Just a little update to say that I am struggling splitting the 02S! If you think it tricky removing 5th from an 02A, then the 02S 6th and 5th is a different ball game! Wasted time and money on buying a puller, got a mate to weld on a slim plate to fit under, but it just bends as you torque it up. I have conceded and given the box to a local transmission specialist. As soon as I mentioned "VW 6 speed " and "difficulty removing 5th/6th" he said "oh is that the Touran box?" - so the guy has been here before! He said there isnt a puller out there that fits, what they do is loosen all the case bolts then use the tranny case to prize off the gears. So long as they spread the load enough to not damage the brittle cast ally! So these thread on the interweb about fitting an 02S that dont mention removing the gears to split the box....it aint a DIY job! Been in touch with Gary Peloquin who is a great help with the tech side of speccing my LSD seeing that I am using a hybrid box. Will be ordering that as soon as I am happy. And I keep mulling over the ratios.....wondering whether to keep as is but I do think will be better with a longer FD.
Well the tranny place has managed to remove the 6th gears and split the box; all looks well inside! He concurrs that as it is the final drive is way too short for a torquey turbo so I am now looking for a 61T crown wheel from an 02A or J - can anyone help? PLease see my wanted add in the parts section. This still means I will need to buy a new pinion shaft from VW, about 140. The tranny guy doesnt see why if I match an 02A/J 61T crown to the corresponding 18T 02S pinion that there should be a problem. I wanted to do 62/17 as I have 62T crown here from the CBA but he reckons I ought to pursue the longest FD, which gives 3.38.
Just a progress report. I will have to upload some pice soon! For anyone thinking of messing with an 02S this may shed a bit of light. It seems the crown wheels ARE interchangeable if using the correct diff. I have recieved the output shaft from VW this week and it meshed fine with my 62t 02A crown wheel. I had doubts as to whether the new shaft would work as VW revised the design; but it looks like the gears off the original low ratio output shaft will fit the new longer ratio shaft. The 02S diff bears 02J numbers and would seem to be interchangealbe as long as you used 02J flanges and seals. I hope to get a phone call from him later today to say the output shaft is assembled
Just a few photos that some of you may find interesting. Was messing around with a few bits earlier just out of interest. 02S ally end cover mates up to 02A 02S tower seems to fit 02A I intend using the later style plastic slave that came on the 02S but have just tried it and the 02A bellhousing will need maching out - the hole for the actuator is too small. Here the 02S drive flange fits into the 02A bellhousing using an 02J seal!
Been to the tranny shop today - no not to buy a dress - but to do a bit more dabbling with the gearbox. We bolted up the 02S 6 speed output cluster into the 02A bellhousing, The only thing we found was that the 02A crown is about 2/3mm thicker than the 02S, so it fouls on the output shaft support. The crown will need maching down. Nothing too serious!
Diff ordered from Peolquin - but they are now on a 3 week lead time - DOH! So along with begin taking the engine and box out I started to play with this. Cant believe how much 6 speed short shifts cost so began making my own. Ground off the back of the rivet and drifter out the pin for the selector cable. All marked up ready to drill tomorrow. The hole is as good as 8mm so a shouldered stainless cap head bolt will do the job for me.
