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    Thread: 02M install information

    1. 04-04-2006 08:20 AM #1

      Finally got my goodies. I spend ~140$ on a cd and a manual for this car 2002, and i dont want to drop another 70$ on a newer CD to get the 02M stuff. I know im cheap.
      Can anyone help me out with some 02M info? Im doing an LSD install prob this weekend.
      I need some torque specs, bearing preload specs. Shim part #'s. Etc.
      I posted in the MT forum, but no one in there apparently.
      PS_ I will be selling raxels axels (GT-ER gets first dibbs), 02J working with installed peloquin LSD, Starter, Slave, O2j 228 mm specj 6 paddle, 20K miles, eurospec 228 mm FW with ring gear. TT short shifter, Shifter cables, 1.8T spindles, ECS tuning 13 in brake kits, used rotors, 1.8T front calipers. I would like to sell complete to a 2.0 or TDi guy.
      I also have a stock 240 mm clutch, and dual mass flywheel in decent condition. And used lower control arms with urethane bushings pressed in.

    2. Member chaugner's Avatar
      Join Date
      Jul 13th, 2002
      Audi TTQ, Touraeg, Passat
      04-04-2006 08:46 AM #2

    3. 04-06-2006 08:45 AM #3
      buh bump. Need some info guys. Probably pulling it apart this weekend.

    4. 04-07-2006 07:52 AM #4
      Started taking my new 02m Apart last night.
      no more of this

      Could really use some ##'s from you guys.

    5. 04-09-2006 11:59 AM #5
      Ok, i Started diving into the LSD install yesterday. The 02M is head and shoulders above the O2J. The shift linkage, and brass shift forks are much nicer. The gears are larger in diameter and wider. This is a much higher quality box.
      Getting into the install is easier with the O2m as well. You dont have to pull off 5th gear, and the selector shaft comes out real easy. 3 bolts and its out.
      Pull the rest of the bolts out of the case and you can open it up.
      I was having big problems splitting the case though. O2J the upper part just comes off and the gearstacks stay in the bell housing side. On the O2m everything wanted to come off with the upper part of the tranny. Was perplexed at first, and then had a sore back after wrenching the thing off with the gearsets.
      When I pulled it off everything but the diff came with it.

      Check out the shift fork. i was able to remove 1 output shaft, 2 shift forks, and the reverse gear shaft.

      The input shaft and 1 ouput shaft will not come out. I am convinced that the input shaft is somehow snap ringed in there, but I dont want to damage the rubber cover to get at it. Ill do the rest of the work with these parts still installed.
      While working on this, I stepped on something soft, and proceeded to dance around like a little girl. Here is my helper snake that I found in the basement. About 3 feet long when I stretched him out. I was going to chop his head off with a shovel, but i tossed him in the woods instead.

      After the brief interlude it was back to work.
      Drilled the rivets on my 30 yr old drill press

      Sheared them off with a chisel

      When I got the gear off, i cleaned it and put it in the toaster over at 250 F for 10 minutes, and installed it on the new diff. Then used my 99$ made in china leprechaun sized 12 ton press to put in the new bolts.
      With the wheel bearings, bushings, and diff installs this press had paid for itself 3X. You absolutely need to use a press, because it takes 4 hours to hammer them in, and they never go in far enough just using the torque specs.

      Torqued them all up, and finished.

      now onto the bearings. I learned a long time ago that heat is way better than brute force. Heated up the case with a heat gun.

      I got the races out. both were shimmed frrm the factory with health ~.030 shims. I installed the races and 1 shim. Put it together, and checked the play. Ive got ~ .008" of play, I need to make a better fixture for my dial indicators to get a more acurate reading, but some shimming is def needed.
      now again, can you guys help me out?
      I need some torque #'s and preload specs, along with part#'s.
      Im going to use some O2J #'s if no one can help a man out.

      Modified by enginerd at 12:05 PM 4-9-2006

    6. Member transient_analysis's Avatar
      Join Date
      Jan 28th, 2003
      San Diego
      2003 Silverstone 1.8t GTI daily, 1969 BMW 1600 project
      04-09-2006 01:18 PM #6
      Try talking to Sean at kraftswerk
      (951) 926-9636
      Sean is notorious for doing beautiful work on VW gearboxes and I'm sure he'd be happy to help out. He is a very nice guy and did my LSD install on an o2j.
      Sorry I can't be of more help on the specific numbers you need. Good luck with the rest of the install
      stock turbo 1.8t.. damn 2-year CA smog.. :/

    7. Member Wolk's Wagon's Avatar
      Join Date
      Sep 27th, 2000
      Houston TX.
      2016 R:. Blue
      04-09-2006 03:26 PM #7
      Sorry I don't have any Tq specs for ya, but looks like you are doing a good job there, and thanks for the pics.
      2016 Golf R

    8. 04-09-2006 04:34 PM #8

      Is that a black snake?
      I would have cried..

    9. 04-09-2006 04:45 PM #9
      Im not sure what it was. It was black with a grey belly. It scared the isht out of me. I stepped right on the thing and felt it move. It wasn't very agressive though. poisonous? Prob lives well on the mice in the basement
      tony, you have done one of these installs.
      I was planning on running the 02J spec for preload. 0.4 mm of preload on the bearings. With 0.009" play I need a .025" shim. To get me there. The case bolts I was going to run the same 25 NM + 90°

    10. 04-09-2006 04:48 PM #10
      I just got the info from http://www.elitedubs.com
      I need torque specs for the case --25 Nm plus 1/8 turn (45 ° ) further
      drive flanges --25nm
      shifter housing -- if im seeing it right there is 2 nuts and 2 bolts on top of the shifter housing,both are 25nmb
      diff bolts --40 Nm and 1/8 turn (45 ° ) further
      I need bearing play numbers for the diff bearings. Recommended preload.
      Press tapered roller bearing outer race with shim (thickness 0.65 mm) into clutch housing => Page VW-A4-TM02-39-002-0139-16.
      Press tapered roller bearing outer race without shim into transmission housing.
      Install differential into clutch housing
      Install transmission housing and tighten 5 bolts to torque setting
      Press differential in direction of clutch housing and turn it eight times.
      Press differential in direction of transmission housing and when doing this turn it eight times.
      Mount dial gauge and zero with 1 mm preload.
      Move differential up and down and recall play indicated on dial gauge (Example: 0.70 mm).
      Determining shim thickness
      The specified bearing preload is obtained by adding a constant figure (0.30 mm) to the reading obtained.
      0.70 mm
      + Preload (constant figure)
      0.30 mm
      Thickness of shim =
      1.00 mm

      I need some part #'s for the bearing shims in a few sizes.
      Size (mm)
      Part No.
      0.65 -- 02B 409 210
      0.70 -- 02B 409 210 A
      0.75 -- 02B 409 210 B
      0.80 -- 02B 409 210 C
      0.85 -- 02B 409 210 D
      0.90 -- 02B 409 210 E
      0.95 -- 02B 409 210 F
      1.00 -- 02B 409 210 G
      1.05 -- 02B 409 210 H
      1.10 -- 02B 409 210 J

      if there is anything else you need im sure i could dig it up for ya on the bentley,it just sucks the new cd version doesnt let you copy/paste like the 2.5v did.

    11. 07-11-2008 04:09 PM #11
      hey how come i cant see the pictures?
      red x

    12. 07-11-2008 04:22 PM #12
      Quote, originally posted by dannydanny »
      hey how come i cant see the pictures?
      red x
      Because this thread is 2 years old and he probably doesnt host them anymore

    13. 07-11-2008 04:33 PM #13
      oh thats a shame.. but thanks for the reply [IMG]http://*****************.com/smile/emthup.gif[/IMG]

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