Tdi 02J trans 5th ratio change

[@crazypeoplearoundtheworld304]

Great job. I live in Florida and have used many of your online tutorials. This video is another good example of your great work.

[@CoolAirVw]

Thanks!

[@CorsairLGM]

Many thanks for making this video! It helped me to do the gear swap in my '02 Jetta. I used an air hammer on light setting, with a flat-faced hammer insert that matched the diameter of the shaft. Also heated the outer splined items (not too much) with a heat gun after reading an article somewhere. Maybe beginners luck, but mine came off / went on pretty easy, with just light hammering. I probably would not have had the confidence to attempt myself without seeing this video, so thanks again !

[@CoolAirVw]

I'm glad my video helped.

[@vwfan1115]

As a VW ALH owner I appreciate all of your videos.

[@CoolAirVw]

thanks for watching

[@kalleradmark4210]

Tanken you for this. Changed gear today. Took me 3 hours to do this at home without lift. Big difference on my vw t4 . Went from 3300 rpm at 70 mph to 2700. Sick! Gonna save alot on the highway!

[@CoolAirVw]

Hey, let us know about how much you save.

[@justinmiller1191]

Which ratio did you go with?

[@BASSBOYDecepticon]

3300rpm at 70? Mines like 2900 at 70.

[@barrybrockp8358]

Thanks a million mate, great tutorial, did my t4 today, my puller would have needed major grinding to fit, love your trick with air hammer, came off nice n easy, watched your vid a couple of times then did it 👍

[@CoolAirVw]

Isn't it great when a plan comes together?

[@barrybrockp8358]

Too right, thanks mate

[@daddyg5654]

Just put my new 5th gear in this weekend. Using your "hammer" technique, everything came out with out a fight. Now at 100 km/hr I'm showing around 1800 rpm...which freaks me out because it would normally run around 2100 rpm. I do a lot of highway miles so I'm going to even save more on fuel....hehehe...I love diesel. Thanks again!

[@bobbydhal2199]

Lower rpm is better . How was your engine behaving at 1800 Rpm ? Did it seem like it lugging the engine ? About how much millage could it go on a full tank . 1300km ? maybe 1400

[@CoolAirVw]

did you gain some mpgs?

[@daddyg5654]

@@bobbydhal2199 I can only use 5th gear when I'm going at least 100km/h (60ish) But that's ok because all the secondary roads are no faster than 80km/h so 4th gets used quite a bit. The rpms are just too low to shift into 5th at 80km/h. Because of this conservative driving I get just over 1100 kms per tank. I haven;t taken it to empty because that would be silly :)

[@daddyg5654]

@@CoolAirVw Yes I did. When I bought the car 20 years ago I was getting 900 to 1000 kms per tank. Now I can easily hit 1100 per tank because of the lower rpm in 5th and the conservative driving in 4th. Not bad for this old car eh? On the Hwy I drive at 130km/h and only show 2400 rpm. It's not a massive increase but the car doesn't work as hard as it use to on the hwy which should extend the life of the engine I hope....

[@alessdiazlopez54]

Which gear do you have? 0.622?

[@multiomer1997]

dear mister. First thank you for the information screen. almost never saw a repair vid when the gearbox is in the car, most remove it. for better access. Now i have the same grinding noise from behind the plate of the fifth gear. when i press the clutch in it goes away. I work now like 3/4 year as a mechanic. in the engine side, but never on the transmission side. so this also very hard for me. cheers!

[@piro9384]

For pressing the hub and output gear on the shaft, I find it easier to just use the torx bolts without the washer to start them instead of beating them to death. Then you don't have to worry about the dogs and stuff falling out.

[@CoolAirVw]

thanks for the tip.

[@barrybrockp8358]

I got a nice big socket with rubber over it and extension, held it with thumb n index finger while holding gear and brass jobby in place with middle finger, nice n slow, went in just fine, hope that helps someone

[@farginicehole513]

@CoolAirVW Where are you located? I have a lightly used Wavetrac LSD I would like installed in my 5-sp 2000 ALH Golf. Also interested in a taller 5th gear "while we're in there." I'm in southwest MI, and haven't been able to find anyone yet to work on manual transmissions.

[@tonygarvey8148]

Great video.i used a longer bolt with washers to pull new gears on .save the fingers and no need for hammer.

[@CoolAirVw]

Excellent.

[@tonydalton6756]

To stop the shafts rotating you can pop it in reverse using the stick shift & 5th at the same time by pushing the synchro unit with your hands.

[@CoolAirVw]

good tip. Thanks

[@armindogomes47]

In the middle of a tear down all the good stuff go go along with the wavetrac lsd. I did notice that you don’t need to take that third bolt out of the linkage, just slide the fork to the left and come out no issues. I also noticed that the two fingers have wear on it due to being a CCM 02A from 96. Wear can you source those fingers, if not I’ll migg a bead on to them reshape, then polish both the inside of the gear selector and mating surface

[@davidparker9676]

I don't recommend welding any wear surfaces. The parts are heat treated and will get softer if you weld on it. Buy a new part or reuse the worn part. You will cause more damage welding and grinding it.

[@CoolAirVw]

You would be better off brazing them than welding, as brass would be soft riding on the slider. I would replace them though.

[@RobDownes-zy8qf]

Thanks for getting back to me great video I made a school boy error I didn’t put the roller bearing back in All is fine now 🤣 Thanks for your help 👍

[@CoolAirVw]

good job

[@EXOVCDS]

Good video... but are those 200 rpm really worth it? I was actually expecting a bigger drop. We don't tear transmissions down, so I don't have any idea if that's a normal amount or if there are gears that can drop more rom.

[@JohnnyK2811]

The difference in fuel economy might be quite a bit different though. I'm going to do this to my V5 golf.

[@CoolAirVw]

Probably isn't enough in MPG to justify the cost of the gears.

[@tonydalton6756]

It can make a huge difference in engine wear & noise plus better MPG mate. Especially in things like the old T4 van 02b box. Even better if the engine is remapped. It means you can use older 02b boxes in the 88bhp van which the original boxes are getting harder to find. I run one from a 2.4 DJZ code.

[@tonydalton6756]

Just realised what you meant lol. he should have gone for a longer gear IMO.

[@roblet5047]

Wouldn't it be down to if engine is powerful enough for longer ratio gears. I have caddy 2.0 sdi very low ratio, but some have tried the 6speed but said wasn't enough power in the engine.

[@vrptstyly]

This way worked out way better for me than applying heat. Definitely worth it if your driving a lot at highways speeds. Doesn't seem to struggle much, down low on Malone stg1.

[@CoolAirVw]

You have to be careful applying heat, especially to the hub and slider as you can melt the plastic 5th gear bearing cage. Also if your doing this on a 06 tdi they have a plastic oil trough that will melt if you apply any heat.

[@bigjules1234567890]

Hey so you have a stage 1 Malone... did you do a .658 gear?

[@bomberman809]

Muchas gracias me ha sido de gan ayuda. Saludos desde Buenos Aires Argentina!

[@CoolAirVw]

I'm glad my video helped.

[@RobDownes-zy8qf]

Hi I followed your video and I have a problem with it jumping out of 5th the gear folk is fine It goes into gear but just pops out I put a 717 gear in the box o2a. Fbk Any help would be appreciated Thanks

[@CoolAirVw]

adjust the "throw" into 5th and hope. . That 's the large torx bolt under the 5th cover. Movement in the shaft due to wear in trans can cause it to pop out and your not gonna fix that without major work or replacement.

[@ianmoberg374]

What would make an 02j transmission have a ticking noise coming from behind the the cover plate for 5th gear? Transmission works how it should from what I was told but have been trying to find videos on possible causes before I tear it open so I know what to look for as I'm ripping it open ty in advance ur vids have helped me.out so much it's insane, I love watching actual mechanics like urself work on stuff, free education baby!

[@CoolAirVw]

take it apart an dlook.

[@multiomer1997]

hey, and did you open it and saw whats inside. cuz i got the same now. Audi car. comming behind the coverplate of the fifth gear!

[@farginicehole513]

@CoolAirVW Where are you located? I have a lightly used Wavetrac LSD I would like installed in my 5-sp 2000 ALH Golf. Also interested in a taller 5th gear "while we're in there." I'm in southwest MI, and haven't been able to find anyone yet to work on manual transmissions.

[@CoolAirVw]

Kansas City area of Missouir.

[@todays_classics3571]

sounds like it needs a head job too .. dammm thank you .. saved my day..

[@CoolAirVw]

Thanks for watching.

[@clairestevens9418]

Anyone have an issue with a terrible rattling/whining sound after the install? Everything went on fine for me. Followed the video to the T. I haven’t gotten it out of first because I don’t wanna break anything.

[@CoolAirVw]

adjustment?

[@rhfd324]

Found chunks in my trans oil during a change....considering doing this when I tear it down.

[@CoolAirVw]

DO IT!

[@largeanucristina3588]

from romania thank s man realy good work

[@CoolAirVw]

Thanks!

[@davidcolin1457]

The 5ft gear of my 03 jetta gasoline with the o2j is not working, im trying to replace the same, so can i change on a gasoline too so i can better lower rpm on freeways?

[@CoolAirVw]

You can change both gears for a ratio change.

[@guayaco-dm3vu]

Good stuff.. now if you film a o1m rebuild.it will even be better.lol Thanks for the video n tips..

[@abbestoltzfus6741]

do you have a part number for the snap ring also where i could possibly get one?

[@CoolAirVw]

the snap rings that hold the dogs? I have the updated version from VW for 6 each plus shipping. Contact me throughemail listed on my website

[@davidparker9676]

I love your videos! I'm planning on doing this on my 98 TDI. Do you know the part numbers of the gears or where to find the part numbers? Thanks again, keep the TDI videos coming!

[@CoolAirVw]

try cascadegerman.com search for 5th

[@andrewlace]

Not sure about the face but I subd enjoyed the video. Very informative.

[@CoolAirVw]

Yeah, I'm not sure about my face either! Thanks for subscribing!

[@andrewlace]

Lol

[@CoolAirVw]

@@andrewlace I appreciate it.

[@j.m.5995]

I think I'm gonna do this on my AAA VR6.. I've found a .622 ratio gearset that's available should drop the RPMs a few more #s

[@gabrieljonas2009]

I have a golf 2.0 gasoline 116cv. How can I stretch the 5th gear

[@CoolAirVw]

I dont understand

[@abrahambeltran6241]

I have a question about my 2003 jetta tdi 5 speed manual and my 5th gear wont engage. If I do a taller 5th upgrade will I need any additional parts? 5th gear may have gone out due to low trans fluid. Thanks for the video. Any advice will help.

[@CoolAirVw]

Probably your supplier will send you everything you need to install the "taller" gear. But if something was damaged due to low fluid you may need additional parts. Take it apart and see.

[@James-co2pl]

Is it possible to put the .658 in a trans from a gas engine, I have a tdi but lost reverse so when I swapped the trans I wasn't aware at the time the Gasser had shorter gears

[@CoolAirVw]

Yes. That may help your issue but the diff gears are different. too. You should look for a tdi trans.

[@James-co2pl]

@@CoolAirVw I sent you an email

[@stevenharpervw]

Great video ❤

[@CoolAirVw]

thanks!

[@BRWfilms]

Hey so I am rebuilding my transmission or trying to. It may not be worth a rebuild tho cause If I remember correctly I had that problem fifth gear was like neutral. So that means my shaft may be messed up Also my current fifth gear was chipped and missing it's retainer ring on the slider when I pulled it off retainer ring was laying in the cover

[@4x4iwheelit]

I'm gonna do this in my mk4 UTE this weekend.

[@UATUNER]

Hello Where can I find taller TDI 5th gear set for my 2003 Audi A4 B6 FWD 1.8T 5 speed ? Looking to cruise @ 80 mph at 2500-2700rpm

[@CoolAirVw]

Its not a simple drop in on your trans like the one in the video. Would probably require complete removal and complete disassembly of the trans, meaning most shops would charge you like a rebuild. I dont know where to buy gears like that but most people would not do such a modifiation due to the expense.

[@UATUNER]

@@CoolAirVw I see I did it few years back on 02 mk4 gti 1.8t swapped TDI 5th gear set. But b5 passat tdi is not similar to the 1.8t b6 a4 fwd?

[@CoolAirVw]

@@UATUNER Your 02 Gti is the 02J trans just like hte one in this video. A B5 passat doesn't have a 5th gear cover to remove to do that. You would have to pull the trans out and mostly disassemble the whole thing.

[@mechanicalmanny494]

I cant f…….g see those massive pythons are in the way😂

[@CoolAirVw]

HULK SMASH! It aint easy being a "highly successful" internet influencer! (sarcasm of course)

[@mistasoulsnatcher7402]

Where are u guy located my Mk4 Jetta TDI just lost 5th please help

[@KenPaisley]

Why not use a harmonic balancer installer to put the gear back on instead of beating on it? Just a suggestion.

[@CoolAirVw]

Okay but what is your harmonic balancer going to pull against?

[@CoolAirVw]

what are the chances your harmonic balancer puller matches the threads inside that shaft. I suppose a guy could make an adapting shaft.

[@tinware]

Which gear should I put in the FZT - VW Touran gearbox? Currently I have 37/50 - 02T 311 158 P and 02T 311 361 N. I would like to have a gear ratio of around 0.62

[@MrDRSNUGGLES007]

Wow man. Nice. I have watched a few videos of this. Yours is by far the best. Thanks. Just a quick question. I have the passat tdi. It's jumping out of 5th. Could you help me with guidance on the repair or to identify the issue? Thanks again. Dario

[@CoolAirVw]

what year?

[@MrDRSNUGGLES007]

@@CoolAirVw good day. Thank you for the reply. It's a 2006. As far as I understand it's the 02J.

[@CoolAirVw]

@@MrDRSNUGGLES007 Are you in usa? Never seen a 06 passat with 02j. 04 and 05 passats defiantly would NOT be 02j.

[@CoolAirVw]

@@MrDRSNUGGLES007 for 02j popping out of 5th there is a 5th gear adjustment. I believe I mentioned it in this video, but if the adustment hasn't been messed with it probably has worn 5th hub and slider or potentially worn bearings allowing movement in the shaft that makes it pop out of gear.

[@CoolAirVw]

@@MrDRSNUGGLES007 If you have 02j you will probably have to pull 5th cover and inspect then pull 5th hub and slider to inspect.

[@alexmontanamc]

So mine broke the clip and is missing some of the dogs. Any chance you know of where I can purchase those? My fifth gear goes in but pops out automatically

[@CoolAirVw]

I probably have those things I can send you. email me through my website.

[@jakabmirgai3388]

Could i run this .658 gear set down to 60 or is that hurting the engine?

[@SheriffofYouTube]

i subbed because i liked your craze face for a sub approach.

[@CoolAirVw]

I'm glad you like my craze face. Watch my mechanics shorts video.

[@jeffersonmoctezuma3733]

So there’s this guy that is selling me a 2006 vw Jetta tdi 1.9 with 317k miles for $2k says 5th pops out of gear and been thinking about it. You think it’s worth it?

[@jeffersonmoctezuma3733]

Has reman engine and turbo what he says.

[@bbstacker70]

Am I to assume that this is only relevant to the diesels, because of the torque? My wife has a 2005 Golf with 02J and gas engine. I suppose this wouldn't be very effective, am i right? Thanks for an interesting video.

[@CoolAirVw]

The ratio that we use on the diesels would be counter productive on a gas engine. But I've heard that folks with gasser cars take the stock 5th gears from the diesel and put them in their cars., but I've never done that.

[@seannaesseannaes]

CoolAirVw Rm yea I have done it many times. It runs great!

[@T.TECH3991]

Hey I have a o6 tdi mark 5 Jetta The gearbox is gone. do you know what years will fit

[@CoolAirVw]

just 2005.5 and 06 with tdi.

[@kalef1234]

bruh you don't have to take the trans out?? How much do you charge for this mod? sub $600 I would definitely do it. always want a 6th gear in my mk4 TDI but a taller 5th gear would be fine

[@CoolAirVw]

No you dont have to take the trans out.

[@Roaggie]

By any chance would you know the bolt size & thread pitch of the 2 gear bolts?

[@barrybrockp8358]

Vw t4 is t60 for gear bolts and m12 for selector

[@Roaggie]

@@barrybrockp8358 thanks! I'm going to make a tool so it'll be quicker/easier to do the job. Whats thw pitch on the M12 bolt?

[@petervanguilder6276]

I thought the .658 was a 600rpm drop

[@Rokynutz]

~13% drop

[@jerrybaustian5256]

The higher the speed, for instance at 85 or 90 mph, the greater the difference in engine RPM between the two gear sets.

[@javierleon2579]

Where's your shop at???...thanks

[@CoolAirVw]

Just south of Kansas City Missouri

[@javierleon2579]

O have The same problem ,but mines is a 2002 beetle 2.0 gasoline, is the parts to change are the same as my car?and if it is what's the name of the parts a need the gears,how or where can I get it?thank you!

[@CoolAirVw]

@@javierleon2579 Sometimes you can get used gears on ebay. new gears are dealer only and expensive. Used transmissions are not that high for your car.

[@javierleon2579]

@@CoolAirVw so my best choice is to replace the whole transmission then??.... thank for the advice

[@CoolAirVw]

@@javierleon2579 that is your choice. But its definatly a good option.

[@mechanicalmanny494]

Should have put the camera on the top and his next video is how to fix an air leak🤌

[@CoolAirVw]

so funny! thanks for commenting

[@vrsickkkk]

What are the RPM differences?

[@CoolAirVw]

I believe I show the rpm difference in the video.

[@onavianva]

Awesome

[@fastinradfordable]

damn bro thats brutal to force that gear on cold

[@CoolAirVw]

Damn bro post a video showing how you do it.

[@Tonil875]

Hi Who is the manufacturer of this gearbox? Regards!

[@CoolAirVw]

vw

[@Tonil875]

@@CoolAirVw I was thinking that ZF was the manufacturer. But OK. Thank you! Regards!

[@CoolAirVw]

@@Tonil875 Not zf, it is Vw.

[@Tonil875]

@@CoolAirVw yeah! I know... Thank you mate!! Regards!

[@johnsonoda9271]

Is this only for the mk4?

[@CoolAirVw]

you can do it on others. 2004 and up tdi a gear ratio change will make cruise not work in that gear.

[@jaggass]

What's the stock 5th gear ratio?

[@CoolAirVw]

thanks for watching. Sorry I don't have that memorized. I would love to impress you by just spouting out the answer, but I just dont have the time to look it up. Honestly though, you can certainly find that info with a little bit of internet research.

[@jaggass]

@@CoolAirVw Found it. When this horrible virus has gone i'm swapping 5th gear on my Toyota Corolla from 0.815 down to 0.725 for better mpg and lower revs.

[@CoolAirVw]

@@jaggass Might want to do some research to see if that is gonna give you better MPG 's or not.

[@jaggass]

@@CoolAirVw With it drop of 0.95 i can't see the MPG increasing but it will certainly be more relaxed at 70mph and even 50mph.

[@CoolAirVw]

@@jaggass ok.

[@coreycrosswhite8890]

That cant be good for the bearing

[@CoolAirVw]

How do you do it?

[@mechanicalmanny494]

Put taller tires 😎

[@davidparker9676]

That affects all gears. Not to mention inaccurate speedo readings.

[@SimonElenor]

That is not a wise way to remove the gear. If you don't have the correct puller don't do the job.

[@CoolAirVw]

Strange, I worked in transmission shop for 23 years. We did tons of manual trans gears just that way, and I'm just now learning that isn't correct. Even as professional transmission rebuilders we didn't have perfect tools for every job, and sometimes had to improvise to get the job done. Buy I think this method isn't improvisation at all. I've rebuilt or repaired 40 or more of Vw 02J transmissions since working at trans shop, and this method worked great every time. I also think DIY'ers appreciate learning alternative ways to do things so they don't have to buy a expensive puller for a one time repair. That's what youtube is for. I think I'll continue doing what I do, because it works.

[@earth7551]

Simon Elenor Do you have video on how to do it properly?? Nope I didn't think so

[@earth7551]

@@CoolAirVw Great video 👍👍

[@CoolAirVw]

@@earth7551 Whenever I receive a comment like the one saying" your not doing it right" or basically any negative comment, I click on their name to look at their channel to see what videos they have posted. Usually NONE or at least none of any value that would help anyone do anything. No auto repair videos, no wood working videos, no cooking videos, no legal help videos, no financial advice videos. But they certainly can "knock down" what others are doing. Several times a month someone tells me, "that is exactly that problem I have and your video helped me fix my car". That feels great! Thank YOU for the positive comment on my video!

[@earth7551]

@@CoolAirVw I know right Quick question Sir I bought a used 5spd transmission for my 2004 Volkswagen Golf gti 1.8t And the mechanic who installed it never put oil in the transmission I can't believe it was working with little oil that was in it but the bad part is now 5th gear is not engaging not working at all So it was all due to the mechanic who never put in fresh oil very frustrating All gears work now 1-4 and reverse Can 5th gear be replaced with a 5th gear like this and does the whole transmission have to come down or it just be replaced like this I really would appreciate it some advice thank you sir It's very difficult to find a mechanic that will do what you do down here in miami Florida And 0.756 ratio 5th gear work on my EHA 02j Awp my transmission