anybody have install guide for 02M LSD?

fenwick458

Veteran Member
Joined
Feb 3, 2008
Location
England
TDI
'12 T5 Van
as above. local specialists want far too much money, it can't be that hard can it?
it's just that i have never taken a gearbox apart :eek: (yet)

i have seen some pictures, but no detailled instructions or torque settings, drill sizes for drilling out the rivets etc..

standard gearbox open:

standard diff, getting rivets drilled out:

finished LSD fitted with new crown bolts



any help would be appreciated.
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
It's quite straightforward I guess, open tranny, easiest is to do it like on the first pic (which is opposite way as vw suggests) and leave shafts in that housing, then remove stock diff, drill out rivets, press off gear, clean good, maybe also good to have it resurfaced, screw on lsd with the 2 supplied bolts, install bearings, find yourself a think enough shim, you have to be set the diff bearings at .25mm negative clearance IIRC.. might want to check it in the manual..

oh, and also don't mix bearing shells offcourse..


 

Sc0

Veteran Member
Joined
May 21, 2000
Location
Houston, TX USA
TDI
'02 Golf GL 5sp Candy White Tan cloth interior
Experiences with a 02J, while not hard you have to have access to a few tools:

Use heat when seperating the ring gear.
Use something soft either aluminum/copper/or thick compressed cardboard to protect the teeth while pressing the ring gear on/off.
You have a shim/shims under the bearing race that is used for bearing preload. (new bearings/races loosen up after breakin)
Use a nice drill press or mill for the rivets, drill on theproper side...

Other things to do:
Replace the tranny input/output shaft seals, easier to do now...
Might want to upgrade the shift fork pins to bolts while things are apart.
I used red-loctite on the ring gear bolts.
 

fenwick458

Veteran Member
Joined
Feb 3, 2008
Location
England
TDI
'12 T5 Van
thanks for the replies. i'm gonna try and reing around see if a can get cheaper quote than the first one as i don't have some of the tools needed, or any shims etc..

went out and had a look at my donor gearbox today (EFF code) and i noticed one of the dogbone mount bolts has sheared in the casing and cracked a bit off the casing. :mad:

and also, what tool do i need to drain the oil?? never seen one of these before....
 

rscott4563

New member
Joined
Jul 26, 2009
Location
UK
TDI
PD130 - Hybrid 240bhp/350lbft
The transmission bit is a Sealey XZN M16 security bit, I've got one if you need to borrow it.

If you do end up doing it yourself Stu I'll be really interested to hear how difficult it is. If it's something I could manage myself it could nudge me that little bit closer to getting a Wavetrac LSD myself.
 

fenwick458

Veteran Member
Joined
Feb 3, 2008
Location
England
TDI
'12 T5 Van
ok i have made a bit of progress, got the sheared stud out no problem and i bought a XZN M16 security bit to drain the oil out.

i am probably going to end up doing this job myself, the only thing that bothers me a bit is i do not know if the gearbox i have is good, or if it is trashed. so it would be nice to have the re-assurance of a gearbox specialist checking it over, but they want £300 for labour only to do a full strip re-build :mad:.it came from a low (30-40K) mileage car so i am hoping it will be ok , i have drained the oil just now and no swarf/cogs fell out in it so i guess thats a good sign!

also how do i measure to see if i need to add/remove shims? is there a strong chance i will not need to do anything and it will be spot on as is the case with most 02M's?

and i have never fitted any gearbox seals before, is it a simple task? or do i need some special tools? and what about bearings, can i reuse them or should i just replace them too?

i still have not received my LSD yet, it's being shipped accross from the states as we speak. i went for a Wavetrac, cost £675 + £12 delivery from PSI tuning in Stoke. also the bolts required are costing me £120 ish i have still not ordered them yet though.
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
paid mine less and it was peloquin with bolts and bearings :p

any bearing you replace you need to recheck for clearance, and def the lsd as it has probaly new bearings and diff lentgh itself also has a tolerance.. it's explained good in the manual how to check clearance, it involves adding a too thick shim and then measuring the negative clearance and then you know what shim you need for the desired cleance..

getting the diff bearing shells out of the casing isn't that easy if you don't have the pullers for it..
 

Whitbread

Vendor , w/Business number
Joined
Jan 21, 2007
Location
Johannesburg, MI
TDI
Several
Rub87 said:
any bearing you replace you need to recheck for clearance, and def the lsd as it has probaly new bearings and diff lentgh itself also has a tolerance.. it's explained good in the manual how to check clearance, it involves adding a too thick shim and then measuring the negative clearance and then you know what shim you need for the desired cleance..

getting the diff bearing shells out of the casing isn't that easy if you don't have the pullers for it..
Getting the hard to get to bearing race out is super easy without the pullers. All you need is a tig welder :). Take the axle seal out (as you should be replacing them anyway) and run a bead of weld around it the race. Wait about a minute, turn the case upside down and it will fall out. Knock the new race in with the old shim behind it.

Easiest way to setup the carrier bearing preload starts by knocking one race out with a punch from the back side. I forget which side it's on, but it has a groove on the backside of the race in the case to get a punch in there. Tap your new race in without the shim behind it. Put diff in cases and put case halves together with 4 bolts or so. Use a dial indicator mounted on a magnetic base to measure how much the diff moves up and down inside the cases. Measure your old shim and subtract the free play from it. If you get .006" to .012", the old shim will work just fine. Go much further in either direction and you'll either over preload the bearings or not load them enough.
 

Pat Dolan

Veteran Member
Joined
Apr 19, 2002
Location
Martensville, SK
TDI
2003 A4 Variant, 2015 Q7
Fenwick:

Somehow, everyone seems to have missed the obvious: BUY A BENTLEY MANUAL. It IS the factory information (North America, granted, but gearbox procedures are identical). No sense learning by mistakes when you can learn from the facts and truth. Just read it through carefully, and take you time. It isn't all that difficult, or none of us would be doing it (nor would the dealership techs who have nothing to lose).
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
unfortunatly not, it was from a chap in UK who bought it but then changed his mind and went for a haldex setup so hee needed to buy a different one, really got a god deal on the diff..
 

fenwick458

Veteran Member
Joined
Feb 3, 2008
Location
England
TDI
'12 T5 Van
yes, i sent it away in the end and got it re-built with new seals,bearings and the LSD for £250. fitted it last weekend and it has made a big difference. accellerating out of corners in the wet is loads of fun:D
 

uzi_cupra

Veteran Member
Joined
Apr 30, 2010
Location
Uk, Scotland
TDI
04 Ibiza Cupra TDi
yes, i sent it away in the end and got it re-built with new seals,bearings and the LSD for £250. fitted it last weekend and it has made a big difference. accellerating out of corners in the wet is loads of fun:D
who did it for you? was it too much of a task?
 

fenwick458

Veteran Member
Joined
Feb 3, 2008
Location
England
TDI
'12 T5 Van
a place called stephensons transmissions in preston. not sure if it was much of a task as i never did it, but it doesn't really look that hard from the info abovebut you do need some special tools.
main reason for me sending it away was because the gearbox came from ebay, and i wanted it checked by a specialist before i fitted a lsd to it and put it in my car
 
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