5th Gear swap - recommend a puller?

Wankel7

Veteran Member
Joined
Dec 25, 2012
Location
Indiana
TDI
2003 Jetta Wagon
In my searching I have seen folks get a generic Craftsman puller and grind the teeth down so they interface with the backside of the gear and not the teeth.

Trying to make sure I have all the tools before I get home to start the work.

This kit looks really good with good reviews...
http://www.amazon.com/TEKTON-5696-G...F8&qid=1405335394&sr=8-1&keywords=gear+puller

But then I saw these types of pullers....

http://www.amazon.com/Wilmar-W141-2...8&qid=1405335394&sr=8-13&keywords=gear+puller

http://www.amazon.com/Custom-Access...8&qid=1405335394&sr=8-15&keywords=gear+puller

Would those be better?

Thanks!
 

50harleyrider

Top Post Dawg
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
Get a cheap one from Advance and grind the teeth a little so they'll fit behind the gear. The trick to easy removal is to heat the gear with a propane torch while the puller is on and has some force on it. I usually keep a styrofoam cup of frozen water (ice) and peel it back and hold it against the shaft immediately after heating and it pops right off . The first time the gears are removed they are really tight. I've done a bunch of 5th changeouts and it works every time. Good luck!
 

Wankel7

Veteran Member
Joined
Dec 25, 2012
Location
Indiana
TDI
2003 Jetta Wagon
Awesome thanks for the advice!

Can I use a propane / blue bottle torch or do I need to get a mapp / yellow bottle torch?

Did you get a two or three jaw?

My goal is resale on the stock gear :)
 

50harleyrider

Top Post Dawg
Joined
Jun 16, 2007
Location
charleston,wv
TDI
2005 B5.5 TDI/geared BSM, BV43A turbo,stage 2 TDTUNING. 2005 5sp manual passat tdi stage 2 tdtuning,BSM delete. 2015 Passat TDI 6sp manual.
The middle or small one will be the one and you'll still have to grind on it. Save your money and get the cheap one from Harbor Freight. PM me if you run into any problems.
 

Jesse_Boyer

Veteran Member
Joined
Aug 16, 2007
Location
Sioux Falls, SD
TDI
I'm all out...
50's right, you'll need to grind either way. I bought a $10, 3-jaw puller from my local joint and probably removed about HALF of the arm near the end. (pic below.) This was the only way I could get the arms behind the small gear.

http://imgur.com/vdpjue7
Note the size of the body near the fulcrum and the design near the tip of the jaws; it used to be the same thickness on either side.

The 5th gear selector is much easier to maneuver the puller's arms in place to remove, but the small gear has very little ancillary space between the gear and the case (both behind and to the side.) I took the puller apart, maneuvered the arms in place one at a time, assembled to the body one at a time, and pulled it off without heat. Add heat if you'd like, but it doesn't take much effort to pull the gear off without it. I just did my current DD this weekend and its quite easy. Note, the first car I installed a 0.658 gear on didn't need a puller... the OEM 5th about fell off in my hand (240k miles on the OEM gear.)
 
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Wankel7

Veteran Member
Joined
Dec 25, 2012
Location
Indiana
TDI
2003 Jetta Wagon
The smaller puller in the three puller set was the winner. The arms were labeled 3". I ended up having to rent a two arm puller though from Auto Zone for the small gear. I didn't have to use the puller advantage though. I just put the two arms behind the small gear and pulled hard.

Here are the ground down arms I used on the selector gear to get the 5th gear stack out. The far right one was my final one made. It was the best one.
https://dl.dropboxusercontent.com/u/16359949/Puller/2014-09-12%2019.10.00.jpg

Here are the measurements of the lands that fit into the selector gear.
https://dl.dropboxusercontent.com/u/16359949/Puller/2014-09-12 19.11.02.jpg
https://dl.dropboxusercontent.com/u/16359949/Puller/2014-09-12 19.11.18.jpg

As a side note I did have to remove the collar that goes around the selector gear. The myturbodiesel write up describes pushing it back to get the puller in place. There is no reason to leave it in place and makes getting the puller into the selector gear a pain. And might lead you to putting the puller on the 5th gear which is a poor idea if you are trying to preserve it's resale value.
 
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jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
How much was taken off in the end?. The Dropbox links are 404ed.
 
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