VW 02S 6 speed swap into 02J case for Mk4

Рет қаралды 14,322

VW Diesel Dork

Күн бұрын

Пікірлер: 28

@BenBelty Жыл бұрын

You can also adjust the cluster eeprom to read from the abs module and run the later 6 speed cables and shifter box.

@dzelpwr Жыл бұрын

I've seen coding available on BEW clusters to do this, but notsomuch on ALHs. I also don't know if it even works. Would an older Mk20 system actually broadcast a VSS on CAN, or is it only Mk60 systems that do it? My 01 doesn't have a Mk60 ABS module for sure...

@MrStevecrasher Жыл бұрын

My main reason for converting from the 02J to 02M was the increased diameter clutch which solved my slip problem but it was a complex job in the PQ34 platform.

@dzelpwr Жыл бұрын

Definitely a lot of different associated parts, at least. And you need to recode the instrument cluster for the different pulses per mile of the 02M VSS. There are some good aftermarket clutches for the 02J/MQ250 family that hold a good bit of torque. South Bend makes some excellent ones.

@EandEDesign Жыл бұрын

Okay this is awesome. Thanks for all of the info! Does the 02S bolt up on a MK4? I wonder if it would be worth making a modified 02S case to make everything work.

@dzelpwr Жыл бұрын

It can bolt up, but it is spaced a few mm further away from the engine due to the bellhousing design. Really would need a different flywheel spaced out further to work on a Mk4. I've detailed the other challenges of using the standard 02S/0A4 case in a mk4. Swapping into a Mk4 02J case really is the best solution, especially for the vehicle speed sensor.

@BRWfilms Жыл бұрын

I really appreciate you making these. Put a place people can donate for the trouble of you making these vids. Cause really I hope you continue making them. I need this. Or a crypto address

@BRWfilms Жыл бұрын

So why couldn't you use the 02s selector forks, you mentioned having to use 0a4 selectors cause of the cut out and all, being able to shift in sixth but how does the 02s selector shaft not work?

@dzelpwr Жыл бұрын

I do have the 02S/0A4 selectors in my final transmission build. The pivot points just don't line up with the 02J back case half. Since this was going into a Mk4 and I didn't need the provisions for the much older style transmission mount bracket, I just ended up using the 0A4/02S case back half to retain the 0A4 fork/rail assembly. If I were building one of these transmissions specifically to go into an older car (mk3/B4 or older) I would have to modify the 5th gear selector rail to be able to go into the 6th gear position and use the 02J shift tower in order to use the 02J (or 02A) rear case half because how different the pivot pins line up that go through the case and into the 1-2 and 3-4 forks.

@dzelpwr Жыл бұрын

I should clarify the second paragraph... I would have to modify the 02A/02J 5th gear selector rail.... Because that assembly has the holes and bearings for the pivot pins in the correct location for the 02A/02J back case half, and again would have to use the 02J shift tower to match as well, not to mention the lower bushing that is part of the casting with the big VW logo on the bottom of the transmission. 0A4/02S shift tower won't fit the openings in the selector rail assembly for 02A/02J. The bottom of the 0A4/02S selector shaft is smaller diameter as well, so you have to be mindful of the difference in the bushing size on that piece of casting with the VW logo that bolts to the bottom of the transmission. Similar stuff, just slightly different enough to not be easily interchanged.

@SarahDay-ze2xb Жыл бұрын

Hi do you think you could do the swop with a 02B box ?

@dzelpwr 11 ай бұрын

I believe you can, yes. Would need to use the 02B bellhousing, but being that the 02B is still effectively an MQ250 family gearbox, it should be doable.

@Leo.G 6 ай бұрын

Is it possible to convert the 02j to 02m? Just swaping the internal parts?

@dzelpwr 5 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.

@Kaos_roshi Жыл бұрын

so this would be say straight swap to a 2010 golf 2.5 with a 5 speed?

@dzelpwr Жыл бұрын

Yes, it would. The 5 cylinders use the same bellhousing bolt pattern as the 4 cylinders. There might be an extra bolt hole in the bellhousing that's not used. Older 4 cylinders don't use that extra hole either, but these newer 0A4/02S transmissions just happen to have an extra bolt hole above the passenger side axle flange. No big deal.

@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.

@steambuns2283 9 ай бұрын

hey man. how much torque can the 02j handle?

@dzelpwr 8 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.

@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.