(for MK5 only) M14(14mm) 12 point xzn bit(three square).ħ You did read the warning by now right? If you didn't, please go back to the second page.Ĩ Gear Pullers: Compliments of velvetfoot these are the gear pullers I used. Torx screwdriver for removing plastic pieces. If you dont know what a spring plate is go with the Z A 02Z AĦ Tools Required: Torx socket set including a T-40, T-45 and T-60 bit. This document is for educational purposes only.ĥ Parts Required 5th Gear Set Transmission End Gasket 2 Liters Gear Oil.681 5th gear set Transporter Synchro 02D (32 tooth) 02D (47 tooth) 02A A (gasket).658 5th gear set: Requires modification to spring plate.
#Tdo 5th gear swap on o2j transmission manual#
I HIGHLY recommend you obtain a legal copy of the Bentley CD manual as it includes additional detailed instructions pertaining to swapping out the 5th gear in your transmission. I did have success with this modification in my own vehicle but your results might vary greatly. For safety reasons I cannot recommend you drive your car after doing this and should thus be considered an Off road only modification. Be advised, there is also the possibility that this might result in your death if things were to fail at speeds other than being not moving. If you do screw this up there is potential that your car might stop function as per the specifications of Volkswagen. I take no responsibility for the whatever outcome you might have. In doing this there is a large potential that you might screw something very important causing damage to your very expensive perfectly good transmission. In doing so you might or might not gain any benefits. WARNING!!!! This procedure discusses the way you would open up the end of your very expensive transmission in order to replace a gear that is perfectly fine. Ok, If that didn't leave you horribly terrified here is the more detailed overview.Ĥ BIG IMPORTANT WARNING AGAIN in case you skipped the first one.
#Tdo 5th gear swap on o2j transmission crack#
Mine let out a loud crack which fortunately was the gear coming off the shaft. Once the puller is on the gear selector assembly and you are cranking down on it, it can take A LOT of force to get the gear office. At about this point you would reach the scary part of the project. Once you get the puller on you will want to heat the gears so they expand as this should make the removal a little easier. For the selector assembly any gear puller about the right size should work without issue but for the smaller gear some modification might be needed as the case is pretty close to the gear which makes getting the puller arms around the gear a little challenging. So to remove both of these you will need a gear pullers. The smaller gear along with the selector are both pressed onto a splined shaft. You have 2 gears to remove, The larger drive gear with the associated selector assembly and the smaller driven gear. Sounds simple enough right? It basically is except for the removing of the original gears, thats where things get tricky. In short all you have to do is remove the end cover of the tranny, remove 2 retaining bolts, remove both the gears, put on the new gears, replace bolts and end cap, refill with gear oil and you are done. The procedure for swapping out the 5th gear is rather simply. This document is for educational purposes only.ģ Prelude: Welcome to dave's 5th gear swap. 1 th 5 Gear Swap How-to 02A/02J By david_594 5/9/06 v 1.32Ģ BIG IMPORTANT WARNING WARNING!!!! This procedure discusses the way you would open up the end of your very expensive transmission in order to replace a gear that is perfectly fine.
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