I could watch your videos for hours, no faff and overly complicated stuff, just a guy who knows VW gearboxes taking one apart, shown from hands on perspective.
Thank you for sharing this set of videos. Stored a bunch more techniques into my noggin for when I attempt disassembly. These fill in steps with disassembly that taco8v's videos didn't cover, so I'm quite grateful. Your technique to use the case and the pry with the air-hammer looks similar to what CoolAirVW showed when he removed 5th gears off an 02J in the car. Only, he used a lady's foot pry bar under the gears, instead of the long bar between the case and bellhousing. Always another way to tackle the task. Saw now you added more to the series, so I'll dive in with part 4!
Yeah, the challenge with the output gear for 5th on this one is the casting appears to have changed and you simply cannot get the feet of a puller underneath that gear now. I use a puller almost every time on 02A/J and most 0A4 5 speeds to remove that gear, but there just is no teeth sticking out of the casting to be able to grab onto, so I resort to alternate methods. And my method basically requires the trans to be out of the car and for you to be splitting the case open anyway.
Hello, I own a Seat Leon mk3 1.8 FR with manual 6spd gearbox. It's an MQ250 and RSN code. Before 1,5 year and after two very aggressive starts that the car bumped up and down in 1st gear until the cutter and until it found traction, my car did whine sound after that. I decided to keep it as it is until the flywheel change and alongside with installation of bigger turbo, so I was in need for better clutch. Before one month I left the car at the garage for the new setup. IS38 turbo, handmade racing 6pad flywheel and opening the gearbox to change all the bearing. Seven bearings as I remember. 5 for the gearbox and 2 for the differential. Basically, I bought a fix kit for the RSN MQ250 (corteco, coyo, jtekt, snr some of the brands of the bearing kit). Anyway, my mechanic found the old bearings in very good shape and the magnets just had physiological powder. I said that this is good, he said no. He was sure that the bearings change, won't fix the whining. Forgot to mention that before 1 year, i started with gearbox oil change (Liqui Moly 5300 with 2 MoS2 additive, to see if there would be any improvement. My car does the same noise. Whine noise when cruising with 3rd, 4rth, 5th and 6th gear. Another situation is if I engage 1st gear and have the clutch pedal pressed while the car is running, the whine noise is really hard. I'm desperate because I decided to fix my gearbox (brand new car with only 60K kms since 2017) instead of buying a second hand. What is your opinion about my issue? I would appreciate any info. We can contact via mail, FB if you want. Thanks!
ive been in the vw scene since 1999... but this is the first time some one posts a well explained no BS fancy pants show of a gearbox teardown of a 02S yesh i could try my self but being autsitic i dont start stuff with alteast a little bit of background info..... that said this is BIG background info FYI
Увидел съёмник шестерни 5-ой передачи.Не имея его я снимаю привод выключения оси вилок располовиниваю коробку и подложив под шестерню тонкие стальные подкладки выдавливаю вал на прессе.Но шестиступенчатая коробка здесь отличается от той что разбирал я .У моей индекс LHX .Но автору благодарность за аккуратную работу правильным инструментом!
In my experience, at least on the mk6/7 platform, the transmission (Mine's a late 0a4) is tilted forward compared to how it sits on mk4/5. My transmission was underfilled by about 0.4-0.5 liters from the factory, and the fluid level was still a little bit above the fill plug, even with the front of the car raised. In my case, with the correct fill, the fluid level sits more than 1" above the fill plug. Really appreciate you doing this series of videos, watched them a while back when is was acquiring parts for my 0A4 LSD install and clutch upgrade. Now that i'm about to tear open my transmission case for the first time, I'll be giving them a rewatch.
Maybe there is something to VW saying the drivetrains are mounted more upright as well. Then they went and compounded the problem by making drainage into the differential space almost non-existent 🤣
Hi there great vid. I have this 02s box and i have a slight whine only in 6th gear and only under load, im thinking the 6th gear teeth maybe worn , what do you think. Cheers .any advice much appreciated
Bit of an unusual one. Could be that the gear itself has worn a little funny, causing the noise, yes. Might also just be a little low on oil. These have a special drain and fill procedure since there is poor drainage into the differential space due to the design of the bellhousing. You need to drain not only from the drain plug beneath the diff, but also by removing one of the lower shift pins held in place by a T45 bolt. Once drained, it should be re-filled with about 2.2 liters, if I recall, and not from the fill plug. Due to the poor drainage into the diff space, the oil will come out of the fill port before you've got the correct amount of oil in the transmission, so VW's recommendation is to remove the reverse light switch, insert a hose into that hole attached to a funnel with which you can fill the transmission with the correct amount of oil. Germans...
Would you have any idea what would cause this in an 02j. I can't downshift 5-4-3 1-2-3-4-5 works perfectly but downshifting to 4 or 3 it feels like there is a block. No grinds every just a block If i go down to second I can get into 3 or 4th 100% of the time but if i try to just down shift normally with out going to second prior it doesn't work I've adjusted the cable ends a few times also installed diesel geek short throw shifter
Downshifting is made easier by double-clutching and rev-matching, would be interesting to see if it does go into those gears easier when doing so. It can be something as simple as the adjustment for 5th gear is a little off, so it doesn't allow the selector shaft to re-center as easily as it should, but then you're forcing it to do so when you go down towards the 1-2 gate. Could also be maybe one of the springs for the 3-4 selector retainer has broken, thus those aren't springing out and staying in place the way they're supposed to, making it difficult when downshifting, but possible to make it OK when upshifting. Eventually, if both springs break in the 3-4 selector, you won't be able to get into 3rd or 4th from either direction. At least with the 5th gear adjustment, you just need to remove the rear pan (transmission stays installed) and put the selector in 5th, loosen the T45 screw, that secures the small fork to the shift rail that goes between the rail and the rocking lever that operates the 5th gear collar. The shift tower has detents that should keep the 5th gear rail aligned where it needs to be when you've selected 5th. So, with the T45 bolt loose, just push on the selector collar, make sure it is fully seated on 5th gear, then press very lightly on the fork the T45 screw holds to the rail to back off the rocker arm just slightly. Then re-tighten the T45 screw, put the rear pan back on, add some gear oil back in and see if it made an improvement. If that adjustment doesn't make an improvement, the transmission will have to come apart, the gear stack off the pinion shaft removed and inspect the 3-4 selector collar and hub for broken springs.
Hi. I watched this video for repairing my 02S 6 speed box. It was very helpful, thx very much! But, i have a problem now. I changed all the bearings because of a noise when accelerating/decellerating. That noise is gone now! But now i have a grinding sound, only in 1st gear. It goes in gear perfect without grinding, but when i start driving in 1st gear it grinds. It gets less noisy around 3000 rpm. I took it apart again today, no damage. All the gears look like new. Put it back together, still grinds in 1st. I decided to make a longer test drive and the noise is less now, but its still there. With youre experience, you have any idea what went wrong? Thx in advance.
That's very unusual! Can't say I recall having one that would grind after 1st was engaged and just continue making the noise. Especially one that wasn't making that noise to begin with. You sure the needle bearings went back in the correct order, with the washer underneath the needle bearing for 1st gear? And the washer was installed on top of 2nd gear before pressing on the sleeve for the 3rd gear needle bearing?
@@dzelpwr The weird thing is, the grinding is not there when i turn left while driving in 1st gear. Going straight or to the right, you hear it. It got a bit less but still there. Im thinking their is to much play on the diff. Because when you turn the steering wheel, the Cv joints tilt, and maybe the diff inside tilts a bit to...? Im going to get it back open tomorrow and see.
Здравейте, поздравления за чудесната работа! Искам да сменя само шеста скорост на JYK (02S) със такава от ERF (02m), дали ще е възможно? Благодаря и успех!
It is possible. A lot of parts need to be changed to make it work. Shift cable bracket/holder is different. Shift levers on top of the transmission as well. Different starter, axles as well as clutch and flywheel. Clutch line between master and slave is also different, but all very doable. Looking into the gearing of the JYK, it has a 3.65 final drive. The TKR and TDZ code boxes I've been doing here in the U.S. have a 3.39 final drive. Also, 6th gear in the JYK according to the parts cat is a 0.73. This makes for a total gear reduction in 6th gear of 2.66. Your ERF gearbox has a 2.615 final drive for 5th, 6th and reverse gears, and 6th gear is a 0.814. This makes for a total gear reduction in 6th gear of 2.128. SUBSTANTIALLY taller than the JYK 02S. For the record, the TKR gearbox I used here has a 3.39 final drive and a 0.625 6th gear, which ends up slightly taller still than the ERF at 2.119. The DRW 02M is slightly taller than both at ~2.1065, it has a 0.805 6th gear.
Hi there, first of all i wish you a great 2024 😁🎊🍾. So, i have a question. I got a VW Golf V, 1.9 TDI from 2005 with a GQM 02S six speed manual gear box with problems. It started doing a lot of noise on 2nd and 3rd gears, and when the oil level plug was removed to see if it was short on oil it came out oil with silvery color. That was only 2 weeks after i bought the f*king car 🤦🏻♂️ from a private person, so no warranty. I bought the exact same gear box from a car that had crashed but had only 160k kms. The gearbox was not expensive but the thing is, it was cracked with a small part missing due to the crash. My idea was to take all the inside of the one i bought and install it on the casings of the one that is on the car, that is if they are in good shape. Already bought the 462 032 710 bearing kit from Luk. Do you think this is something i could do as DIY thing, or i wont be able to and should take it to a mechanic?
I have no idea on your own abilities. You can use my videos as a step by step, and if at any point you feel like it's not worth it for you to buy all the specialty tools and attempt this yourself, then I would say yes, it's a good idea to pay a mechanic who also has invested in similar special tools and has familiarity with the internals of VW gearboxes.
I bought mine straight from the U.S. vendor for VW specialty tools: Snap-on. vw.snapon.com It's T10309 The other long legged puller is a cheapo generic one from Amazon. Doesn't appear to have the greatest metallurgy, but it's still working.
This entire series of videos is how I go about that. Swapped the bellhousing for an 02J version, installed a limited slip diff with speedo gear, and installed the Mk4 sensor. I probably would not have done this work if I had thought of a better solution. Turns out, you can hack 2002 and later Mk4 clusters to pick up VSS via CAN, but I have not figured out how to do that with my 2001 Golf's cluster. I had been sitting on that Wacetrac differential for a couple years anyway, figured this was as worthy a project as any for it. The 02S diff wasn't machined down adequately to accept the speedo gear, unfortunately. But, I'm sure some time on a lathe could fix that if someone didn't want to spend the money on 02J-B limited slip diff.
@@MrSnowman777 the 0AJ is a different transmission family altogether. I believe that's MQ200 instead of MQ250 like this box. There's quite a bit that's different with those gearboxes. We also didn't get many of them here in the U.S.. Maybe some of our 8 valve 2.0L equipped Mk6 Jetta sedans had them, that's about the only MQ200 (0AF) I can think of in our market.
@@dzelpwr hmmm alright I didn't know that. Do you happen to know if I need this tool at all? I'm still trying to find information about this gearbox but there isn't much out there
Not sure if it's used on those boxes at all. You can find all the special tools related to that gearbox family in the VW repair manual. I get my repair info direct from them at erwin.vw.com All special tool part numbers are listed in the procedures. So, you can read through the procedure, see if there's any pullers and such you have that might work in place of the original VW tool, or if it seems to much of a specialty, maybe just break down and buy the tool from VW. Snap-on runs their tool program for the U.S., so you can take whatever part numbers you find in the repair manual and plug it into vw.snapon.com search bar.
Животные
I could watch your videos for hours, no faff and overly complicated stuff, just a guy who knows VW gearboxes taking one apart, shown from hands on perspective.
Well, lucky for you there's more than 5 hours of videos just on the one gearbox 😅
I appreciate the comment.
Thank you for sharing this set of videos. Stored a bunch more techniques into my noggin for when I attempt disassembly. These fill in steps with disassembly that taco8v's videos didn't cover, so I'm quite grateful.
Your technique to use the case and the pry with the air-hammer looks similar to what CoolAirVW showed when he removed 5th gears off an 02J in the car. Only, he used a lady's foot pry bar under the gears, instead of the long bar between the case and bellhousing. Always another way to tackle the task.
Saw now you added more to the series, so I'll dive in with part 4!
Yeah, the challenge with the output gear for 5th on this one is the casting appears to have changed and you simply cannot get the feet of a puller underneath that gear now.
I use a puller almost every time on 02A/J and most 0A4 5 speeds to remove that gear, but there just is no teeth sticking out of the casting to be able to grab onto, so I resort to alternate methods.
And my method basically requires the trans to be out of the car and for you to be splitting the case open anyway.
Brilliant video. Just found it as I'm finishing putting my one back together. Keep up the good work
Doing a 02S/02J hybrid as well?
get her done!
Great informative video, man you know your topic respect to you excellent
Hello, I own a Seat Leon mk3 1.8 FR with manual 6spd gearbox. It's an MQ250 and RSN code. Before 1,5 year and after two very aggressive starts that the car bumped up and down in 1st gear until the cutter and until it found traction, my car did whine sound after that. I decided to keep it as it is until the flywheel change and alongside with installation of bigger turbo, so I was in need for better clutch. Before one month I left the car at the garage for the new setup. IS38 turbo, handmade racing 6pad flywheel and opening the gearbox to change all the bearing. Seven bearings as I remember. 5 for the gearbox and 2 for the differential. Basically, I bought a fix kit for the RSN MQ250 (corteco, coyo, jtekt, snr some of the brands of the bearing kit). Anyway, my mechanic found the old bearings in very good shape and the magnets just had physiological powder. I said that this is good, he said no. He was sure that the bearings change, won't fix the whining. Forgot to mention that before 1 year, i started with gearbox oil change (Liqui Moly 5300 with 2 MoS2 additive, to see if there would be any improvement. My car does the same noise. Whine noise when cruising with 3rd, 4rth, 5th and 6th gear. Another situation is if I engage 1st gear and have the clutch pedal pressed while the car is running, the whine noise is really hard. I'm desperate because I decided to fix my gearbox (brand new car with only 60K kms since 2017) instead of buying a second hand. What is your opinion about my issue? I would appreciate any info. We can contact via mail, FB if you want. Thanks!
ive been in the vw scene since 1999... but this is the first time some one posts a well explained no BS fancy pants show of a gearbox teardown of a 02S yesh i could try my self but being autsitic i dont start stuff with alteast a little bit of background info..... that said this is BIG background info FYI
Увидел съёмник шестерни 5-ой передачи.Не имея его я снимаю привод выключения оси вилок располовиниваю коробку и подложив под шестерню тонкие стальные подкладки выдавливаю вал на прессе.Но шестиступенчатая коробка здесь отличается от той что разбирал я .У моей индекс LHX .Но автору благодарность за аккуратную работу правильным инструментом!
In my experience, at least on the mk6/7 platform, the transmission (Mine's a late 0a4) is tilted forward compared to how it sits on mk4/5. My transmission was underfilled by about 0.4-0.5 liters from the factory, and the fluid level was still a little bit above the fill plug, even with the front of the car raised. In my case, with the correct fill, the fluid level sits more than 1" above the fill plug.
Really appreciate you doing this series of videos, watched them a while back when is was acquiring parts for my 0A4 LSD install and clutch upgrade. Now that i'm about to tear open my transmission case for the first time, I'll be giving them a rewatch.
Maybe there is something to VW saying the drivetrains are mounted more upright as well. Then they went and compounded the problem by making drainage into the differential space almost non-existent 🤣
Is there any ways of removing the selector without the tool? Like a homemade way?
Hi there great vid. I have this 02s box and i have a slight whine only in 6th gear and only under load, im thinking the 6th gear teeth maybe worn , what do you think. Cheers .any advice much appreciated
Bit of an unusual one. Could be that the gear itself has worn a little funny, causing the noise, yes. Might also just be a little low on oil. These have a special drain and fill procedure since there is poor drainage into the differential space due to the design of the bellhousing.
You need to drain not only from the drain plug beneath the diff, but also by removing one of the lower shift pins held in place by a T45 bolt.
Once drained, it should be re-filled with about 2.2 liters, if I recall, and not from the fill plug. Due to the poor drainage into the diff space, the oil will come out of the fill port before you've got the correct amount of oil in the transmission, so VW's recommendation is to remove the reverse light switch, insert a hose into that hole attached to a funnel with which you can fill the transmission with the correct amount of oil.
Germans...
Would you have any idea what would cause this in an 02j. I can't downshift 5-4-3
1-2-3-4-5 works perfectly but downshifting to 4 or 3 it feels like there is a block. No grinds every just a block
If i go down to second I can get into 3 or 4th 100% of the time but if i try to just down shift normally with out going to second prior it doesn't work
I've adjusted the cable ends a few times also installed diesel geek short throw shifter
Downshifting is made easier by double-clutching and rev-matching, would be interesting to see if it does go into those gears easier when doing so.
It can be something as simple as the adjustment for 5th gear is a little off, so it doesn't allow the selector shaft to re-center as easily as it should, but then you're forcing it to do so when you go down towards the 1-2 gate.
Could also be maybe one of the springs for the 3-4 selector retainer has broken, thus those aren't springing out and staying in place the way they're supposed to, making it difficult when downshifting, but possible to make it OK when upshifting. Eventually, if both springs break in the 3-4 selector, you won't be able to get into 3rd or 4th from either direction.
At least with the 5th gear adjustment, you just need to remove the rear pan (transmission stays installed) and put the selector in 5th, loosen the T45 screw, that secures the small fork to the shift rail that goes between the rail and the rocking lever that operates the 5th gear collar.
The shift tower has detents that should keep the 5th gear rail aligned where it needs to be when you've selected 5th. So, with the T45 bolt loose, just push on the selector collar, make sure it is fully seated on 5th gear, then press very lightly on the fork the T45 screw holds to the rail to back off the rocker arm just slightly. Then re-tighten the T45 screw, put the rear pan back on, add some gear oil back in and see if it made an improvement.
If that adjustment doesn't make an improvement, the transmission will have to come apart, the gear stack off the pinion shaft removed and inspect the 3-4 selector collar and hub for broken springs.
Hi. I watched this video for repairing my 02S 6 speed box. It was very helpful, thx very much!
But, i have a problem now.
I changed all the bearings because of a noise when accelerating/decellerating. That noise is gone now! But now i have a grinding sound, only in 1st gear. It goes in gear perfect without grinding, but when i start driving in 1st gear it grinds. It gets less noisy around 3000 rpm.
I took it apart again today, no damage. All the gears look like new. Put it back together, still grinds in 1st. I decided to make a longer test drive and the noise is less now, but its still there.
With youre experience, you have any idea what went wrong?
Thx in advance.
That's very unusual! Can't say I recall having one that would grind after 1st was engaged and just continue making the noise.
Especially one that wasn't making that noise to begin with. You sure the needle bearings went back in the correct order, with the washer underneath the needle bearing for 1st gear? And the washer was installed on top of 2nd gear before pressing on the sleeve for the 3rd gear needle bearing?
@@dzelpwr The weird thing is, the grinding is not there when i turn left while driving in 1st gear. Going straight or to the right, you hear it. It got a bit less but still there.
Im thinking their is to much play on the diff. Because when you turn the steering wheel, the Cv joints tilt, and maybe the diff inside tilts a bit to...?
Im going to get it back open tomorrow and see.
Здравейте, поздравления за чудесната работа! Искам да сменя само шеста скорост на JYK (02S) със такава от ERF (02m), дали ще е възможно? Благодаря и успех!
It is possible. A lot of parts need to be changed to make it work.
Shift cable bracket/holder is different. Shift levers on top of the transmission as well.
Different starter, axles as well as clutch and flywheel.
Clutch line between master and slave is also different, but all very doable.
Looking into the gearing of the JYK, it has a 3.65 final drive. The TKR and TDZ code boxes I've been doing here in the U.S. have a 3.39 final drive.
Also, 6th gear in the JYK according to the parts cat is a 0.73. This makes for a total gear reduction in 6th gear of 2.66.
Your ERF gearbox has a 2.615 final drive for 5th, 6th and reverse gears, and 6th gear is a 0.814. This makes for a total gear reduction in 6th gear of 2.128.
SUBSTANTIALLY taller than the JYK 02S.
For the record, the TKR gearbox I used here has a 3.39 final drive and a 0.625 6th gear, which ends up slightly taller still than the ERF at 2.119.
The DRW 02M is slightly taller than both at ~2.1065, it has a 0.805 6th gear.
Hi there, first of all i wish you a great 2024 😁🎊🍾.
So, i have a question. I got a VW Golf V, 1.9 TDI from 2005 with a GQM 02S six speed manual gear box with problems. It started doing a lot of noise on 2nd and 3rd gears, and when the oil level plug was removed to see if it was short on oil it came out oil with silvery color. That was only 2 weeks after i bought the f*king car 🤦🏻♂️ from a private person, so no warranty. I bought the exact same gear box from a car that had crashed but had only 160k kms. The gearbox was not expensive but the thing is, it was cracked with a small part missing due to the crash. My idea was to take all the inside of the one i bought and install it on the casings of the one that is on the car, that is if they are in good shape. Already bought the 462 032 710 bearing kit from Luk. Do you think this is something i could do as DIY thing, or i wont be able to and should take it to a mechanic?
I have no idea on your own abilities.
You can use my videos as a step by step, and if at any point you feel like it's not worth it for you to buy all the specialty tools and attempt this yourself, then I would say yes, it's a good idea to pay a mechanic who also has invested in similar special tools and has familiarity with the internals of VW gearboxes.
where can i buy one of those pullers used for 5th and 6th gear?
I bought mine straight from the U.S. vendor for VW specialty tools: Snap-on. vw.snapon.com
It's T10309
The other long legged puller is a cheapo generic one from Amazon. Doesn't appear to have the greatest metallurgy, but it's still working.
So how do you deal with the lack of VSS?
This entire series of videos is how I go about that.
Swapped the bellhousing for an 02J version, installed a limited slip diff with speedo gear, and installed the Mk4 sensor.
I probably would not have done this work if I had thought of a better solution.
Turns out, you can hack 2002 and later Mk4 clusters to pick up VSS via CAN, but I have not figured out how to do that with my 2001 Golf's cluster. I had been sitting on that Wacetrac differential for a couple years anyway, figured this was as worthy a project as any for it.
The 02S diff wasn't machined down adequately to accept the speedo gear, unfortunately. But, I'm sure some time on a lathe could fix that if someone didn't want to spend the money on 02J-B limited slip diff.
What tool did you use at 16:09?
Official VW gear puller, T10309. Can be purchased in the U.S. through vw.snapon.com
@@dzelpwr thank you! Will be looking into getting one to help rebuild my moms LHY 0AJ gearbox
@@MrSnowman777 the 0AJ is a different transmission family altogether. I believe that's MQ200 instead of MQ250 like this box. There's quite a bit that's different with those gearboxes.
We also didn't get many of them here in the U.S.. Maybe some of our 8 valve 2.0L equipped Mk6 Jetta sedans had them, that's about the only MQ200 (0AF) I can think of in our market.
@@dzelpwr hmmm alright I didn't know that. Do you happen to know if I need this tool at all? I'm still trying to find information about this gearbox but there isn't much out there
Not sure if it's used on those boxes at all.
You can find all the special tools related to that gearbox family in the VW repair manual. I get my repair info direct from them at erwin.vw.com
All special tool part numbers are listed in the procedures. So, you can read through the procedure, see if there's any pullers and such you have that might work in place of the original VW tool, or if it seems to much of a specialty, maybe just break down and buy the tool from VW.
Snap-on runs their tool program for the U.S., so you can take whatever part numbers you find in the repair manual and plug it into vw.snapon.com search bar.