Starting this thread to get as much information about upgrading theese gearboxes as possible.
If you know anything you'd like to share, please post it here.
The 02M gearbox came in 1999 with the Golf 4 and other VWs and Audis. It differs from the previous transmissions in that it has two different output shafts. This gives different final drives for 1st to 4th gear and 5th to 6th gear.
4Motion-gearboxes came with both 4-cylinder and 6-cylinder engines. The difference between them is the clutch housing.
For the 6-cylinder boxes, one gearbox is stronger than the oter models. This is the DRP and it was delivered in Golf Mk4 2.8 l. 4Motion 1999-2000. This is maybe the best start for a transmission for high effects. Cluth housing from a 4-cylinder engine can be mounted to the 6-cylinder gearbox.
Transmissions to the 3.2-liter engines (from R32) have a weakness. The bearing on the input shaft may loosen, most often seen where a lightweight flywheel. Different companies offer a modification of this, but the gearbox must be removed to get this done. HPA is one of several that can fix this:
Lightweight flywheel will also course problems with Peloquins and Quaiffe diffs:
CAUTION ALL 02M Owners: Do not use a lightened flywheel on the 02M, the stock clutch and flywheel is tuned for the 02M, for weight distribution, and a light flywheel goodwill pickup harmonics from the main shaft. It sounds like the trans is about to self destruct.
The ratios for the DRP
Final drive, 4.333 for 1-4. gears, 3.421 for 5-6. provides.
1st gear 3.417, 2nd gear 2.105, 3rd gear 1.429, 4th gear 1.088, 5th gear 1.097, 6th gear 0.912.
A common problem for vehicles with high power engines and 6-speed gearboxes is the close ratio between the gears, and the top speed suffers as well. It is possible to use the final drive from the other models, here is a selection from Bora and Sharan. Here we can get ratios that gives theoretic top speeds over 320 km/h at 7000 rpm.
FD ratio for Sharan and Bora:
With 195/45-16 tires and 7000 rpm top speed is 246 km / h.
With ERR final drive, 3.1 for 5-6 gives increases the top speed to 271.5 km/h.
With EHH final drive, 2.926 for 5-6 gives 287.6 km/h top speed.
The EFF final drive, 2.727 for 5-6 gives 308.6 km/h. top speed.
With DRW / ERF final drive, 2.615 for 5-6 gives 321.8 km/h. top speed.
Sharan transmissions with 22/27/79 teeth are EHH, EHL, FGM, FVP, FJG and FVR.
Golf and Bora transmissions ERR have FD 71/17/23 (FD 3.087) and 62/16/20 (FD 3.1).
A little bit more about ratios for different 02M boxes: http://workshop-manuals.com/volkswag...os_capacities/
Dogbox gearsets are supplied by multiple companies:
PPG, Pfitzner Performance Gearbox. http://www.ppgearbox.com.au
DM motorsport: http://www.dmmotorsport.com/wb/pages/english/home.php
ForceFed Engineering: http://store.forcefedengineering.com...ts.asp?Cat=131
This is a weak point on the 02M. The shifting forks for 1-2. gear will easily brake at high loads. Here is a fork of brass fastened with a rivet. This was 6 mm. thickness of the first models later this upgraded to 7 mm. Still it’s weak, and a common way to improve it is to use a high quality bolt and TIG weld the nut to prevent it from loosening.
The 3-4. shift fork is made in one piece, and this may breake under hard use. DM Motorsports offers a stronger fork in billet brass. The price is 400 CAD.
SQS Racing offers a billet shifting fork in high strength aluminum. The price is € 200 pluss taxes.
The shifting fork to 5-6. is riveted. This can be reinforced with a high strength bolt with the nut TIG welded. SQS Racing has developed an improved version that appears in the manual.
Here’s an article about the shifting forks issue:
Steel shift forks by USP Motorsports:
Support for 4th gear is offered by Epytec:
Diffs from Quaife and Peloquins:
For engines with high power is difficult to find a suitable clutch. So far I have found two options that stand out:
Clutch Masteers have several models with different type of surface. In addition, they have two flywheel options, aluminum or steel.
http://www.clutchmasters.com/shop/?p... toYear = 2006
For those who must have the highest outputs the Clutch Masters clutches may be too weak. DM Motorsports have developed a kit , a Tilton clutch with steel flywheel. This weighs 14 lbs. and can be supplied for both the 4 - and 6-cylinder engines. The kit costs 2800 Canadian dollars.
ARP offers reinforced bolt kit for the flywheel: