02M Swap Parts List?

[Tybolltt]

What parts are needed to swap a 02M into a 2000 Golf?

[TyrolSport]

Tranny w/release bearing and upper mount
Flywheel
Clutch kit
starter
axles
release bearing line
shifter assembly

[EdsGTI]

tranny, axles (1.8t ones need hubs and wheel bearings, VR6 ones bolt into existing hubs, but are not as strong) Power steering line, clutch slave cylinder line, lower transmission mount bracket that bolts to the upper frame rail on the drivers side.

Clutch, flywheel, pressure plate, throwout bearing/slave cylinder. Shifter cable bracket, both shift linkages (stock shifter box works, calbes are switched with the bracket) and a starter.

[TyrolSport]

shifter cable bracket I missed.

There are ways around the hub/wheel bearing issue with the 1.8T axles if you are looking to save money. The right way would be to swap the hubs and bearings though.

[EdsGTI]

do you guys usually tweak the stock 5 speed power steering line too? Ive heard about many people bending it to make it fit since. The 02m does have a different power steering line, line routing and mouting position.

[Tybolltt]

Thanks Tyrolsport, huge help. How many hours does the install usually take?

[EdsGTI]

figure a clutch install, plus maybe 3-5 hours. Depending on what you decide to go with. concerning axles, power steering etc

[nerdhotrod]

This list was compiled from a few sources. I added notes.

This will get you 95% through the swap.

Transmission 1 DRW -- WWO3 02m-301-107-D - 800-1200

Left Drive Shaft 1 1J0 407 271 GC $756.77 - you can find for way less then this
Right Drive Shaft 1 1J0 407 272 GD $364.00 - you can find for way less then this

Eurpspec has these new or call denon for used. These are direct bolt in for 5 speed cars.

Driveshaft axle 12pt nuts 30mm 2 N 905 876 02 $5.50 ea.
N 105 316 01 Bolt, with multi spline socket head M10x23 $1.44 ea x 12
Driveshaft Bolt Retainers 6 1J0 407 357 A $1 ea.

Transmission Mount 1 1J0 199 555 AQ $78 - used ~ 25 bucks
Transmission Brace 1 1J0 199 117 AK $32 - used ~ 15 bucks
N 102 096 03 hexagonal head bolt M12X1, 5X65 qty 2 trans mount TTY Single Use
N 102 683 02 hexagon head bolt c/w shoulder AM8X45 qty 2 dogbone to trans TTY Single Use
N 102 466 04 hexagon head bolt c/w shoulder M10X30-SW!6 qty 1 dogbone to body TTY Single Use
N 905 970 01 hexagon head bolt c/w shoulder M10X70-SW!6 qty 1 dogbone to body TTY Single Use

BOLT for trans to engine N10242102 $3.08
BOLT,HEX for trans to engine N90884601 $4.23

Dust Cover 1 06A 103 645 $8.32
Inspection Cover 1 068 103 645 M $6.49
Bolt for inspection cover 1 N 010 208 5 $.50
Washer for Inspection Cover 1 N 012 226 5 $.20

Mounting Bolts 2 N 908 703 01 $1.54 ea.

Starter Bolts 2 N 907 665 02 $6.76 ea.
Starter 1 02M 911 023 $350 - any o2m will work, including TT. DONT SPEND MORE THEN 100 bucks used.

*****************************************
Stock stuff - Buy aftermarket.
Flywheel 1 038 105 266 Q $599
Clutch Disc 1 06A 141 031 Q $208 2.8L VR6 24V Jetta
Pressure Plate 1 06A 141 025 K $177 2.8L VR6 24V Jetta
Pressure Plate Bolts 6 N 903 086 05 $0.29 ea.
******************************************

Release Bearing - Hydraulic - 02M141671A (or B?) $132.45 - Should come with clutch.
Bleeder 1 1J0 721 468 B aka "BREATHER ASSY." $26.52
Slave Cylinder Hose aka "tube line" 1 1J1 721 465 AJ $114 common to vr6 6-speed - used 50 bucks
Hose Clip 1 1J0 721 491 $1.33 x 2 or 3?

3 qts of Redline MTL gear oil $9 each or similar

N 90908301 Shouldered Hex Nut, Self Locking $1.45
1J0711067L Bushing $1.35 ea. (need 2)
1J0711202J Relay levr $22.27

1J0 711 781 D Abutment / bracket for shifter cables $14.77
N 90815903 Locking Washer for cable ends (need 2) $0.29 each

1J0711280B Lock Washer $0.52
N 10106903 Hex Head Bolt (Combi) M8x32 $0.52

06A103171A Crankshaft oil seal $45.00

If you car is 00-02 you will need cable ends. BUT you DONT need new cables.

[EdsGTI]

I <3 tony

[beetlevdubn]

Quote, originally posted by nerdhotrod »

Starter Bolts 2 N 907 665 02 $6.76 ea. Starter 1 02M 911 023 $350 - any o2m will work, including TT. DONT SPEND MORE THEN 100 bucks used.

The starters are different between the VR6 and 1.8T 02M's, have you bolted both up to make sure they will in fact interchange? The flywheels may also make a difference on the starter, since they are also different. The R32 starter is different than the other 02M starters as well, not sure about the TT.

It is possible that they will interchange, but having seen both next to each other, there are differences, but I haven't tried swapping them into opposite applications to see if there are issues.

[VDubClub1]

R32 and TT have same starters and tranny

[EdsGTI]

Quote, originally posted by VDubClub1 »

R32 and TT have same starters and tranny

incorrect. The bellhousing is differnt between a 4cyl and a 6cyl. Assumign you are talking about a TT225. If you are talking about a TT with an R32 they will be the same.

[Vdubin372]

my automatic to O2M swap is almost complete, I just cant get the car to turnover now. Something with the park lock out, immobilizer, or brake switch... i have no idea. anyone have a wiring diagram or any idea what to do next??

[navynukenate]

if anyone has read this lately, will the speedo sensor from an 03 6spd work the same and plug into a speedo sensor and ecu from a 01 5spd??

[ubermatt]

fantastic thread, glad it got bumped back up.

[navynukenate]

yes great thread. anyone know where the listed prices are?? Im trying to get the bleader assembly and the "tube line" and i can only find them at the dealer

[turbo-y-zel]

i just used this thread to do my swap.....05 awp 5-speed o2j.....to 6-speed 02m.......

i used the new power steering line for mine and the only problems i encounterd were not having the 3 throw-out bearing bolts ...inside the bell housing..... then the next day all was well until i went to put the starter bolts on and the old 5-speed one's were to short

also i order'd a "6-speed" starter from the dealer w/ doner vin# and upon arrival...it had the same serial# as the 5-speed one from my old trans......so i got some calipers and measurd the gear and housing and prettymuch everthing i could think of and they were the same

but now it's together an work's like a charm......thanks to another informative vortex thread

[k24kid]

does anyone have a write up on this like with wireing and all that stuff?? i tried searching but couldnt find much

[BiH]

keep this up top incase search goes down again.

[navynukenate]

Quote, originally posted by turbo-y-zel »

i just used this thread to do my swap.....05 awp 5-speed o2j.....to 6-speed 02m....... <IMG NAME="icon" SRC="http://www.vwvortex.com/zeroforum_graphics/biggrinsanta.gif" BORDER="0"> i used the new power steering line for mine and the only problems i encounterd were not having the 3 throw-out bearing bolts ...inside the bell housing..... then the next day all was well until i went to put the starter bolts on and the old 5-speed one's were to short also i order'd a "6-speed" starter from the dealer w/ doner vin# and upon arrival...it had the same serial# as the 5-speed one from my old trans......so i got some calipers and measurd the gear and housing and prettymuch everthing i could think of and they were the same

I just went ahead and worked with the fellows at ecstuning to get the entire bolt set for the motor to tranny new. Just one of those smalle things for me. But overall, This was of tremendous help!! Thank you.

[atoson]

bump for ref.

[navynukenate]

keep it around, it helped me out big time!!!

[robingohtt]

good stuff

[Njegos18t]

anyone got a pic of the 5 speed powersteering line with a o2m swap mk4

[BiH]

so I can just swap out the hubs and bearings into my existing spindles? sweet

[homegrown24]

can someone hook me up with the part numbers for the following OEM parts for an 02M (6 speed manual - 20th) transmission?

-clutch
-pressureplate
-fly wheel
-throw out bearing
-master cylinder
-slave cylinder

thanks!

[skin1488760]

where can I get a good price on the tranny?

[TBT-Syncro]

Quote, originally posted by skin1488760 »

where can I get a good price on the tranny?

the classifieds??

[ejg3855]

Quote, originally posted by EdsGTI »

tranny, axles (1.8t ones need hubs and wheel bearings, VR6 ones bolt into existing hubs, but are not as strong) Shifter cable bracket, both shift linkages (stock shifter box works, calbes are switched with the bracket) and a starter.

So from reading this the VR6 02M axles are a direct bolt in ? Not needed to replace the hubs?

And as for shifter bracket is this the piece that the cables mount into? just before the shifter on the trans itself?

[md3788]

Hate to bring this up from the dead, but im looking for someone to confirm that the bracket that holds the shift cables to the transmission is different between an 02J and 02M. I have a full swap from a 20th going into an 04 GTI but that is the one part I dont have and it looks like the 5 speed bracket will not work