02j shift tower rebuild.

I've managed to get hold of an 02j shift tower. But it seemed to have a bit of movement between the shaft and housing.

The top oil seal looked grotty so i ordered a new one. I then opened it up and the sleeve bearing is dry and rusty looking so i'll order a new one of those too.



My question is how is this lubricated? Is it by the gearbox oil? Or, I assume it needs greasing anyway but what type of grease for all associated parts?

 

Please be careful taking that bearing out, it's not as easy as people think, and you can end up breaking the centre support out of the housing if you're not careful.
Even heating the housing up can sometimes result in failure.

The bearing is lubed by oil splashing up onto it. Not brilliant, but it does work. The main problem being the actual bearing is pi55 poor in general.

 

What the best way to try and get the bearing out then? I was going to try and use a drift of some sort on the inner lip or maybe try and cut part of the sleeve and carefullty break it out from the middle.

 

Right bear with me here.
With the seal out of the top, you want to make 2 notches opposite each other(I used a sharp 4mm wide blade screwdriver) so you can see the top of the bearing sleeve. Just use it like a small chisel and cut them out.
You then need to have a pipe that will sit under the alloy holder of the bearing sleeve, with a bore big enough for the bearing to slide into.
From the top you need to have a flat dolly(4mm thick plate the same width as the gap across the notches) that will fit down into the notches and press against the sleeve, and just press it out. The pipe underneath will stop you pressing the middle housing out of the main housing, and believe me, it's easy to do. DO NOT press it out against the main housing, you'll pop the centre out!

Just DON'T use a hammer to tap it out, press it nice and easy! lol

 

Thanks for the heads up on the notches. I did think to myself, how can i get to the top of the sleeve.. I usually use a socket big enough to allow things to be pressed into. I'll give this a go.
Nearly 4 for a new sleeve bearing 02A 311 648 C is the part number should anyone need it.

 

Managed to get the sleeve out today. Put ot on the press. It didn't wanna budgeand i didn't fancy try too hard and breaking it. Instead i used a dremel and a grinding stone to wear a groove until it split. Then i could press it out with a vice and a piece of copper sheet made to fit.

Ordered my short shifter and some bushes for the relay lever.

Anyone know what grease to use on parts of the shifter?

Apparently its a high temp poly grease that VW use, but im sure it would be expensive.

 

Any i suppose, I cant see it getting that hot.

You will need the grease the pin that goes into the bushes, Mine were really tight.
The shift weight is also keyd so dont force it on with the nut. It will slop in if you have it in the right place.

You will need a tube of sealer/gasket to mount it back onto the gearbox

 

This is the grease. I think the bay can get fairly hot. It is connected to the block. I noticed the grease is fairly dry on the parts at the moment.
I know about the shift weight only going on one way and noticed the sealer on the housing.

 

Does anyone know the part number for the relay lever with the earlier type of bowden cable catches?

The part number on mine is 1j0711203E but this is not listed in etka.

I've ordered the part from the dealer and seem to get a corresponding pn as 1j0711202E but is the wrong part it is like a mirror image of mine and slightly bigger. Dealer cant understand it either.

 

Ive got mine here, Its the ball & socket type.
1J0 711 203E

 

That's the problem. That part number is unknown in etka. I need the right number to order another.

 

I may try the later type part number to go with the TT short shift.

 

As per this thread
http://www.clubgti.com/forum/showthread.php?t=199935

1J0 711 202 P Is the later type you want

 

I've just ordered these two from dealer. I'm gonna go for the later type. The Bowden cable catch will match the TT short shifter.

The 1j0711202E is like a mirror image of what I have. Dealer said it's a six speed also. Wish the pn on the parts were the actual pn's you ordered. But NO, that would be too easy mr Vw.

 

Exactly. No registration or chassis number these days is a nightmare to get bits. Joys of modding eh?

 

I have etka. But the it still comes up with a few options to choose from depending on chassis number etc. I didn't see any ref to RSI though.

 

RSI would be a refernce to the beetle RSI perhaps?