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    Thread: Manual Transmission FAQ - Please Read

    1. Moderator groggory's Avatar
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      12-17-2005 08:53 PM #1
      This is a condensed, but full version of the Current FAQ. The old one was getting far off topic and horrific to navigate. Feel free to post new information at the end of this thread if you want something added, but please discuss it in its own thread. This thread is not for conversations. This thread is a reference, just information.

      How To Section
      Transmission Information
      Part Numbers
      Sample Gear Ratio Setups
      Aftermarket Transmission Parts
      Useful Links
      Acronyms & Lingo


      Modified by groggory at 5:05 AM 12-18-2005


      Modified by groggory at 5:10 AM 12-18-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    2. Moderator groggory's Avatar
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      12-17-2005 08:53 PM #2
      How To Section....

      O2J Transmission Oil Change
      Throwout Bearing/ Finger Check in O20
      O20 Oil Change
      020 5th Swap
      020 Flange Removal
      020 Diff Shim Kit Test
      Mk2 Shifter Alignment FAQ
      O20 to O2A Swap
      - Pictures
      O2M into Mk3
      - O2M 6spd into Mk3
      - Source 2
      02a into a A1 chassis
      O20 Teardown Procedure
      -Source 1
      -Source 2
      O2M 5spd to 6spd retrofit
      Auto to Manual (any O20) Swap in A1 Cabby
      Tearing an 02A/O2A tranny down to its sub assemblies

      -How to: VR6 (02A) Shift Box Bushing Replacement.

      The Shift Box is located inside the car under the shift boot. Several bushings inside the shift box may need replacing if your car is more than 8yrs old or has more than 125K miles. My 95 Passat wouldn’t easily engage first gear because of a missing plastic cuplet that fits on a ball stud at bottom passengers side of metal shift cage. If the cuplet is worn or missing, it will be very difficult to engage first gear and you’ll hear a metallic clanking sound when moving the shift lever from side to side. No matter how hard you try, the situation can not be corrected by making adjustments to either cable end on top of tranny.

      Parts replaced:
      1. 357 711 590 B, Bushing, Clear hat-shaped located at front of shift cage
      2. 357 711 590 C, Bushing, Gray hat-shaped located at rear of shift cage
      3. 357 711 164, Cuplet, Clear spherical located on ball stud at bottom of shift cage
      4. 357 711 234 A, Hex Bolt, stainless steel located below shift weight (top of tranny)

      All parts except the hex bolt are located inside the shift box. To replace both bushings and the cuplet, the long pivot pin (running front to rear) must be removed. Remove the 13mm retaining bolt first. Next, the circlip on drivers side of the shift cage gets removed. Removal of this circlip allows the white plastic “cross” (which shift shaft runs through) to be removed from the shift cage.

      Once the shift cage is out, both bushings were greased and replaced. The small cuplet needs to have the “eye” opened up some (use a flat blade screwdriver) before it would fit over the ball stud.

      While the shift cage was out, I removed the special cotter pin at the bottom of shift shaft that retains the front/rear shift cable. Use a jewelers screwdriver through one eye of the cotter pin (and your thumb on the other side) so you don’t lose the cotter pin when removing it. Since no replacement for the cable end bushing was available, I used about 3-4 inches of Teflon tape wrapped around the pin at the bottom of shift shaft to compensate for slop in the bushing…this may be a “getto” fix, but it beats replacing a shift cable.

      Place the front/rear cable end back onto the shift shaft pin, then carefully push the cotter pin back through the hole in the shift shaft pin. Next, replace the circlip after installing the plastic “cross” onto the shift cage. Now lower the shift cage so that the new bushings align with the holes in the shift box and the plastic covered ball stud aligns with the side/side relay lever. Slide the pivot pin in from the front of shift box (use a flat blade screwdriver to help the pivot pin over the flange in the body sheet metal….or use a Dremel tool to grind away the flange). Replace the 13mm bolt that retains the pivot pin.

      The hex bolt runs through the shift weight on top of transmission. The front/rear shift cable also attaches to this hex bolt. Replacement should be straightforward.

      The above parts (#1-3) were about $4 from the dealer; however, if you buy a short shifter these parts (minus the cuplet) are usually included. The hex bolt (#4) was about $13…not bad for a custom machined factory part.

      Bushing replacement should take about 2-3 hours.



      Modified by groggory at 5:05 AM 12-18-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    3. Moderator groggory's Avatar
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      12-17-2005 08:54 PM #3
      Transmission Information

      084
      AKV, AKY, CEL and CEL

      O20

      - ~85 lbs dry
      -Any 020 works in any 020-equipped car. The only variables are the clutch disc (16v and Mk3 ABA trannies need a larger disc which fits on their larger output shafts) and possibly some extra bolts/mounts for the Mk1 trannies when they are installed in later cars.
      - 020 Pushrod Seal/Bushing - http://www.thediygroup.com/020seal.htm
      - 020 Release Arm - http://www.thediygroup.com/020clutcharm.htm
      - 020 5th Damage - http://www.thediygroup.com/5thdamage.htm
      - 020 Tooth Count/Ratios - http://www.thediygroup.com/020ratios.htm
      - Lock the PP Trick - http://www.thediygroup.com/images/pic%20036ss.jpg
      - MK1/MK2 020 Mounts - http://www.thediygroup.com/020mount.htm
      - Reverse Switch Wiring - http://www.thediygroup.com/reverse.htm
      - Mk1, Mk2, Mk3, Scirocco, B4 passat 4cyl gasoline engines,
      - the bolt for the 020 speedo gear plate is M7X1.25
      - Lots of Information here
      - Possible Cause for 2nd Gear Grind in cable shifted transmissions
      - O2A & O2J Are interchangable. Some of them require replacing the flanges. but is very easy to do with a sledges hammer and a chisel.
      -These flanges come out very easily if you run 2 long bolts through opposite sides of the flange against the flat areas provided on the case! the flanges will pop right out and this is the preferred method.
      - 2Y transmission is from 86/87 production date 020 trans equiped 16v cars


      O2A
      - Corrado, B3 Passat, B4 passat TDI & VR6, Mk3 VR6 & TDI
      - ~100 lbs

      _________1st___2nd___3rd___4th___5th___R&P___Notes
      ATA====3.778 =2.105 =1.345=0.971=0.795=3.684==Corrado G60

      AYL====3.778=2.118=1.429=1.029=0.837=3.684==Corrad o G60

      CAW====3.77=2.118=1.458=1.034=0.838=3.647==Corrado G60

      CDM====3.300=1.944=1.308=1.034=0.838=3.647==Corrad o VR6

      AGC====3.778 =2.105=1.345=0.971=0.795=3.944= Passat 16V

      AYK====3.778=2.118=1.429=1.029=0.837=3.684= Passat 16v

      CES====3.778=2.118=1.429=1.029=0.837=3.684== Passat?

      CHA====3.778=2.118=1.360=0.917=0.717=3.944==VR6 Canada

      CGY====3.778=2.118=1.458=1.029=0.837=3.684== Passat?

      CNL====3.778=2.118=1.458=1.029=0.837=3.684==VR6 Passat?

      CCM====3.300=1.944=1.308=1.034=0.838=3.389==VR6 Passat, Jetta, Golf

      CTN====3.778=2.118=1.360=1.029=0.755=3.157==Jetta/Golf TDI

      DQY====3.778=2.118=1.360=1.029=0.755=3.389==Jetta/Golf TDI

      ASD====3.300=1.944==1.308==1.09==0.717==3.16==TDI I've heard of a few being bought in the USA but I believe its a euro MK3 TDI tranny

      CHN==== Golf

      CHU==== Passat

      CRU==== Passat

      O2C trannys (SYNCRO):

      CBC,CHD=3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro CDN

      AYR ====3.778=2.118=1.345=0.971=0.756=3.944== Passat Syncro

      CDH====3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro

      O2J

      - Mk4, B5
      - ~100 lbs

      Ratios

      EGX - 3,938 - 3,300 - 1,944 - 1,308 - 1,029 - 0,837 = Mk4 Golf/ Jetta
      EGR - 3,389 - 3,778 - 2,118 - 1,360 - 0,971 - 0,756 = Mk4 Golf/ Jetta TDI

      1.8T trannys coded: EBQ, EMT, EGX, FBW:
      _1st___2nd___3rd___4th___5th___R&P_
      3.300-1.944-1.308-1.029-0.837-3.938

      TDI trannys coded: DQY, EBJ, EGR:
      _1st___2nd___3rd___4th___5th___R&P_
      3.788-2.118-1.360-0.971-0.756-3.389

      2.0 trannys coded: DZQ, EBP, EGT, EKG, EKH, EMS, EZK, FBV:
      _1st___2nd___3rd___4th___5th___R&P_
      3.778-2.118-1.360-1.029-0.837-4.235

      VR6 trannys coded: DZC, EHC, EGF, EWW, FBY, FCF
      _1st___2nd___3rd___4th___5th___R&P_
      3.625-2.071-1.474-1.038-0.844-3.389

      O2M

      - 6 speeds from Mk4's
      - 02M from a golf v6 4motion weighs 65KG (142lbs)

      Modified by groggory at 5:06 AM 12-18-2005


      Modified by groggory at 9:32 PM 12-21-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    4. Moderator groggory's Avatar
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      12-17-2005 08:55 PM #4
      Part numbers


      -fifth gear housing gasket part# 020-301-215C dealer list price $7.00
      - selector shaft detent spring PN# 020-311-597 dealer list $.73
      - Torque converter oil seal in an 010 autmatic tranny, the vw part number is 010 409 568
      -- Do not buy this from Napa. They have the wrong seal
      - 020 Trans Speedometer cable gears
      -- 020 3.9= 171 957 821 A (WHITE)
      -- 020 3.6= 171 957 821 B (RED)
      -- 020 4.2= 171 957 821 C (Green)
      - For using a 02A without a hydro clutch, get a Clutch cable from a Transporter: P/N: 02B141708A

      Part Notes

      - vr6 outer cv joits will NOT fit into the pre 92 4cyl hubs, the splines are totally different. I tried it myself
      - Differences between the quaife and peloquin


      Modified by groggory at 5:06 AM 12-18-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    5. Moderator groggory's Avatar
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      12-17-2005 08:56 PM #5
      Sample Gear Ratio Setups

      Rally Driving

      Ratios:
      1st .... 2.73
      2nd.... 2.06
      3rd .... 1.68
      4th .... 1.43
      5th .... 1.26

      I am using a 4.64 final drive. This box is very short and very close ratio.

      8v 020 vw motorsport
      1st 2.50
      2nd1.79
      3rd1.44
      4th1.13
      5th1.03
      fd was 3.94 its now 4.25

      Ratio Lists & Ratio Calculators

      Complete Ratio List
      Ratio & MPH Calculator | Missing Some Information



      Modified by groggory at 5:06 AM 12-18-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    6. Moderator groggory's Avatar
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      12-17-2005 08:56 PM #6
      Aftermarket Transmission Parts

      Heavy Duty Linkage Kit for Linkage Operated Transmissions
      Motor Mounts
      - KCD
      - VF Engineering


      Modified by groggory at 4:44 AM 12-18-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    7. Moderator groggory's Avatar
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      12-17-2005 08:57 PM #7
      Useful Links

      Why you should run an LSD
      The DIY Group | Site Dedicated to How-To Articles
      JWS VW | Transmission Swap Compatibility Guide among other useful things
      Why you should check your transmission lube frequently (5th Gear Failure)
      What 020 tranny should I use with a G60 swap into an A1 or A2?
      - Source 1
      - Source 2
      1st impressions of 02A/O2A CDM gearing in my G60 Corrado transmission
      02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints


      Modified by groggory at 4:52 AM 12-18-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    8. Moderator groggory's Avatar
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      12-17-2005 08:58 PM #8
      Acronyms/ Lingo


      Diff - Differential
      LSD - Limited Slip Differential
      TO - Throw Out
      Trans - Transmission
      Tranny - Transmission



      Modified by groggory at 5:12 AM 12-18-2005

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    9. Moderator groggory's Avatar
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      12-17-2005 09:00 PM #9
      Saved for future use...


      Modified by groggory at 5:03 AM 12-18-2005
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    10. Moderator groggory's Avatar
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      12-17-2005 09:21 PM #10
      Saved for future use...8
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    11. Moderator groggory's Avatar
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      12-17-2005 09:24 PM #11
      Saved for future use...


      Modified by groggory at 5:06 AM 12-18-2005
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    12. Member Broke's Avatar
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      12-17-2005 09:42 PM #12
      http://www.BrokeVW.com

      Broke


      Modified by Broke at 5:42 AM 3/21/2007

      020 trans info pages - www.BrokeVW.com
      NEW 0.7619 5th gears for the 020
      NEW 020 reverse gears
      '86 GTI 8V 2.0L -'88 Scirocco 16V - '10 F150 4x4

    13. Moderator groggory's Avatar
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      12-21-2005 04:33 PM #13
      Trying to get this stickied...Its exactly the same as the current stickied FAQ, but I indexed the whole thread into easily manageable chunks
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    14. Moderator groggory's Avatar
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      01-05-2006 02:10 PM #14
      This thread has everything the current FAQ has, except it is organized.

      Another request to get this stickied.

      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    15. 03-22-2007 12:14 AM #15
      glad to find this thread again!

    16. 08-05-2007 05:24 PM #16
      much much better. nice work.
      Quote Originally Posted by Travy View Post
      error404: Stance not found.

    17. Member austin neuschafer's Avatar
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      08-07-2007 11:03 PM #17
      RESERVED FOR FUTURE INFO
      87 rocco 2l16v MS3 02a/j with 4.24 on LSD. 91 rado geting 1.8t, 02 cabrio geting vr6, 04 r32 vf stg 2 sc, and a few other goodies

    18. Member austin neuschafer's Avatar
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      08-07-2007 11:04 PM #18
      RESERVED FOR FUTURE INFO
      87 rocco 2l16v MS3 02a/j with 4.24 on LSD. 91 rado geting 1.8t, 02 cabrio geting vr6, 04 r32 vf stg 2 sc, and a few other goodies

    19. 11-06-2007 11:45 AM #19



      Modified by nOOb at 11:12 AM 11-12-2007
      My Legen...wait for it....dairy VRT build thread http://forums.vwvortex.com/showthread.php?3571869

    20. Member the_mad_rabbit's Avatar
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      11-14-2007 06:16 PM #20

      -AJ


      Modified by the_mad_rabbit at 5:39 PM 11-14-2007

      All up in your harble, stealing your internets.
      "Life is like a bad margarita with good tequila, I thought as I poured whiskey onto my granola and faced a new day"
      Grow old or die trying.
      My headache...

    21. Member V-dubbulyuh's Avatar
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      01-03-2008 05:46 PM #21
      the shizzle.
      "OP sounds like a MKIV guy"

    22. Member G60ING's Avatar
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      01-04-2008 07:41 AM #22
      For the gear ratios you might want to referance my gear ratios thread as I will continune to update that. Just the other day I added the 02J EHA gearing. But I will agree that the FAQ was diluted.

      If you could fine the thread where a guy rebuilt his 02A transmission in a barn in the winter in Upstate NY that would be great because he had a lot of pics and homemade tools


    23. Member Zupek's Avatar
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      01-08-2008 01:39 PM #23
      PLEASE STICKY THIS!!!!!!
      My 24v 3.1L Syncro Mk3 build here

    24. 06-13-2008 12:23 PM #24
      pls to make sticky

    25. Member e.Mills's Avatar
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      06-23-2008 11:29 AM #25
      why is this not a sticky!?! thanks so much for the help!
      i heart avant.

    26. Member e.Mills's Avatar
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      06-23-2008 11:31 AM #26
      also... diygroup is down, so half the 2005 links are dead. thx
      i heart avant.

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      06-28-2008 02:04 AM #27
      For those folks who want to convert their 5th gear to TDI spec, here is the info you're looking for:

      What does the taller 5th gear actually do to your RPMs?

      Stock VR6 5th (dashed cyan line) compared with 0.755 (blue) and 0.717 (purple) gears.

      Where to get the gears?
      # http://www.autotech.com/prod_drive_gearconv.htm
      # http://thescirocco.com can get Autotech parts at %10 off.
      # http://vwgenuineparts.com
      # http://www.1stvwparts.com
      # http://www.worldimpex.com
      # http://www.tdiparts.com
      # Your local VW dealer will generally match online prices and won't charge shipping if you ask nicely or if they have a "web wholesale" offer.
      # El Romano Loco can get the gears for you at German wholesale cost
      # Transmission rebuilders
      # VWVortex classifieds


      Part numbers:

      30/39 (0.769) gearset DEA,EBF,EGS:
      # 02A311361N gear output shaft
      # 02A311158L change gear propshaft

      34/45 (0.755) gearset DQY,EBJ,EGR:
      # This is the most popular conversion for non-diesel folks since this is the OEM gearset for many North American TDI models. You can find these for about $100 used from transmission rebuilders or TDI dubber who have swapped to a 0.6xx gear.
      # 02A311361Q gear output shaft
      # 02A311158E change gear propshaft

      29/39 (0.744) gearset EWX,EUH:
      # PD engines only?
      # 02A311361AD gear output shaft
      # 02A311158AE change gear propshaft

      33/46 (0.717) gearset CZL:
      # This is best for cars with a higher ratio R&P or significant power adders. This is the kit that Autotech sells. (BTW I have this on my MkIV VR6 Kinetic stage 2 turbo @7PSI. Works really well on the highway - rarely requires a shift into 4th. The turbo spools so fast that I can still pass in 5th gear!)
      # 02A311361M gear output shaft
      # 02A311158R change gear propshaft

      28/40 (0.700) gearset:
      # From an older Eurovan - hard to find
      # 02A311361AM gear output shaft
      # 02A311158AF change gear propshaft

      32/47 (0.681) gearset:
      # From an older Transporter Synchro - note 02D part numbers as opposed to 02A. Most popular upgrade for TDI folks.
      # 02D311361 gear output shaft
      # 02D311158 change gear propshaft

      25/38 (0.658) gearset:
      # From European TDI 2.0. Installation requires modification to existing spring plate or purchase of matching smaller spring plate.
      # 02Z311361A gear output shaft
      # 02Z311158A change gear propshaft


      DIY guide:
      http://www.rpi.edu/~carabd/gearswap.pdf


    28. Member BiH's Avatar
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      02-10-2009 10:58 PM #28
      lots of links down. been loking for a 02M sawp info and cant find anything yet, stupid search is down. found this thread tho
      I do work on cars, anything short of engine and transmission rebuilding can be done. welding, custom and aftermarket as well as regular repairs. IM me for details, shop is in WOodbridge.

    29. Member Broke's Avatar
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      02-11-2009 01:44 AM #29
      Quote, originally posted by e.Mills »
      also... diygroup is down, so half the 2005 links are dead. thx

      Quote, originally posted by BiH »
      lots of links down.

      All of the old DIYgroup links have been moved to http://www.BrokeVW.com now, all of my 020 trans info is on that site now. My partner in the DIYgroup deal lost his mind and bailed from the VW scene, so I moved it all over to the new site at BrokeVW

      Brian

      020 trans info pages - www.BrokeVW.com
      NEW 0.7619 5th gears for the 020
      NEW 020 reverse gears
      '86 GTI 8V 2.0L -'88 Scirocco 16V - '10 F150 4x4

    30. Member BiH's Avatar
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      02-11-2009 02:31 PM #30
      Quote, originally posted by Broke »

      All of the old DIYgroup links have been moved to http://www.BrokeVW.com now, all of my 020 trans info is on that site now. My partner in the DIYgroup deal lost his mind and bailed from the VW scene, so I moved it all over to the new site at BrokeVW

      Brian

      thats cool and all but nothing on 02M swap!

      props for having a BHtuning link on there. didnt even know there was bosnian tuning scene, haha

      I do work on cars, anything short of engine and transmission rebuilding can be done. welding, custom and aftermarket as well as regular repairs. IM me for details, shop is in WOodbridge.

    31. Member Broke's Avatar
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      02-11-2009 03:45 PM #31
      Quote, originally posted by BiH »
      props for having a BHtuning link on there. didnt even know there was bosnian tuning scene, haha

      I didn't either, until Google found my site name on their forums

      020 trans info pages - www.BrokeVW.com
      NEW 0.7619 5th gears for the 020
      NEW 020 reverse gears
      '86 GTI 8V 2.0L -'88 Scirocco 16V - '10 F150 4x4

    32. Member BiH's Avatar
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      02-11-2009 08:47 PM #32
      yeah I just galnced over the site briefly, thats my hood man gotta see whats up over there! haha
      I do work on cars, anything short of engine and transmission rebuilding can be done. welding, custom and aftermarket as well as regular repairs. IM me for details, shop is in WOodbridge.

    33. Member animaniac's Avatar
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      02-11-2009 09:27 PM #33
      Thanks for the info, may come in some use one day...
      Diagnostic technician and conspiracy theorist.
      www.infowars.com www.davidicke.com
      Fixed the infowars link.
      Alex jones powered by the souls of the founding fathers!

    34. Member GinsterMan98's Avatar
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      09-20-2010 12:04 PM #34
      I know its an old thread but I will add this for anyone who cares. I may also post 02A bearing part numbers and the places you can get them in the USA for cheap.
      http://forums.vwvortex.com/showthrea...rt-number-info.

    35. Member BigWilieStyle's Avatar
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      04-25-2011 09:11 PM #35
      gonna grab this! pleaseeeeeee STICKY!

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