[DIY] Make your 02J/02A Cross Shaft Pin Stronger

Discussion in 'Transmission' started by HidRo, Nov 11, 2010.

  1. HidRo Forum Member

    Joined:
    Jan 30, 2004
    Likes Received:
    12
    Location:
    Portugal
    So, as I was not able to find much info until G60Dub mentioned it, I'm creating the little DIY.

    From:
    VW 5 Speed 02J Transmission Problems:
    http://www.vwtransaxles.com/diff.html

    Cross Shaft Roll Pin Breaks & Cross Shaft Punctures Case-This is the most common failure for all o2j rebuilds that come into our shop. There is a single 5 MM roll pin retaining the cross shaft. We double roll pin the shaft with an SAE type pin inside the metric pin. Next we grind a small "V" groove between the cross shaft and differential. Then a small root weld is applied. We haven't had a roll pin failure since using these procedures.

    So, because of this:
    [​IMG]

    I got this:
    [​IMG]
    [​IMG]

    Decided to reinforce the pin.
    Basically, just insert an extra pin inside the existing one, or remove the existing one, and insert a stronger one.

    [​IMG]
    Cross shaft, broken roll pin, & replacement double roll pins
    [​IMG]


    I hope that this will be the last issue with the gearbox :lol:
     
  2. Dave

    Dave *Very Smart* Pedantic Old Fart Paid Member

    Joined:
    Feb 26, 2007
    Likes Received:
    473
    Location:
    Sligo, Eire
    Nice one HidRo!:thumbup::clap:
     

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