![]() This is not enough info to properly install a LSD because there is shimming/back spacing involved due to the installation of new bearings and races but it should give you an idea of what is involved. The left overs of the 3rd gear syncro and hub I've done this twice now and not thought of it until a tech recomended itģrd gear syncro is destroyed and the syncronizer hub dropped a catch(dog) Now pounding them out (I should have just used an air hammer. Step 13 lift out the pinion shaft and now the diff and now you have completed taking your tranny apart or at least down to the sub assemblies Step 11:Unbolt the reverse linkage and remove the reverse shaft Step 10:Lift away the sfift linkage assembly Step 9 take a block of wood and hammer and separate the case halfs and lift the case off Step 8 remove all the 13mm bolts on the differential end of the case the 1st is on the bottom almost in between the linkage pivot points and the other it inside the 5th gear end case Step 6: remove the shift linkage pivot points 2 on top and 2 on the bottom Also I will add that I applied heat with a heat gun for a few minutes after I had the gear puller in place and ready to crank away. Last night I modified my craftsman gear puller a little more and I think I have made it very simple to do everytime now. Pulling the 5th gear: I pulled my DZSL SLC's 5th gear last night and it was easy but I've done it several times now. This one is from sears and I have not chipped a tooth yet on 5th gear but I've seen a VW tech chip some teeth before using the actual VW tool I have had to grind the prongs on the gear puller to fit between the case and the 5th gear. I screw in an allen bolt to center the gear puller Make certain you do not press on the end of the shaft directly. then you will need to pull the 5th gear off. and then you will need to remove the 5th gear syncro/hub assebmly with a gear puller. Step 4: Remove all the 13mm bolts and nuts inside the bell housing area The G60 and later VR6 shift towers have differnt thickness shafts and when swapping them you need to swap out the bottom cap/guide: It should be noted that when switching shift towers that there are differances to note. There are indents on the cap and tower to do this remove 13mm bolts and then heat the area around the sealant with a torch(propane) and then smack with a piece of wood and hammer the cap and shift tower from the side to spin them. Step 3 remove shift tower and bottom cap/guide. Step 2: remove output flanges with bolt from tranny case(threaded all the down shaft) Step 1: remove tranny oil before beginning Here is a link to my photo album with the full size pictures: just in case!! and here's a link to the component teardown by Pashat: Jeres a gallery on swapping an 02A in an A2 in case anybody wants'needs that: īTW loaded all the pix on my hardrive. Improved and redesigned first gear getter bushing (repair and fix) for VAG 02J manual trans gear shift lever Cure the issue of first gear finding difficulty. Done 020 without any probs or major special tools so this looks relatively easy Didn't do squat for me, and from what I've read one or two other people have tried with the same poor result.DIY Tearing a VW 02A/O2A/02J/O2J Transmission Down to its Sub Assemblies Oh yeah, someone was dead sold on heating up the tower in the oven and that the bearing would just about fall out. I was transferring it to a new (rebuilt) transmission and thought that now was the time to do this. There wasn't anything apparently wrong with this shift tower. The rubber washer actually installs over the shaft. The ordering top to bottom of the bits: seal, bearing and then rubber washer. Used a screwdriver and hammer on the top lip (once it was exposed enough) to get it the rest of the way out. I used a chisel from the top to catch the slight lip (lip on either end to keep bearing cage in place) and was able to start driving it out. I used a Dremel sanding drum (small), three of them, to cut away enough material that I could bend and snap off some of the shell metal: this is from the bottom edge. Not going to look back on this job! What a PITA. This missing bearing might be why 5th gear disappeared. There was a rubber washer in the kit I got. Is that lever called the "shift adjustment pin" in post #16 of this thread? I didn't know what the little right angle lever was for so I pulled the tower off separately. I stuck my magnet way down inside trany and nothing came back with it. There was no sign of the old bearings or cage when I opened it. It was in there so good the tacks would break off and take some race with them. Nothing to grab so I tacked some welds to the inside. Might get an answer to my rubber washer question.ĭamn that was just as nasty as some of the pics I've seen. I posted some of this in my first TDI project thread.īut it seems like the info would be better placed here.
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