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Пікірлер
@brysondowell3045 21 сағат бұрын
This seems too good to be true, doing a 02j swap on a 2003 1.8t. Running into the issue of getting speed signal to the cluster. I have a KKL cable, is this eeprom programming really all that’s required? Did CC still work? I still haven’t wired the CC clutch switch but I’ve been putting it off since getting Speedo signal is step one for working CC
@dzelpwr 17 сағат бұрын
@brysondowell3045 yes, this cluster EEPROM hack is most of what you need. If the car was previously a 09A tiptronic automatic, you'll also want to wire the T32/3 VSS output from the cluster to the ECU for cruise control and correct drivability. The way the manual transmission cars are normally wired, the G22 VSS sensor goes to the cluster at T32/28 and the cluster repeats the VSS signal, output from the aforementioned T32/3 to the ECU. On 09A tiptronic cars, the vehicle speed sensor goes straight to the transmission computer, and then the TCU has two output wires of the VSS signal, one to the cluster at T32/28 and one to the ECU, which means the cluster output from T32/3 is not used on the 09A cars. But when swapping to a manual, you will want to use that cluster to ECU connection so the ECU gets the signal regardless of how the cluster is receiving the signal. So, hacking the cluster for VSS via CAN a least saves having to wire from the G22 to the cluster, but you'll still want to make the correct connection from the cluster t32/3 output to the ECU, which a car that originally had an 09A transmission won't have.
@stefanramirez1999 4 күн бұрын
Hello again sir Do you know of any lsd diffs with 1 way locking diffs as in only locks on acceleration that would fit my 02S to 02j 6 speed project i figured it would be a nice thing to have during snowy weather and heavyrain/mud any tips would be very helpful my only concern is that it must last for dayly normal use not track driving Hope you had a nice new year's eve🎉🎉
@stefanramirez1999 16 күн бұрын
hey Mr Dork i have a question ive recently put a AGG engine from a mk3 gti in my mk2 golf and is in the process of putting in stuff for a hydralic clutch instead of the old cable such as b4 pedal box i found your post on the tdi forum about a 6sped 02S but in a 02J do you think if i made a identical gearbox to yours but maybe swap out some gears for gears with higher ratios for that nice highway cruising and fuel economy. do you think this or a exakt one you made will this fit straight on to my AGG or am i setting myself up for a massive headache thanks in advance for any advice or help! Kind regards -Stefan Ramirez
@dzelpwr 16 күн бұрын
I'm not as familiar with the AGG, I had to look it up. It looks about equivalent to the ABA code 2.0L 8 valve engine we got here in the U.S.. So, a couple things, taller gearing with a relatively low power 8 valve gas engine may be counter productive. It will be slower accelerating. It should still get better fuel economy, of course. The other thing is Mk1-3 era cars have shorter diameter tires, so that's like making all of the gears effectively shorter. It does change the math compared to what I'm doing with a mk4 that has taller tires. So, what market are you in? You may have completely different code 02S gearboxes available to you. Then the next question is what is the target RPM to speed relationship you'd like to see in 6th gear on the highway?
@stefanramirez1999 15 күн бұрын
@dzelpwr hey thanks for a swift reply im not concerned about acceleration i daily drive mh can im just looking for a comfortable and fuel efficent ride my goal is to reach at least 110 or 120 kmh and sit at 2000 rpm in the sixth gear or not much above 2000 rpm at all if any is my goal i rgink it would be achivable but maybe not easy and yes its true i use 14 inch tyres very thin ones for as little rolling resistance as possible
@stefanramirez1999 15 күн бұрын
@@dzelpwr but would the tyre dimensions be that drastic of a difference dont the mk4 golfs that use o2j and mk5 use 02S both use 15 inch wheels and maybe sports versions 16s?
@dzelpwr 15 күн бұрын
@@stefanramirez1999 it looks like the TKR/TDZ codes we get here, which have a 3.39 final drive and 0.625 6th gear, you'd be doing about 105 km/h at 2000 RPM with 195/60R14 tires. 120 kmh in 6th gear and those tires would be about 2300 RPM. There are other 02S gearboxes available in other markets that have a taller final drive (3.16) and there's also some 3.39 final drive boxes that have a taller 5th and 6th gear. 6th at 0.59. If you got a PTW code 02S, it will still have a 0.625 6th, but the taller 3.16 ring and pinion/final drive, which shifts you to between 112-113 kmh at 2000 RPM, 120 kmh would be about 2150 RPM. That sort of gearing tends to work better with the diesels that have more torque down there, or a modern DI turbo gas engine that also has excellent low end torque, but if you're on flat, level ground, you'd probably get pretty great fuel economy for sure.
@stefanramirez1999 14 күн бұрын
@@dzelpwr awesome i will look into this and use your video series to put the internals from the 02S in the 02J you seem to know what your doing when it comes to gearboxes thanks for the good tips and professional videos you produce. Thanks a bunch!
@sheaneumann1411 17 күн бұрын
Hey, great video. I am about to do the 02s direct swap into my 04 wagon, and am trying to gather all the supplies so that I can have everything ready. For hacking the cluster, do you just need the KKL cable and the downloaded kw1281 program? If you have any tips/suggestions, it would be very much appreciated.
@dzelpwr 17 күн бұрын
@sheaneumann1411 yep, just need the KKL cable, a Windows laptop and the free kw1281test program from GitHub and also linked on TDIClub by the creator.
@sheaneumann1411 17 күн бұрын
@@dzelpwr Thank you.
18 күн бұрын
I've been thinking of this same swap in to my FWD mk1 TT but do not have the space to do a complete transmission rebuild. Theres so many good gearing options to improve fuel effiency in daily driving. Has someone come up with a solution to speedo signal without having to rebuild that entire thing? I was thinking the way of a small external trigger disc and sensor on the driveshasft flange ..
@dzelpwr 15 күн бұрын
Yes, someone has come up with such a solution. He goes by user name "caffeine" on TDIClub. I know on the Volkswagen side, 2002 and newer clusters (immo III) can have the EEPROM hacked to pick up vehicle speed by CAN bus from the ABS module instead. My Golf being a 2001 with immo II cluster, could not. But, a new cluster can be retrofit to it easily enough that would allow that capability. I don't regret doing it this way, though. I got a limited slip differential and improved oiling by doing what I did.
15 күн бұрын
@dzelpwr LSD would be nice.. But putting one in, in a car that is only worth the the same as the part itself... ..Hmm.. ill cobble up a sensor and circuit that groundsthe signla and put tabs or a trigger plate on either driveshaft flange would be easiest for me.
15 күн бұрын
@dzelpwr oh, my tt is 1999 i think theres no canbus anyway.
@zerovandez 28 күн бұрын
I just bought a wavetrac and didnt know why other than it is an LSD lol. Now I know why I went with wavetrac and not the other options. Thank you!
@Hippie9D Ай бұрын
Ah, now it makes sense. Thanks!
@kona5853 2 ай бұрын
Do you know the differences between the 02S and 02R? I’m getting an 02R(from a tdi) delivered in a few months. I cannot seem to find any official references only a couple claims that it’s identical to the 02S other than ratios. Also cannot seem to find full rebuild kits, I’d like to fully clean, thermal coat the exterior, replace all synchronizers, bearings and seals and maybe re-shim for the correct clearances, Also putting a eurotuning 6 speed conversion in it (.58 6th gear).
@dzelpwr Ай бұрын
02R is from the same MQ250 family, but they are 5 speed, not 6. The 02S is a 6. The 02R is odd, it has a rear case and rear pan shape that is different from all the other MQ250s boxes (02A, 02J, 0A4, 02S). As such, it needs a different gasket for the rear pan that none of the other MQ250 boxes use. It also has a unique 5th gear selector fork. I work for a company that has gotten a few very cheap 02Rs brand new through VW, and in order to use them on North American cars, we take these brand new 02Rs apart and swap a 02J rear case half on them along with the 5th gear fork and the entire selector assembly. This also means getting a 02A/J/0A4 rear pan as well. This makes me worry about the compatibility of the Eurotuning 6 speed add on because the shape of their pan extension is meant to line up with the normal 02A/02J/0A4 rear cases, not necessarily the 02R. It might not seal. The 02R does have a vehicle speed sensor like an 02J, but oddly many of them also have the weird casting that blocks gravity drainage of gear oil into the differential like the 0A4 and 02S do. It's really an oddball in the world of MQ250 gearboxes. Just like the other gearboxes, there are a number of different 02Rs with different gearing in them.
@dzelpwr Ай бұрын
The point of me doing the 02S but with a 02J bellhousing is so I didn't have to buy an add-on kit like Eurotuning. It's so I could have a gearbox that has factory VW parts in it that's still the same architecture but with the additional gear... Plus, I rather like the 0.625 6th gear. I didn't like that Eurotuning only offered a 0.65 and a 0.59 6th. I wanted something more inbetween that was closer to the ERF and DRW 02M 6 speeds VW offered in Europe, and the TKR and TDZ code 02S gearboxes are exactly that. It actually falls exactly inbetween the ERF and DRW in terms of total gear reduction in 6th.
@dantemagz6672 2 ай бұрын
Is it possible to hack the abs module on a 2000 golf tdi
@dzelpwr Ай бұрын
It's not the ABS module that needs to be hacked, it's the instrument cluster. You would need a cluster from a 2002 or later car, immo III, which requires different immo chips in your keys as well usually.
@РусПутин-щ5ъ 2 ай бұрын
Hi, sir! Thank you so much for all these videos! Could you tell what were the letters of 02s gearbox?
@dzelpwr Ай бұрын
TKR and TDZ are the two common 02S codes available in the U.S. starting in 2019. I've torn down a TDZ and that one did *not* need to have machining done to the pinion shaft. It still used the older style bearing. The TKR, however, uses the different bearing and slightly bigger short end of the pinion shaft for that bearing.
@РусПутин-щ5ъ Ай бұрын
@dzelpwr thanks a lot for the answer!!! 🤝
@kerrvfx 2 ай бұрын
nice stuff, great to watch w this camera setup.
@sooos7453 2 ай бұрын
Yeah.. i wanted to cheap out and buy a smf but now i'll just swap my 1.9tdi to a vr6
@billasohyeah 2 ай бұрын
Did you ever put the 02s into an 02a case? Would it be the same as an 02j? I have a vr6 and was thinking of upgrading the original 02a with an 02s KWB internals.
@dzelpwr 2 ай бұрын
@billasohyeah no, but I could. At the same time, 02J cases are basically interchangeable. On the gearbox case half, there will be an extension where the axle seal goes. You'll probably want to use 02J style axle cups regardless of what cases you choose because the only diff that accepts a 02S ring gear is 02J-B, which has bolt-in flanges. So, you can use a 02A case, but you'll want to use two 02J409528C axle seals that extend out from the case. Using a 02A/02J gearbox case also means you have to use the internal selector arms from one of those. This means you will have to mill an extra opening in the 5th gear rail to allow the shift tower to get to the 6th gear position. Then you might also want to use the 02A/02J 5th gear lever at the back of the case, as the 02S lever is setup for a shorter throw. But you will have to use the longer spacers the 02S comes with. And you need the 02A/02J upper idler shaft support plus the idler shaft itself from an 02A/02J. I have not personally done it this way yet. I keep using the 0A4 rear case half because it's easier, but the problem with that is there are no provisions for the Mk2/Mk3/Corrado/B3/4 transmission mount bracket. So, if that's what you're swapping into, you'll either consider swapping all those individual parts and modify the shift rail as described, or fabricate a custom trans mount bracket that bolts to the bellhousing in a different manner.
@billasohyeah 2 ай бұрын
@@dzelpwr yes my problem is I have a mk3 VR6. The VR6 has a different bell housing compared to the 4 cylinder engines and where I'm from there's not much of those available. Thank you so much for your detailed explanation. It's something I'm going to study, collect all the parts and then try it myself.
@giorkar2116 3 ай бұрын
Hello sir! I have a 6 speed O2S MCB gearbox and when the engine is running in neutral i hear a tik tik tik noise from the gearbox and when I press the clutch pedal to the end the noise dissappear (when the gearbox stop spinning). In a few days I will take the gearbox out and open it to repair it. Can you help me please to tell me your opinion what do you believe is the problem? It's that same tiking noise sound as the 5 speed with the double "cassette bearing " skf that always destroyed, but the 02S MCB doesn't have this "double cassette bearing ". Thanks in advance!! Looking forward for your help!!
@pali4life48 3 ай бұрын
Question.. I put in my pinion shaft without the shim like you did and it has 0 play. It spins but take a tiny bit of force. Also I do have the gear stack (straight cut gears) pressed on there could that be why? P.S. thank you for these videos, never thought I’d tear into a transmission but with how in depth these vids are it gave me the confidence to do so!
@dzelpwr Ай бұрын
I've never seen one that had adequate preload without a shim. They would absolutely have play if you pulled up on the pinion shaft with adequate force. This video does show how to properly measure for what size shim and then also double-check with a beam/twist type torque wrench how much friction torque it takes to move the pinion shaft against the bearing preload. Ideally, with new bearings, it should take 8-12 in-lbs. 5 on the low end, 15 on the high end range of acceptable. If it's taking less than 5 in-lbs once you've installed a shim, you need to go upto a thicker shim to get within that desired window.
@user-gl4jy8lz4o 4 ай бұрын
Hey man i put a mk5 gti steering wheel on my 9n3 polo any idea how i can make the buttons work
@Revaldi 4 ай бұрын
thank you very much for this video, very helpful for me!
@sunoclockoneday2576 4 ай бұрын
You do nice work man. Appreciate the videos , very thorough.
@normancharboneau7446 5 ай бұрын
What do I do now that the the odometer blinks while engine is running after doing this? Otherwise it worked great!
@dzelpwr 15 күн бұрын
I don't know! I haven't heard of that before! What cluster software version/part number do you have? And what codes are being set?
@Steele44320 5 ай бұрын
Outstanding work! This was kind of a good thing bad thing for me. I was putting my MK6 back together after a total clutch job and snapped off one of the output flange bolts. Looks like there are more than a few few people listing the spec at 31, but we both know that is not or would be driving my TDI now lol. So I have to drop the trans (again) , spilt it and after that I'm a bit lost. I would appreciate any additional info. Thanks for your time.
@dzelpwr 5 ай бұрын
If you're in the U.S., your Mk6 TDI will have a MQ350 02Q 6 speed. Bigger gear box with two pinion shafts instead of just the one like what I'm working with in this MQ250 02S. The center bolt for securing the flange into the differential only needs to go to 20 ft-lbs. There's only maybe 6-7 mm of threads in the round tab in the spider gear that this bolt is threading into. Really can't get away with a ton of torque with that small surface area threads. VW's actual spec is 25 NM, which translates to around 18.5 ft-lbs, I just round up to 20 and have never had an issue. 31 sounds closer to what the M8 sized perimeter bolts securing the axle to the axle cup would be for MQ250 boxes with 100 mm cups and matching inner CV joints. Spec is actually 33 ft-lbs for those bolts. Your MQ350 should have bigger flanges and bigger diameter bolts (M10) for the inner CV to secure to the axle, and the torque spec there is more like 52 ft-lbs.
@sajidqureshi2175 5 ай бұрын
Very nice i have mk7 golf wheel in my mk4.. horn and airbag works .. any tuturial to make the buttons just light up
@dzelpwr 5 ай бұрын
I haven't done a newer wheel like that myself, but someone does make a LIN to CAN bus converter for those wheels on older cars. Check this out: lavky.com/home-and-living/everything-else/auto-parts/steering-wheel-adapter-converter/?product=WC808908 Again, I haven't used it. I've heard from others that they have had success with it, but don't count on me to troubleshoot something I have not personally worked with yet.
@Leo.G 6 ай бұрын
Is it possible to convert the 02j to 02m? Just swaping the internal parts?
@dzelpwr 6 ай бұрын
02M is completely different architecture with two pinion shafts instead of just one. There are exactly 0 parts that interchange with the 02J.
@mikekongsiri 6 ай бұрын
Great video! Doing the research on a 02A->02S conversion for my Corrado. Do you know what 02S versions would work best? Im having a hard time finding any 02S gearboxes, what year/models were fitted? Thanks again for passing on your expertise!
@dzelpwr 6 ай бұрын
Here in the U.S., we only get the following gearing: 3.39 final drive 4.11 1st gear 2.11 2nd gear 1.36 3rd gear 0.97 4th gear 0.77 5th gear 0.625 6th gear TKR, TDZ, UJC and UEB codes all have the same gearing. They came in 2019 and newer 1.4 and 1.5 TSI powered Golf/Jetta cars in the U.S.. The non-GTI Golf died after 2021. After the 2024 model year concludes, the 1.5 TSI in the Jetta will only be offered with an automatic transmission. So, these gearboxes only exist in our market from 2019-2024. There are multitude other 02S gearboxes that have been available in Europe since around 2005 or so. Wide ranging gearing. So, depending on what exactly you're after. If you want a closer ratio box for sporting intentions, or if you want the longer legs for much higher speeds, quieter and more efficient highway operation. Also have to bear in mind that anything Mk1 through Mk3 era, including Corrados, have smaller diameter tires than Mk4 and newer cars, and that affects gearing as well. You need taller gearing on a car with smaller tires to make up for the difference.
@mikekongsiri 6 ай бұрын
@@dzelpwr Wow! thank you so much for sharing that. No way I could ever have ever researched that on my own! thank you!
@mikekongsiri 6 ай бұрын
@@dzelpwr If I can find a US spec 02S and want different ratios, are the gears available through VW or other source? are the parts interchangeable?
@dobriy9853 6 ай бұрын
Здравствуйте хорошо было бы если на русском языке.
@TheOlehal 6 ай бұрын
Are the synchros brass on 0a4 looking to replace the flywheel to solid. Clutch starting to slip
@dzelpwr 5 ай бұрын
Yes, they are all brass and fairly thick. Exceedingly rare to see them crack or break even when converted to single mass.
@LUIS-659 6 ай бұрын
nice video, some time i think that idea, but you became real job,
@BRWfilms 6 ай бұрын
If you had to make another bracket would you do it the same way if you needed to buy that bracket?
@dzelpwr 6 ай бұрын
Yes. I rather like how it turned out. I've done a couple more since the video.
@BRWfilms 6 ай бұрын
@@dzelpwr what kind of cable do I need to do the can buss hack? I just ordered a vcds cable for Ross tech vag com the other day but my understanding for running I need something called a mpps cable as well
@gabifilip9976 7 ай бұрын
Forza Ferrari
@empleodecogno 7 ай бұрын
Very helpful vids. Thank you very much. We currently swap the 02s internals to my 02a case which should be the same as the 02j. We now found out the selector of the 02s don’t fit the 02a case because of the lever length. If I understand correctly you used the 04a (0A4311490B) selector which already has the 6th cutout. I really want to use the 02s tower because of it’s very straight and quick gearselection. Hope you have an answer!
@empleodecogno 7 ай бұрын
So after my post I saw your comment to BWRfilm. I believe this video has been made and you ended up with a different solution as you said. That means I have to adjust the 02a selectors. The only thing I’m not sure about is if I can use my 02a tower or do I need to switch to a 02j tower?
@dzelpwr 7 ай бұрын
You will have to remove the 5th gear rail from the 02A selector assembly and modify it so it will be able to go into the 6th gear position. You can still use the 02A tower, but changing the shift linkage cables, box and tower to later 02J style makes for a much more robust, reliable and precise shifting experience. My first VW was a Mk3 about 20 years ago that had an 02A and I grew to despise that shift linkage. Once I hacked the 02J Mk4 parts into the car, it made me enjoy the car all over again as if it were something new. I used the 0A4 rear case half so I could retain the 0A4 selector and 02S tower, which does shorten the throw some. But, for Mk2-3 era cars, the 0A4 case half does not have the provisions for that transmission mount bracket. So, if you want to use that OEM bracket instead of fabricating something new, then yes, you will need to modify the 02A 5th gear selector fork/arm to be able to go into the 6th gear position. Also note that the lever for 5th and 6th gear likely also has the pivot point in a different position than it does for the 02A/02J, making the throw shorter there as well. So, matching 02A parts with that 5th/6th gear arm may cause 5th and 6th gear to have a oddly shorter throw than the rest of the gears. I am unsure on if you can just use the 02A/02J fork/lever there or not. It will probably still work with the 02S' lever, just may feel a little odd with the different throws for 1-4 vs. 5-6.
@BRWfilms 7 ай бұрын
Dude you should make vcds for dummies course. I haven't bought vcds yet or did much electrical diag so some of this went over my head but still this is a high quality video in information your giving. Your talking about stuff that you only know cause you have years of experience on these cars which is awesome to see in a video
@dzelpwr 7 ай бұрын
I could try something like that. Do you have some specific ideas on which things you'd like more information on? I've been pondering on a video for some basic CCM hacks using both VCDS as well as the kw1281test command prompt program to setup certain cars with the specific tweaks I prefer. I could cover some additional basics in that same video, as in some sense most modules have the same set of functions available in VCDS.
@BRWfilms 7 ай бұрын
@@dzelpwr well to be honest with you I haven't used vcds yet so I don't know a lot about it. I know it would be useful to use to look at the different data variables on engine and transmission If I can check if a car is tuned or not with it Things like testing modules or systems would be useful Not sure if this can be done in vcds or if you need a tuner but things like clearing the EGR code completely so that it doesn't trip every time your start the car on deleted vehicles How to program keys If you can turn off the immobilizer in vcds that would be useful Maybe go over various ranges you want to see in an alh or bew engine for data like what is normal and what is not and what various data can indicate How to set timing would be a must. Fueling things How to set up the car when you had a 10 mill pump and swapped to 11 it's my understanding that something needs to be changed when you swap in an 11 mill on a manual for it to run properly If it can be done how to stop the car from locking it's self. I absolutely hate that. I don't generally look my doors specially at my house so I would prefer the doors to be unlocked when I walk up to it but 2-3 are usually locked I'm sure there are a lot of other things maybe ask in facebook groups. I'm sure others will give some others ideas to consider. If I had started using vcds already I would probably have more ideas
@BRWfilms 6 ай бұрын
@@dzelpwr another thought is a set of videos for transmission rebuild on 02js or similar transmissions. I want to start doing them my self. Honestly would pay a few hundred for videos coving the tools, use of press dial indicator, checking for wear and general assembly and disassemble of the transmission. I come access bad transmissions a lot in older high mileage Mk4s. Currently taking them 2 hours away for rebuild. No one in GA that does them. Have to go to Tennessee I know your 02s videos has a lot to offer but still more to it if your completely stripping the shafts and replacing every synchro and bearing race ECT.
@javierholland1446 7 ай бұрын
Promo`SM
@kellym5200 7 ай бұрын
Well done Matt
@ZakariaeEnnahas 7 ай бұрын
hello sir , first thank you so much for the video it helped me a ton to disassembly my 02s , my 5th did not engage and it made a very bad sound when i opened it i found that the outer sleeve of the synchro hub the part you have in your left hand at 29:07 is eaten , can you please help find the spare part for it , i cant find it. waiting for your reply. thanks
@dzelpwr 7 ай бұрын
Hi! For a part like that, you're only likely to be able to buy it through VW dealers. Amazingly, this part appears to be substantially cheaper through VW than the 5 speed selector hub and collar assembly is! It is part number 02S 311 241 F, VW's current retail price on it here in the U.S. is $176.05. The 5 speed selector hub and collar is somewhere around $400 retail these days!! So, very surprised that the lower volume 02S part is that much cheaper.
@petarpetrov255 7 ай бұрын
Здравейте, поздравления за чудесната работа! Искам да сменя само шеста скорост на JYK (02S) със такава от ERF (02m), дали ще е възможно? Благодаря и успех!
@dzelpwr 7 ай бұрын
It is possible. A lot of parts need to be changed to make it work. Shift cable bracket/holder is different. Shift levers on top of the transmission as well. Different starter, axles as well as clutch and flywheel. Clutch line between master and slave is also different, but all very doable. Looking into the gearing of the JYK, it has a 3.65 final drive. The TKR and TDZ code boxes I've been doing here in the U.S. have a 3.39 final drive. Also, 6th gear in the JYK according to the parts cat is a 0.73. This makes for a total gear reduction in 6th gear of 2.66. Your ERF gearbox has a 2.615 final drive for 5th, 6th and reverse gears, and 6th gear is a 0.814. This makes for a total gear reduction in 6th gear of 2.128. SUBSTANTIALLY taller than the JYK 02S. For the record, the TKR gearbox I used here has a 3.39 final drive and a 0.625 6th gear, which ends up slightly taller still than the ERF at 2.119. The DRW 02M is slightly taller than both at ~2.1065, it has a 0.805 6th gear.
@bendover-uf9st 8 ай бұрын
How the transmission holding up? Heard the synchro get “wrecked” from the diesel vibration.
@dzelpwr 7 ай бұрын
It's great so far! I do have a single mass flywheel on it, but the clutch disk is one meant for a 4 cylinder, so it absorbs the vibrations reasonably well. The "VR6" clutch kits do not... I just drove this wagon from Oregon to Ohio and back again in the last couple weeks. Put more than 5000 miles on it in 2 weeks, got fantastic fuel economy and was an absolute pleasure to drive. I've not had too many issues with MQ250 synchros with diesels and single mass flywheels. But certainly, MQ350 02Q synchros do not hold up well to the vibrations! Most of the 02S synchros aren't too different from what the old 02As used. They're pretty thick, yellow metal synchros that seem to hold up just fine.
@mistron71 8 ай бұрын
Just watched your new wavetarc lsd video and now this one, I wanted to know your opinion on the lsd conversion kits made by racingdiffs, they currently just make them for 02a and I have a 02s, but this year they will release more gearboxes. I'm planning on making the mod myself here in spain, the wavetrac is 1500€ and the other kit is 200€, I understand that the performance won't be the same but if it's 75% of the wavetrac I can't justify spending more than a grand extra.
@dzelpwr 7 ай бұрын
I have zero experience with those. It looks a little hokey, if I'm being honest. You're also still using the original differential, which has its own weak point--the roll pin holding the main shaft for two of the spider gears. Going to a proper, full limited slip diff is substantially sturdier than the stock diff could ever hope to be, with or without an add on kit like the one you mention. For me, it's either leave the original diff as it is, or put in a proper limited slip.
@GiuseppeBusso7 8 ай бұрын
Hello, I own a Seat Leon mk3 1.8 FR with manual 6spd gearbox. It's an MQ250 and RSN code. Before 1,5 year and after two very aggressive starts that the car bumped up and down in 1st gear until the cutter and until it found traction, my car did whine sound after that. I decided to keep it as it is until the flywheel change and alongside with installation of bigger turbo, so I was in need for better clutch. Before one month I left the car at the garage for the new setup. IS38 turbo, handmade racing 6pad flywheel and opening the gearbox to change all the bearing. Seven bearings as I remember. 5 for the gearbox and 2 for the differential. Basically, I bought a fix kit for the RSN MQ250 (corteco, coyo, jtekt, snr some of the brands of the bearing kit). Anyway, my mechanic found the old bearings in very good shape and the magnets just had physiological powder. I said that this is good, he said no. He was sure that the bearings change, won't fix the whining. Forgot to mention that before 1 year, i started with gearbox oil change (Liqui Moly 5300 with 2 MoS2 additive, to see if there would be any improvement. My car does the same noise. Whine noise when cruising with 3rd, 4rth, 5th and 6th gear. Another situation is if I engage 1st gear and have the clutch pedal pressed while the car is running, the whine noise is really hard. I'm desperate because I decided to fix my gearbox (brand new car with only 60K kms since 2017) instead of buying a second hand. What is your opinion about my issue? I would appreciate any info. We can contact via mail, FB if you want. Thanks!
@miketaggart4183 8 ай бұрын
Great explanation of the mechanical operation of the differential. I love my Wavetrac and now I know what's inside it. Thanks
@DopeTDI 9 ай бұрын
This is amazing. I am going to search for a 6 speed now. Thank you for experimenting with these old dinosaurs!
@steambuns2283 9 ай бұрын
hey man. how much torque can the 02j handle?
@dzelpwr 9 ай бұрын
I know a couple people with 350 ft-lbs being sent regularly through them and they're holding up. Adding a pinion brace helps a lot. As you get above that, the clutch needed to hold much more is substantially stiffer and has the tendency to bend the clutch fork. Buying a reinforced clutch fork for such a clutch setups would be required. Obviously an old, worn-out transmission with bearings that are no longer as well-preloaded as they were when new can make it easier for gears to strip out under those high loads. Also, when making that much power, a limited slip differential would be ideal to both eliminate the potential failure point of the little roll pin that holds the main spider gear shaft into the differential, plus having ARP hardware securing the ring gear to the differential is an upgrade over the original rivets the VW differential would have from the factory to secure the ring gear to the diff assembly. You do those upgrades, they can certainly hold more torque than that, although if you are constantly putting that level of power through it because it's a track car, maybe you would be better served with an 02M or 02Q MQ350 gearbox.
@faculng3579 9 ай бұрын
Hi! I love your work , greetings from Argentina. I would love to add MFS to my Vw Golf 2004 (Mk4) 1.9 TDI , it's an AGR 90cv Model with EDC15VM+. I got the same steering wheel in the video from a 2010 Volkswagen Sharan, (the same one in the video). Any advice to install it?
@szymonbednarczuk4176 9 ай бұрын
So can i swap to octavia 2 wit 1.6 mpi ?
@dzelpwr 9 ай бұрын
I'm sure you could. I don't know what those originally came with. We never got Seat or Skoda brand vehicles in the U.S.. We also never got 1.6L MPI or FSI engines here, but generally speaking, VW has not changed the bellhousing bolt pattern on their water cooled 4 cylinders. They've added extra bolt holes over the years, but any transmission meant to bolt to a VW/Audi water cooled inline 4 is technically interchangeable. Might need a different clutch and flywheel depending on what it had in there originally. Might need different axles and a different mount bracket. Maybe the clutch hydraulics change and the bracket that holds the cables to the top of the transmission. All depends on which exact transmission your car currently has. There's also numerous different 02S 6 speeds available in Europe we never got in the U.S., and with a wide range of different gear ratios and final drives. So, depending on exactly what you're after, there may well be a specific code that best suits your wants/needs.
@gryphonking133 9 ай бұрын
How would someone go about buying one of these transmissions from you and how much would they cost
@dzelpwr 9 ай бұрын
Well, if you have a 2002 or newer, you can just bolt the transmission in as-is. Make cable shift adapters like I did here, and then hack the instrument cluster to pick up VSS via CAN so you don't have to worry about the lack of vehicle speed sensor on the transmission--I have another video that covers how to do that. At that point, all you'd need is the transmission itself. I buy them through car-part dot com. It's just a junkyard aggregation website where junkyards from across the country list parts from vehicles they have. LKQ can transfer a part from another location to their local one and deliver it to you. Otherwise, if you wanted the bellhousing swapped to retain the vehicle speed sensor and also get a limited slip differential, probably better to contact me through Cascade German for an estimate. Expect all-in to be above $3k with the bellhousing swap and limited slip.
@Albert87nl 10 ай бұрын
ive been in the vw scene since 1999... but this is the first time some one posts a well explained no BS fancy pants show of a gearbox teardown of a 02S yesh i could try my self but being autsitic i dont start stuff with alteast a little bit of background info..... that said this is BIG background info FYI
@rubenwarmerdam-m3l 10 ай бұрын
Dude, I want to thank you so mutch, found you here and later on the forum. Been on the hunt for a long gearbox for the AHU swaped mk1 for way to long. Your hint on the PTW gearbox was a golden one. Swaped over the bellhousing to one of a 02j, and it just fits speedo drive and all. Dropped it of at a specialist for the setup today. Its about as long as a LBQ trans, but i hope the extra gear alows me to fit bigger tires ontop of the 17% ill get over the ASD that is in there. Thanks from Europe.
@vwfatmobile3275 10 ай бұрын
Great video. I was screaming 10400 at you, glad you heard, ha. Is the 02S a stronger trany than the 02J and what cars did they come in?
@dzelpwr 10 ай бұрын
Not necessarily any stronger, as it is the same family as the 02J. The basic architecture is the same, hence my whole video series on swapping a 02J bellhousing onto a 02S box. Though I suppose the 02S does come with a reinforced region around the pinion bearing on the bellhousing side. In the U.S., these come in 2019 and newer Mk7 Golfs and Jettas with the 1.4 TSI. TKR and TDZ codes are the most common. Later 1.5L engines will also have a similar 02S gearbox with a couple other different codes that start with the letter 'U'. I don't recall them, they're also too new to get any affordably used from wrecking yards at the moment, so I don't bother with trying to remember them. heh First video I did on the 02S last year goes over some of the differences and details. Too bad I can't do the math of multiples of 16 in my head--maybe I would have gotten the baud rate right on the 2nd try. 9600 is a valid rate, but the cluster doesn't like it. But I use it for address 46 central convenience hacks all the time, which is probably why I did it the first attempt. I do more CCM hacks than cluster hacks and that was what was in my mind. Could probably do a video on that. It's fun hacking for window 'komfort funktion' to be used via the remote for keyless entry. Also is nice to hack these American versions to put the hatch on central locking on wagons and Golfs. So much more convenient.
@miltiadisdalaris6200 10 ай бұрын
Can you swap 1.6 16v from 5 speed to 6 speed, like golf 5 1.6 16v fsi?
@dzelpwr 10 ай бұрын
Where there's a will, there's a way! Would need to know what gearbox you have currently, because it can be a completely different family that might require totally different shift linkage, starter, axle, clutch and flywheel, clutch hydraulics etc. But certainly such a swap is possible. It's just about knowing what exactly you have, which gearbox you want to change to, and what parts need to be changed with it to make it work. What I did to this Mk4 was take the original 02J 5 speed out, which is in the MQ250 family, and replace it with a much later 02S 6 speed, which is still in the same MQ250 family, so most of the original items I was able to keep. The same starter, clutch and flywheel, axles, mount bracket etc. But, since the mk4 02J has a vehicle speed sensor, and that's how the car is wired, but the 02S did not have a vehicle speed sensor, I had to perform this hack to get vehicle speed to work via ABS. Otherwise, the other option was swapping an older, but compatible bellhousing onto the 02S to have the physical vehicle speed sensor again, which is something I did on another car before this... And it's WAY more work.
@chrstphrr 10 ай бұрын
Had a similar issue in a mk4 wagon losing power to a bunch of systems (driver's door everything, sunroof, etc). The taped up sonic weld behind the lower A-pillar was ALL green verdigris corrosion, very little metalic copper left. It literally crumbled apart, freeing up the wires that were supposed to be spliced. Definitely no power could pass though that junction!
@chrstphrr 10 ай бұрын
I've a question you're likely going to know: With the immo3 era cluster being able to receive the VSS signal via CANbus from that ABS module... Is the newer ABS module needed for this to happen? Or would an early mk4 with an immo3 cluster swapped in be able to "ask" the older mk20 ABS module for that same VSS info?
@dzelpwr 10 ай бұрын
This was the exact same question I had. It seems the swap from immo II to immo III on Mk4s also coincided with a change from ATE Mk20 to ATE Mk60 ABS. However, on my thread on TDIClub, someone did say that swapping the immo III cluster into a 2000-2001 car that originally had an immo II cluster does actually allow for VSS to be picked up via CAN bus. So, it does appear, at least according to that one poster, that the older Mk20 module does indeed send a signal on CAN bus the later cluster can use to do VSS via CAN.
@Jakey959 10 ай бұрын
@@dzelpwr I have a 2000 Mk4 was orignally a 1.6SR, I did the engine swap to 1.8t AUM changes gear shifter from bar type to cable, had lot of issues with wiring as the car was 4-5 years older that the engine i was using but I got there in the end and it my daily, I have the MK20 ABS and it works a treat, I coded it with VAGCOM at first It had faults buy when i cleaned up all my old ground points and greased them i didnt got the fault anymore and my ABS began to work. Strange..
@chrstphrr 8 ай бұрын
@@dzelpwr sorry I didn't notice you replying back with the answer, Matt! Thank you! That's great news, 'cause then this is JUST a software mod, and, at most, an immo3 cluster swap. This evening, I need to stop ambivilating, and settle on which Immo3 cluster I want to use in my 2000 car. I'll throw an update onto the kw1281test wiki after I prove out this mod.
@jamescallahan6166 8 ай бұрын
@@dzelpwr This fix would not apply to the 99.5 cars correct? I.E. swapping in the immo III cluster to do VSS via CAN.
@dzelpwr 8 ай бұрын
@jamescallahan6166 I've been told it is possible, but it does involve more work than just a cluster swap. I don't have specifics, but I try to avoid owning 99.5s anyway. 😅 So many weird things are specific to them.
@abranbarraza6915 10 ай бұрын
I’m thinking about doing this kinda swap into my 03 golf tdi. From 5 speed to this 6 speed. You make it look easy but sounds intimidating at the same time lmao 😂
@dzelpwr 10 ай бұрын
If you've done a clutch job on a 5 speed from that era, you already know 95% of what you need to do the job. The two gotchas are the hacking the cluster that I show here, and the different bolt hole locations for the shift cable bracket--which you can address by either just getting a Mk5 cable shift bracket, though that seems to strain the side to side cable a little, or have to fabricate two brackets to relocate two of the bolt holes so you can reuse the original Mk4 bracket. That's what's great about the 02S is aside from the cable shift bracket bolt hole locations moved, you get to reuse all your original 5 speed parts. Same hydraulics, clutch and flywheel, axles and starter. When you do a swap to a Euro 02M 6 speed, all of those also need to get swapped along with a different still bracket specific to the 6 speed and an oddball bellhousing bolt with an extra long stud and nut to go with that different cable shift bracket.