◆ From gearbox build date 06 08 1 additional locking mechanism in end cover =>Fig.◆ Revised stop sleeves, which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 =>Fig.Special tools and workshop equipment required Special tools, workshop equipment, test and measuring appliances and auxiliary items required –> Contact page….Dismantling and assembling gearbox selector mechanism from 05.99 Ship them in to us and we can make it work again.Ĭontact us in the following link. We’ve repaired bunches of these and can offer repairs for these even if your out of town. So with bearing wear, 5th gear slider and hub wear, fork wear, spider thrust wear, differentials exploding we feel like we can handle any repair on these. So with diff problems so common I wanted to show a good used cleaned up diff.Īnd here’s the new parts including, bearings, speedo gear, spider gear thrust washer and new rolled pin.
Here’s another pic of the wavetrac since its pretty. Grinding off the rivots is a labor intensive process, and we have to do this when we have to replace a stock differential also. You’ll see grind marks in the next pics on the gear from cutting the rivots.
VW O2J TRANSMISSION BOLTS INSTALL
Wavetrac or Peloquin differential installĬomes with a nice install kit with the speedo gear, the bearings and the bolts to install the original ring gear. These are some expensive parts but there are some used available to save money. Treat your reverse well or else you’ll end up chipping the teeth on your gears. Its not a real expensive part so it goes in everyone.
I’ve find these broken or worn on about 50% of the ones I take apart so its a good idea to change this on every one. We have fixed some of these without removing the trans, so that is a possibility, but sometimes we find this wear while repairing some other part and this jumps the price up as these are some expensive parts. This pic shows the matching wear on the slider. Keeping the revs up and driving in a lower gear will prevent wear on trans and engine. By the way this wear is made worse by “lugging” the motor by driving around in 5th when you should be in 4th. When this wear gets bad enough the ridges keep it from coming out of 5th. This is a common problem and usually results in the trans getting stuck in 5th. Here’s the 1-2 and 3-4 fork with the 5th fork. We fixed this trans with nothing but few seals and this fork.ĥth gear has a fork that can wear as well. Resting the weight of your hand on the shifter can cause this type of wear.Īnd here’s what the fork pads are supposed to look like. We suspected wear like this when we took it apart because 3rd and 4th didn’t work at all. In the next pic the trans had shift problems. Simply replacing the Diff with some new bearings fixed it. Please note that spinning the wheels in the snow or on any slick surface and contribute to breaking the pin or making the diff pin come out.Ĭase had some rub marks from “stuff” hitting it but it was ok and we reused it see pics below. It was pretty amazing to find it this bad. Here’s another one that broke the rolled pin. Sometimes the cause is the rolled pin breaks and allows the pin to come out. After pulling out the trans we found this hole. Sometimes it moves out and breaks the case.
When the Pin that the spider gears spin on comes out the pin moves outwards and rubs the case until the case wears a hole in it. I only saved a picture of the race though. The other pinion bearing had some minor wear.
We can install replacement case when necessary. I would have loved to weld up the hole and replace the bearings, but the race had spun in the case and didn’t fit tightly, so the case half had to be changed. This used to be the lower pinion bearing. This one made a bunch of noise and when we pulled it out we found more damage than we were expecting. We were able to fix this one with just some bearings. It will usually whine on acceleration and quiet down when coasting.Īnd the following pic is the worn bearing race. When the bearings fail on the differential or on the pinion it makes a whine noise. If you want to purchase some of the small parts for 02J transmissions click here-> 02J shopping page I thought I would document some of the failures I’ve seen here on this page. 02J transmissions are fairly reliable but do have their problems.
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