www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You




Go Back   TDIClub Forums > VW TDI Discussion Areas > Upgrades (non TDI Engine related)

Upgrades (non TDI Engine related) The place of handling, lighting and other upgrades that do not relate to the performance or economy of the TDI engine. In other words upgrades to your TDI that don't fit into TDI Fuel Economy & TDI Engine Enhancements.Please note the Performance Disclaimer

Reply
 
Thread Tools
Old August 6th, 2012, 22:25   #31
sardo_67
Veteran Member
 
Join Date: Feb 2010
Location: CT
TDI(s): 2003 Jetta
Fuel Economy: 38mpg (driving like i stole it)
Default

For the case half's there is no gasket, at the shop they use some type of sealer that is made for metal on metal surfaces, works real good from what I hear. I'll have to get the name of it.
Any place that sells car parts should be able to get you the 2 axle flange seals I would think and also the input shaft one as well.
Www.vwtransaxles.com is where I got all the parts for my O2J rebuild.
Do you have all the tooling needed for the shift fork mod? If not shoot me an email.
sardo_67 is offline   Reply With Quote
Old August 6th, 2012, 22:34   #32
Redneck Truck
Gone, but not forgotten
 
Redneck Truck's Avatar
Default

Before I put this back together I have to make 100% sure the ring gear is on the diff perfectly, don't I?

I found a site that's great for the 02j, but it has no 02m parts. Need input shaft seal, axle seals, and shift tower seals. Also may need shims.

Shift forks are done, my machinist buddy let me use his drill press and taps and another buddy tig welded them up for me. Did you braise the brass forks to the bolts?
__________________
- Still parting a 2002 4-door reflex silver Golf TDI 5-speed.
- Still parting most of 2001 Audi TT 225 6-speed engine bay.

Please help me clear out my garage. PM me.
Redneck Truck is offline   Reply With Quote
Old August 7th, 2012, 21:31   #33
sardo_67
Veteran Member
 
Join Date: Feb 2010
Location: CT
TDI(s): 2003 Jetta
Fuel Economy: 38mpg (driving like i stole it)
Default

My brother did some type of TIG brazing on the shift forks. Not sure exactly but I showed him this thread and he went to town on Them.
sardo_67 is offline   Reply With Quote
Old August 10th, 2012, 22:48   #34
sardo_67
Veteran Member
 
Join Date: Feb 2010
Location: CT
TDI(s): 2003 Jetta
Fuel Economy: 38mpg (driving like i stole it)
Default

One thing I noticed on my 6 speed is the shifter is stiff sometimes. I reused the stock 5 speed shift box as pulling off the exhaust and heat shield was too much at the time.
Sometimes after shifting up to 3/4 or all the way to 6 I pull it out of gear and the shifter stays all the way to the right in neutral. I then will push it back towards reverse and the. It frees up like normal, no grinding, noise, just stiff like it just needs to reset or something. I can't figure out what is doing it, nothing is binding on the linkage and it does t seem internal to the trans so....... Any ideas?
sardo_67 is offline   Reply With Quote
Old August 11th, 2012, 02:01   #35
ryanp
 
ryanp's Avatar
Default

the small plastic bushing on the relay lever of the shifter tower can get damaged when removed and is stiff when you put it back in, that or there is something catching internally after the mods!!
__________________

02M 6 Speed Conversions + Euro Parts - 6 Speed Setups for A4 + A5 platform,PD150 Intakes, TIP kits, Turbo's, Injectors as well as anything else!! PM Me! - Click HERE
ryanp is offline   Reply With Quote
Old August 12th, 2012, 22:37   #36
Redneck Truck
Gone, but not forgotten
 
Redneck Truck's Avatar
Default

Did you take enough off the bolt heads? Did the shift bushings/bearings get damaged upon reassembly? Were the ball detents all moving freely upon installation? Unless you had an issue with the shifter box and cables prior to installation, I reckon something is wrong with the shift tower or the bearings in which it rides.
__________________
- Still parting a 2002 4-door reflex silver Golf TDI 5-speed.
- Still parting most of 2001 Audi TT 225 6-speed engine bay.

Please help me clear out my garage. PM me.
Redneck Truck is offline   Reply With Quote
Old August 12th, 2012, 22:41   #37
Redneck Truck
Gone, but not forgotten
 
Redneck Truck's Avatar
Default

to Whitbread, I tried the tig welding method to remove the differential bearing races and it worked like magic. Many thanks for this wonderful thread. However, removing the races created a new concern. Upon removal of the races, I had a shim behind each race. This leads me to believe that preload is not the only concern, but offset as well. Provided the preload is unacceptable with the current shims, should I split the difference between current total shim thickness and new total shim thickness proportionally between the two (i.e. .05 and .10 spacers now and I need .06 more preload, install .06 and .12, or is it more complicated than that?
__________________
- Still parting a 2002 4-door reflex silver Golf TDI 5-speed.
- Still parting most of 2001 Audi TT 225 6-speed engine bay.

Please help me clear out my garage. PM me.
Redneck Truck is offline   Reply With Quote
Old August 12th, 2012, 23:12   #38
Whitbread
 
Whitbread's Avatar
 
Join Date: Jan 2007
Location: Johannesburg, MI
TDI(s): Several
Default

Quote:
Originally Posted by sardo_67 View Post
One thing I noticed on my 6 speed is the shifter is stiff sometimes. I reused the stock 5 speed shift box as pulling off the exhaust and heat shield was too much at the time.
Sometimes after shifting up to 3/4 or all the way to 6 I pull it out of gear and the shifter stays all the way to the right in neutral. I then will push it back towards reverse and the. It frees up like normal, no grinding, noise, just stiff like it just needs to reset or something. I can't figure out what is doing it, nothing is binding on the linkage and it does t seem internal to the trans so....... Any ideas?
Ditto with Ryan. Pull the relay lever off the shift tower, pull the 2 top hat bushings out, run a cartridge roll on a die grinder lightly though the hole in the top of the tower, clean bushings and relay lever shaft, reassemble and enjoy smooth side-side travel.


Quote:
Originally Posted by Redneck Truck View Post
to Whitbread, I tried the tig welding method to remove the differential bearing races and it worked like magic. Many thanks for this wonderful thread. However, removing the races created a new concern. Upon removal of the races, I had a shim behind each race. This leads me to believe that preload is not the only concern, but offset as well. Provided the preload is unacceptable with the current shims, should I split the difference between current total shim thickness and new total shim thickness proportionally between the two (i.e. .05 and .10 spacers now and I need .06 more preload, install .06 and .12, or is it more complicated than that?
Glad that worked for you! It is 10X easier than any other way.

You only mess with the shim that doesn't extend into the bore the axle flange passes through. That's an oil slinger of sorts I believe. The other one is the selectable shim for bearing preload.
__________________
02 Jetta TDI
Whitbread Performance Innovations
-Full TDI maintenance, performance and custom fabrication services. 248-755-8118, 10AM-5PM EST M-F. Please email or call only for business inquiries. PM's are not for business communication.

Last edited by Whitbread; August 12th, 2012 at 23:14.
Whitbread is offline   Reply With Quote
Old August 13th, 2012, 02:15   #39
ryanp
 
ryanp's Avatar
Default

There is a bolt that guides the shifter tower too, it wears quite badly sometimes and when disturbed can break:


Worn on the left and new on the right
__________________

02M 6 Speed Conversions + Euro Parts - 6 Speed Setups for A4 + A5 platform,PD150 Intakes, TIP kits, Turbo's, Injectors as well as anything else!! PM Me! - Click HERE
ryanp is offline   Reply With Quote
Old August 13th, 2012, 09:06   #40
Redneck Truck
Gone, but not forgotten
 
Redneck Truck's Avatar
Default

Good grief! Both of mine looked new. I guess that's the benefit of buying car parts from the UK: nobody drives in the UK :-)

Ryan, I emailed you a request for a quote on a LOT of engine parts. Think you can help me out?
__________________
- Still parting a 2002 4-door reflex silver Golf TDI 5-speed.
- Still parting most of 2001 Audi TT 225 6-speed engine bay.

Please help me clear out my garage. PM me.
Redneck Truck is offline   Reply With Quote
Old August 16th, 2012, 18:20   #41
Redneck Truck
Gone, but not forgotten
 
Redneck Truck's Avatar
Default

new questions. Please, please clarify.
1. Should I grease or lubricate the axle flange and input shaft seals or install them dry?
2. Still unclear about which shim I should leave alone and which I should remove when checking preload.
3. Checked ring gear wobble and have .0015" in each direction, presumably from the gear not seating all the way. What's the tolerance?
4. How much case sealer should I apply, and how long till it cures?
5. Is the G052 fluid acceptable to use?
__________________
- Still parting a 2002 4-door reflex silver Golf TDI 5-speed.
- Still parting most of 2001 Audi TT 225 6-speed engine bay.

Please help me clear out my garage. PM me.
Redneck Truck is offline   Reply With Quote
Old August 18th, 2012, 22:26   #42
sardo_67
Veteran Member
 
Join Date: Feb 2010
Location: CT
TDI(s): 2003 Jetta
Fuel Economy: 38mpg (driving like i stole it)
Default

i just put the diesel geek shifter on mine the other day, the plastic spacer on the stock shift arm was all gunked up and did not slide freely, put the new one in and it is a little better but still has the problem sometimes. what else can i look at other than pulling it back out?
sardo_67 is offline   Reply With Quote
Old August 19th, 2012, 08:57   #43
Whitbread
 
Whitbread's Avatar
 
Join Date: Jan 2007
Location: Johannesburg, MI
TDI(s): Several
Default

Quote:
Originally Posted by Redneck Truck View Post
new questions. Please, please clarify.
1. Should I grease or lubricate the axle flange and input shaft seals or install them dry?
2. Still unclear about which shim I should leave alone and which I should remove when checking preload.
3. Checked ring gear wobble and have .0015" in each direction, presumably from the gear not seating all the way. What's the tolerance?
4. How much case sealer should I apply, and how long till it cures?
5. Is the G052 fluid acceptable to use?
1. lube them with trans fluid
2. The shim you mess with has a very close ID/OD, it has the exact same footprint as the bearing race. The other thing you're calling a shim is an oil deflector that has a much smaller ID than the shim. It protrudes into the bore the axle cup shaft passes through.
3. Don't know what you mean by gear wobble. What you need to measure is the free play of the differential bearings with the shim removed and the race re-installed.
4. Right Stuff for Imports (the grey). Apply an 1/8" bead all the way around, you can smooth it down with your fingers if you feel OCD.
5. Yes, I believe there's a newer one out there too. Any of the VW tranny fluids will work fine as will Pennzoil Syncromesh, redline MTL, or amsoil MTL. Any GL-4 gear oil specifically for manual transmissions with yellow metal parts.


Quote:
Originally Posted by sardo_67 View Post
i just put the diesel geek shifter on mine the other day, the plastic spacer on the stock shift arm was all gunked up and did not slide freely, put the new one in and it is a little better but still has the problem sometimes. what else can i look at other than pulling it back out?
Pull the white tophat bushings out of the shift tower and run a cartridge roll through there. Re-install the bushings with some light lube and see how it feels now. Should be night and day.
__________________
02 Jetta TDI
Whitbread Performance Innovations
-Full TDI maintenance, performance and custom fabrication services. 248-755-8118, 10AM-5PM EST M-F. Please email or call only for business inquiries. PM's are not for business communication.

Last edited by Whitbread; August 19th, 2012 at 09:00.
Whitbread is offline   Reply With Quote
Old August 20th, 2012, 22:13   #44
Redneck Truck
Gone, but not forgotten
 
Redneck Truck's Avatar
Default

Thanks! Next question: the fluid the dealer sold me is a couple of years old and has some caramelly residue in the bottom like it has separated. I ran the oil through a coffee filter and it caught all that stuff. Was the stuff I just removed necessary?
__________________
- Still parting a 2002 4-door reflex silver Golf TDI 5-speed.
- Still parting most of 2001 Audi TT 225 6-speed engine bay.

Please help me clear out my garage. PM me.
Redneck Truck is offline   Reply With Quote
Old February 8th, 2013, 14:18   #45
1972SS454
Veteran Member
 
Join Date: Aug 2010
Location: Fernandina Beach, FL
Default

Just found this and thought this would be a good reference for the job.

O2Q Workshop Manual:

http://docs.jayzone.eu/erWin/VW/Jett...rbox%2002Q.pdf
__________________
09 Jetta TDI, 2060VKLR, Bosch CP3, Peloquin LSD, Clutchmasters SMF & FX400, 3" DP & Exhaust, Balance shaft module delete, Coolingmist w/m injection, Shorai 5lb Lithium battery, Fluidampr
1972SS454 is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
whats the best LSD to buy for 02M ? fenwick458 Upgrades (non TDI Engine related) 27 February 12th, 2013 21:43
anybody have install guide for 02M LSD? fenwick458 Upgrades (non TDI Engine related) 16 August 15th, 2010 15:56
Very limited boost after 6 speed 02M transmission install Mark Rudella VW MKIV-A4 TDIs (VE and PD) 6 September 29th, 2009 14:48
LSD and 5th gear install shop? PHAT-DUB Ontario 30 March 30th, 2007 06:22
Noise on Hard Lefts after Peloquin LSD Install Dante Upgrades (non TDI Engine related) 6 June 7th, 2005 05:59


All times are GMT -7. The time now is 21:59.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.17682 seconds with 10 queries
[Output: 136.74 Kb. compressed to 114.87 Kb. by saving 21.86 Kb. (15.99%)]