![]() If you've not had a gearbox apart before, you are in for a LOT of learning real fast. Same situation with most everything else. Starters are different depending on the engine but they bolt to holes in the transmission case that are in the same place. But, you can take a transmission that originally had a 3.89 final drive apart, substitute ALL the equivalent parts that correspond to a 3.16 final drive, and put it together in the same cases. For example, the input shaft gear and output shaft gear of a given gear set have to match, and the output shaft has to match the final drive because the pinion is part of the output shaft. Obviously certain parts need to operate together. i did post this in the non-tdi upgrades but wasn't getting any responses, if a mod is going to delete one of threads please delete the other one in the non-tdi upgrades, thanks again So basically, is the R&P from the tdi going to be a straight swap with a 1.8T tranny or am i gonna have to take the speedo gear out of the tdi tranny and swap it as well? also the fifth gear should fit from my tdi tranny into the 1.8T tranny right? i realize the final drive ratio is different, so can i take the R&P out of my tdi tranny, along with the fifth gear, and swap it into the the 1.8T/2.0 tranny that i'm getting? i'm also gettting a peloquin LSD so the R&P is coming out to begin with, but my other question is whether i'm going to have to change the speedo gear in the 1.8T/2.0 tranny or if they are the same gear as the 3.389 final drive ratio? 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.Hey my tranny is done, and i'm looking at getting a 1.8T or 2.0 O2J because i like the gear ratios in the first 4 gears, since i do a little 1/4 mile racing. 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. Done 020 without any probs or major special tools so this looks relatively easy DIY Tearing a VW 02A/O2A/02J/O2J Transmission Down to its Sub Assemblies ![]()
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