![]() 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. Done 020 without any probs or major special tools so this looks relatively easy It did improve things, but hasn't got rid of the tight shift.DIY Tearing a VW 02A/O2A/02J/O2J Transmission Down to its Sub Assemblies So I kind of cheated, I locked the shifter end first, then released the cables and took the slack out that way. The counter weight seemed a little stiff and I'm not really good with imperial measurements and being a guy I have a hard time working out what a 1/4 inch looks like My L shaped lever must be snapped as I couldn't lock it in place and I found it difficult to find that little sweet spot in the 1st/2nd gear gate. I replaced that with an OEM one at around £9 uk sterling. Oh yea, I should mention I've already tried to adjust the selector using your handy video, found a weak spot, one of the fingers of one of the cable ends disintegrated as soon as the knurled end was pulled back. I guess it's bad there with this whole VW diesel scandal Well maybe now that "silly season" or marching season is over it's better, but I'm just fed up with how our circus of a government are fighting over an alleged IRA murder and have practically stopped working leaving all our health services and stuff like that with no money, but hey, enough politics. VW did a lot right on the MK4, but the gearbox, not so much. There is side-side slop built into the selection mechanism within the gearbox, so anything outside the box (bushings, ball cup, etc) will help greatly, but you're never going to get rid of some slop. I find that if I grab the "golf club" (or the flat piece that replaces that in the Sigma), I can move it up and down while a gear is selected. I don't have any extra aluminum/McD's receipts, nor the FIGG, but that bushing looked OK at last glimpse. ![]() I have the new ball cup from the MK5 as linked above. If anything, I shift slower with it because I can feel when the gear doesn't want to engage yet, whereas before by the time that feedback came to the lever with the stock setup, I already had put too much pre-load to the rubbery cable-ends and the syncro was over-stressed.Īs for side-side slop, the DG shifter made it proportionally smaller, but it's still there. The throw-length isn't the limiting factor with the 02J, it's the syncro rings. The Sigma greatly improves the tactile feel of the shifting (no flexy rubbery bushings in flimsy plastic cable-ends, no weight to cancel feedback from the syncros), and it changes the throw of the lever to a more comfortable distance which reduces arm strain, but it won't "speed up" gear engagement. That's not a criticism of the Sigma product per se - any short shifter would have the same effect. If you shorten the throw, it becomes even easier to crunch the shift, so you have to be concious to either go extra-easy (two-fingers easy) on the lever. It must be said that I find that the 02J gearbox in general likes to grind/crunch shifts from rushing the lever (maybe I'm just extra ham-fisted?). GASDAG, Jim's (corrado_tdi) DG short shifter does allow you to feel the shift engagement more precisely. I see we really have healthy options to improve the ball cup lol! ![]()
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