Depending on their application whether it be commercial or passenger type and engine type the gearboxes have different ratios some being low revving and others high revving.
#Vw o2j transmission install
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.VW T3/T25 gearboxes come in a variety of flavours ranging from gearboxes designed for early 1600cc and 2-litre aircooled engines to 1.6 litre and 1.7 litre normally aspirated diesel engines and 1.6 litre turbo diesel up to the later 1.9 and 2.1 litre water-cooled petrol engines and Syncro models both 14″ and 16″. 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
#Vw o2j transmission full size
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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