gear change map for extreme downhill stretches, is matched to braking effect of the engine.
z By selecting a gear directly via Tiptronic the engine braking effect can be exploited also with a specific
gear selected, such as when you have gradients in the trailer mode.

LUBRICATION & ADJUSTMENTS

For lubrication and adjustments, see SERVICING - A/T (02E) article in TRANSMISSION SERVICING.

ON-VEHICLE SERVICE
AXLE SHAFTS

For information on axle shaft, see AXLE SHAFTS article in DRIVELINE/AXLES.

TRANSMISSION COMPONENTS

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T
(02E) article.

APPLY & BRAKE CLUTCH APPLICATION

Manufacturer does not provide specific information for apply and brake clutch application.

REPAIR INSTRUCTIONS
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful
transmission repairs. The usual basic safety precautions naturally also apply when performing servicing work.

A number of generally valid instructions for various repair procedures, which are mentioned at various points in
the Repair Manual; are summarized here.

BATTERY DISCONNECTING & RECONNECTING

CAUTION: Before beginning repairs on the electrical system:

z Obtain anti-theft radio security code.

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z Switch off all electrical consumers.

z Switch ignition off and remove ignition key.
z Do not loosen or remove ground strap from body. Disconnect
terminal from battery only.

For work steps required after reconnecting battery, see Fig. 3 .

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 2003 Volkswagen New Beetle GLS
2003-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 02E

Fig. 3: Reconnecting Battery Work Steps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: If desired, print this page and use the table above as a checklist.
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2003-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 02E

RULES FOR CLEANLINESS WHEN WORKING ON TRANSMISSION

z Do not run engine or tow vehicle with oil pan removed or without gear oil.
z Carefully clean all joints and adjacent areas before disconnecting.
z When installing transmission make sure that the dowel sleeves between engine and transmission are
seated correctly.
z Place parts that have been removed on a clean surface and cover so that they are not soiled. Use sheeting
and paper. Do not use fluffy cloths!
z Only install clean components: Unpack replacement parts immediately prior to installation.
z Carefully cover opened components or seal if repairs cannot be carried out immediately.

O-RINGS, OIL SEALS, GASKETS

z Always replace O-rings, oil seals and gaskets.

z After removing seals/gaskets, examine the contact surfaces on housings or shafts for burrs and signs of
damage and repair before reinstalling.
z Before installing a radial shaft seal lubricate the outside diameter with gear oil and fill the space between
the sealing lips (arrow) halfway with G 052 128 A1.
z The open side of an oil seal faces towards the oil.
z Always use transmission oil. Other lubricants will cause the hydraulics to malfunction.
z Check gear oil level after installing and if necessary top off. See SERVICING - A/T (02E) article.

NUTS, BOLTS

z Loosen and tighten nuts, bolts/screws for securing covers and housings in a diagonal sequence.
z Do not tilt the very sensitive parts and also loosen and tighten in a diagonal sequence.
z The torque settings indicated refer to non-lubricated screws and bolts:
z Threads of bolts/screws that are secured by locking fluid are to be cleaned with a wire brush. Then insert
bolts/screws with AMV 185 100 A1.
z All threaded holes where locking fluid is applied must be cleaned with a thread tap to remove remnants of
locking fluid. Otherwise there is a danger that a bolt/screw will shear when reinstalling.
z Replace self-locking nuts.

OVERHAUL
Manufacturer does not provide overhaul procedures or specifications. For fluid capacities and types, adjustment
or servicing procedures, seeSERVICING - A/T (02E) article. For removal and installation procedures, see
REMOVAL & INSTALLATION - A/T (02E) article.

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

2002-04 AUTOMATIC TRANSMISSION

Overhaul - New Beetle, 09G

APPLICATION
TRANSMISSION APPLICATION
Application Transmission Model
1.8L (2002-2004) 09G, 6-Speed
2.0L (2003-2004) 09G, 6-Speed

IDENTIFICATION
Transmission code letters are given on type plate (arrow). See Fig. 1 . Transmission code letters are also given
on vehicle data plate.

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

Fig. 1: Locating Transmission Identification Code

Courtesy of VOLKSWAGEN UNITED STATES, INC.

CODE LETTERS, TRANSMISSION APPLICATION, RATIOS, EQUIPMENT

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

Fig. 2: Transmission Codes GGZ & GHE (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

Fig. 3: Transmission Codes GGZ & GHE (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

DESCRIPTION & OPERATION

TRANSMISSION

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

The 6-speed automatic transmission 09G is equipped with 6 hydraulically activated forward gears. The 2nd,
3rd, 4th ,5th and 6th gears become mechanically driven gears by cutting out torque converter slip when the
lock-up clutch is closed.

TORQUE CONVERTER

The torque converter is equipped with a lock-up clutch. The lock-up clutch is closed dependent on load and
speed. The 2nd, 3rd, 4th, 5th and 6th gears are then driven mechanically independent of slip.

ATF

The ATF oil is filled-for-life. The ATF does not require changing within the framework of a service.

When checking oil level use only ATF with the Part No. G 055 025 A2.

The ATF level in the planetary gearbox and the final drive is checked and filled simultaneously. See
SERVICING - A/T (09G) article.

GUIDED FAULT FINDING, VEHICLE SELF-DIAGNOSIS AND MEASURING TECHNOLOGY

Before performing repairs to the automatic transmission, determine the cause of the malfunction as precisely as
possible with the aid of "Guided fault finding".

The guided fault finding is performed with Vehicle Diagnosis, Testing and Information System VAS 5051.

TRANSMISSION CONTROL MODULE -J217-

NOTE: Determining the driving situation and driving resistance dependent gear change
point occurs automatically.

With Driving Situation Gear Changes (Fuzzy Logic)

Advantages:

z Gear changes are consumption orientated

z Maximum engine output is always available
z Individual adaptation of gear change points in all driving situations
z Gear change points are infinitely variable

Gear Change Point Variations For Hills

An additional gear change map automatically selects gear changes for hills dependent upon accelerator pedal
position and driving speed.

z Gear change map for extreme uphill stretches is matched to engine output

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

z Gear change map for extreme downhill stretches is matched to braking effect of the engine

LUBRICATION & ADJUSTMENTS

For lubrication and adjustments, see SERVICING - A/T (09G) article in TRANSMISSION SERVICING.

ON-VEHICLE SERVICE
AXLE SHAFTS

For information on axle shaft, see AXLE SHAFTS article in DRIVELINE/AXLES.

TRANSMISSION COMPONENTS

For information on components serviceable while transmission is installed in vehicle, see SERVICING - A/T
(09G) article.

APPLY & BRAKE CLUTCH APPLICATION

Manufacturer does not provide specific information for apply and brake clutch application.

TRANSMISSION CHECKING
VAS 5051, CONNECTING AND SELECTING FUNCTION

Special Tools And Equipment

z VAS 5051 Vehicle Diagnosis, Testing and Information System

z Diagnostic cable VAS 5051/1 or VAS 5051/3

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

Fig. 4: Identifying Tester (VAS 5051)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAS 5051, Connecting And Selecting Function

WARNING: z When performing a road test the test and measuring units must be
secured on the rear seat.
z During the road test only one person must operate these units.

With ignition switched off, connect tester VAS 5051 to Data Link Connector (DLC) using diagnostic cable
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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

VAS 5051/1 or VAS 5051/3. See Fig. 5 .

Fig. 5: Connecting Diagnostic Cable To DLC

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Switch tester on (arrow). See Fig. 4 .

Tester is operationally ready when picture of a vehicle appears on display.

Switch ignition on.

Touch key on screen for: Guided Fault finding.

Select one after another:

z Brand
z Model
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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

z Model year
z Variant
z Engine code

Confirm data as entered:

NOTE: Wait until the tester has read all the available control modules.

Using "Go to" key, select "Function/component selection"

Follow instructions on screen to start functions desired.

REPAIR INSTRUCTIONS
The maximum possible care and 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 applicable instructions for individual repair operations, which are otherwise mentioned
at various points in the repair manual; are summarized here.

BATTERY DISCONNECTING & RECONNECTING

CAUTION: Before beginning repairs on the electrical system:

z Obtain anti-theft radio security code.

z Switch off all electrical consumers.
z Switch ignition off and remove ignition key.
z Do not loosen or remove ground strap from body. Disconnect
terminal from battery only.

For work steps required after reconnecting battery, see Fig. 6 .

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

Fig. 6: Reconnecting Battery Work Steps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE: If desired, print this page and use the table above as a checklist.
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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

TRANSMISSION

z When an automatic transmission is replaced the following fluid levels must be checked:

ATF in planetary gearbox and final drive. See SERVICING - A/T (09G) article.

Capacities and specifications. See SERVICING - A/T (09G) article.

z Do not run engine or tow vehicle with oil pan removed or when there is no ATF in transmission.
z Secure torque converter against falling out when transmission is removed.
z Clean joints and connecting points thoroughly before loosening.
z When installing the transmission ensure that the dowel sleeves between the engine and the transmission
are seated correctly.
z Place parts that have been removed on a clean surface and cover so that they are not soiled. Use foil and
paper. Do not use fluffy cloths!
z Only install clean components: Only unpack replacement parts immediately prior to installation.
z Carefully cover opened components or seal if the repair cannot be performed immediately.
z Replace transmission if any of the selector elements are scorched/burned.
z A basic (default) setting must be performed each time the transmission is reinstalled.

GASKETS, SEALS

z Always replace O-rings, seals and gaskets.

z After removing seals/gaskets etc. always check contact surfaces on housings or shafts for burrs and
damage and correct before reinstalling.
z The open side of an oil seal faces toward the oil.
z Before installing an oil seal moisten the outer surfaces and the sealing lip sparingly with ATF.
z Moisten O-rings with ATF to prevent damage to the O-ring when installing.
z Only use ATF in the areas normally lubricated by ATF. Other lubricants will cause the hydraulic
elements to malfunction.
z After installing, check ATF level in planetary gearbox/final drive and correct levels as necessary.

ATF in planetary gearbox and final drive. See SERVICING - A/T (09G) article.

Capacities and specifications. See SERVICING - A/T (09G) article.

BOLTS, NUTS

z Loosen and tighten the screws and bolts for securing the covers and housings in a diagonal sequence.
z Do not cant particularly sensitive parts, e.g. valve body, and loosen and tighten in stages using diagonal
sequence.
z Prescribed torque specifications apply to unoiled nuts, screws/bolts.

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 2003 Volkswagen New Beetle GLS
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z Threads of bolts/screws that are secured by locking fluid are to be cleaned with a wire brush. Then insert
bolts/screws with AMV 185 100 A1.
z All threaded holes where locking fluid is employed must be cleaned with a thread tap to remove remnants
of locking fluid. Otherwise there is a danger that a bolt/screw will shear when reinstalling.
z Replace self locking nuts and bolts/screws.

VALVE BODY

z The valve body is allocated according to transmission code. See CODE LETTERS, TRANSMISSION
APPLICATION, RATIOS, EQUIPMENT .

GUIDED FAULT FINDING, VEHICLE SELF-DIAGNOSIS AND MEASURING TECHNOLOGY

Before servicing the automatic transmission, determine the cause of the malfunction as precisely as possible
with Vehicle Diagnosis, Test and Information System VAS 5051 with the aid of "Guided fault finding",
"Vehicle self-diagnosis" and "Measuring technology".

TORQUE CONVERTER
ASSEMBLY OVERVIEW

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Fig. 7: Overview Of Torque Converter Assembly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

TORQUE CONVERTER, IDENTIFICATION

There are various torque converters. Identification is via code letters (arrows). See Fig. 8 .

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Fig. 8: Locating Torque Converter Code

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Allocating torque converter to transmission, see CODE LETTERS, TRANSMISSION APPLICATION,

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RATIOS, EQUIPMENT .

TORQUE CONVERTER, DRAINING

Special Tools And Equipment

z V.A.G 1358/A Oil extractor unit

z V.A.G 1358 A/1 Oil extraction probe

Fig. 9: Identifying Oil Extractor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drain the torque converter when performing a major overhaul of the transmission or if the ATF has become

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 2003 Volkswagen New Beetle GLS
2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

contaminated by abrasion as follows:

Extract ATF from torque converter using V.A.G 1358 A and probe V.A.G 1358 A/1. See Fig. 10 .

Fig. 10: Draining Torque Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

TORQUE CONVERTER, REMOVING

Special Tools And Equipment

z VW 681 Extractor lever

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Fig. 11: Identifying Extractor Lever

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing Torque Converter Oil Seal

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Fig. 12: Removing Torque Converter Oil Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

TORQUE CONVERTER, CHECKING

Check torque converter hub for scoring (arrow). See Fig. 13 .

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Fig. 13: Locating Torque Converter Hub

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque converter is worn and must be replaced if damaged.

TORQUE CONVERTER, INSTALLING

Special Tools And Equipment

z T10175 press piece

z Depth gauge
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Fig. 14: Identifying Press Piece (T10175)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving In Torque Converter Oil Seal

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2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

Fig. 15: Driving In Torque Converter Oil Seal Until Flush

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide torque converter hub through oil seal and onto first limit stop.

Turn torque converter while pushing in lightly until recesses in torque converter engage into drive of pump and
torque converter slips noticeably inward.

Check Installation Dimension Of Torque Converter

When the torque converter is correctly installed in the transmission, the distance -a- between the contact
surfaces down by the studs on the torque converter and the contact surfaces of the torque converter housing is
approx. 20 mm. See Fig. 16 .

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2002-04 AUTOMATIC TRANSMISSION Overhaul - New Beetle, 09G

Fig. 16: Checking Installation Dimension Of Torque Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If the torque converter is incorrectly installed this distance is considerably less.

CAUTION: When the torque converter is incorrectly installed the torque converter

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 2003 Volkswagen New Beetle GLS
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drive or the ATF pump will be destroyed when the transmission is

connected to the engine.

When subsequently installing the transmission the following points must be observed:

When tightening the bolts on the engine/transmission flange, check often that the torque converter still moves
behind the drive plate.

If the torque converter does not turn, one must assume that it has not been installed correctly and the torque
converter drive or the ATF pump will be destroyed when finally tightening the bolts.

OVERHAUL
Manufacturer does not provide overhaul procedures or specifications. For fluid capacities and types, adjustment
or servicing procedures, see SERVICING - A/T (09G) article. For removal and installation procedures, see
REMOVAL & INSTALLATION - A/T (09G) article.

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December-27-07 1:20:12 PM Page 23 © 2005 Mitchell Repair Information Company, LLC.