getting ready to swap tranny

[CRSMP5]

first... gotta say stop smokin pot...

till tranny removed no way to get to clutch to remove bolts to even inspect it... so once its out you can look at it.. will require a 12 point 9mm socket and a vw clutch alignment DISK as its unlike any other car mfg tool

you said you resealed new tranny.... so you did not do flange seals?? if not you wanna do both.. drivers side way easier out of car vs in car.. rear mount lower subframe makes it harder to do in car..

a long bolt that threads into the shaft that holds the cup, a nut that fits said bolt.. ans a simple piece of angle iron can be used.. drill hole in angle iron, run nut to top of bolt.. stuck thru hole into threaded shaft.. run in a good 10 turns.. then using the nut press cup on.. install clip and remove.. sadly i cannot think of thread pitch/size for bolt.. but i think its 10x1.5 and longer is better.. nut takes up the extra length..

make sure to have the clip on the bolt between angle and flange.. its gap is not big enough to put over the bolt once its all in place..

also best part od doing other flange whe outta car.. you get to test this install with lots of room vs in car with stuff in the way..

[92EcoDiesel Jetta]

I only replaced seals that leaked, flange seals did not leak. I will replace them since I am getting the kits. Once the flange is pushed in to clear the circlip groove, how do you get the circlip into the groove without screwing it up? What tools do you use?

[CRSMP5]

circlip pliers.....

[92EcoDiesel Jetta]

I'll be ordering the flange seal kit from Germanautoparts.com. They can get it to me next day. Are there seal kits ok?

[92EcoDiesel Jetta]

This Germanautoparts seal kit looks like it includes the flange seals and caps but no circlips. Shouldn't the circlips be included since they are not to be re-used?

[R.O.R-2.0]

I would agree MK2 is easier than MK1,  I've done a few MK3 with 020, I find they are easier than MK2 (golf, Don't know about jetta) because they don't have that stamped steel brace that the MK2 has on the tranny mount.  I have an 02a I want to get redone, then we'll see how it fits in MK3...

i take that stamped steel bracket off, throw it as far as i can, and put everything back together.. its not there on the mk3, so it wasnt very important on the mk2s either!

Is that what you did to your mk2? So you only have the front and passenger engine mounts and no tranny mount???

no, the stamped steel piece that connects the 5th gear housing to the trans bracket..

you must use all 3 engine mounts, or else your engine wont be supported in the car.

[92EcoDiesel Jetta]

no, the stamped steel piece that connects the 5th gear housing to the trans bracket..

you must use all 3 engine mounts, or else your engine wont be supported in the car.

W/o that stamped steel piece, the transmission is less rigid as a whole. Wouldn't the torque on that single bolt mounting point stress and break that aluminum bracket on the tranny?

[92EcoDiesel Jetta]

This Germanautoparts seal kit looks like it includes the flange seals and caps but no circlips. Shouldn't the circlips be included since they are not to be re-used?

What threw me off was I was looking for 2 circlips. After enlarging the pic, I see one circlip. They must have left one circlip out when the pic was taken.

[R.O.R-2.0]

no, the stamped steel piece that connects the 5th gear housing to the trans bracket..

you must use all 3 engine mounts, or else your engine wont be supported in the car.

W/o that stamped steel piece, the transmission is less rigid as a whole. Wouldn't the torque on that single bolt mounting point stress and break that aluminum bracket on the tranny?

dude, that stamped steel bracket is made out of POP CANS.. you can FLEX IT BY HAND.. its not very structurally important..

the mk3 never had that piece either, so its not important, in my mind..

[92EcoDiesel Jetta]

no, the stamped steel piece that connects the 5th gear housing to the trans bracket..

you must use all 3 engine mounts, or else your engine wont be supported in the car.

W/o that stamped steel piece, the transmission is less rigid as a whole. Wouldn't the torque on that single bolt mounting point stress and break that aluminum bracket on the tranny?

dude, that stamped steel bracket is made out of POP CANS.. you can FLEX IT BY HAND.. its not very structurally important..

the mk3 never had that piece either, so its not important, in my mind..

Doesn't the MK3 use a different transmission? Any other opinion on this? I'd love to leave that piece out if it is indeed is not necessary.

[R.O.R-2.0]

no, the stamped steel piece that connects the 5th gear housing to the trans bracket..

you must use all 3 engine mounts, or else your engine wont be supported in the car.

W/o that stamped steel piece, the transmission is less rigid as a whole. Wouldn't the torque on that single bolt mounting point stress and break that aluminum bracket on the tranny?

dude, that stamped steel bracket is made out of POP CANS.. you can FLEX IT BY HAND.. its not very structurally important..

the mk3 never had that piece either, so its not important, in my mind..

Doesn't the MK3 use a different transmission? Any other opinion on this? I'd love to leave that piece out if it is indeed is not necessary.

mk3 2.0L 4 cylinder used an 020 style trans still..

VR6 & TDI used the 02A...

[rodpaslow]

R.O.R. is right 02A is used in MK3 tdi & vr6 - just FYI they are hydraulic not cable operated clutch and cable shift, not linkage like MK1 & 2.  Mk3 020 is same tranny as MK2.

[Jvan_wert]

there is only 1 sweet spot it comes off.... and it is a twist, slide main off clutch same time, then tilt nose cone of tranny towards say drivers seat too.... the issue is the flange clearing the flywheel... back in 75-77ish they had a cut out on the flywheel to clear the flange.. then eliminated that...

i too bench press method.. i see no way with 2 wenches with flange on it... you have to hit the sweet spot just right.. its a "feel" thing..

old tranny = who cares if you pull the flange... aka one your taking out... problem is you reinsalled the flange on new one too quick after doing its seals... you did put in new drive flange seals i hope... if not.. do them... your asking for problems if not..

Two wenches? Man if I had two wenches helping me with my car I'd never get anything done.

[92EcoDiesel Jetta]

I have a few hundred miles on the ACN now and everything seems fine except 5th pops out of gear occasionally. I think it needs an adjustment of the shift linkages since it does not feel quite right.

I love how the ACN drives! I really don't feel any reduction in power with the taller gearing but I do notice the lower RPM.

Here's a video of the tach/speedo with the ACN.

http://www.youtube.com/watch?v=XIrQNiyF2SM&feature=plcp

Thanks for all the tips on the tranny swap. It was a long and difficult ordeal since it was my first time doing this job and I did not have any of the special tools, some of which I had to make. Special thanks to Brian of brokevw (not sure if you read this forum) who answered my many questions on the ACN prep (bought from a junkyard) before I felt confident installing it.

My flange tool I fabricated made installing the flange and circlip with tranny in car a snap. I made a circlip install attachment to the flange tool where cir-clip pliers is not needed and it literally was tapped and snaps into the groove.

[R.O.R-2.0]

I have a few hundred miles on the ACN now and everything seems fine except 5th pops out of gear occasionally. I think it needs an adjustment of the shift linkages since it does not feel quite right.

I love how the ACN drives! I really don't feel any reduction in power with the taller gearing but I do notice the lower RPM.

Here's a video of the tach/speedo with the ACN.

http://www.youtube.com/watch?v=XIrQNiyF2SM&feature=plcp

Thanks for all the tips on the tranny swap. It was a long and difficult ordeal since it was my first time doing this job and I did not have any of the special tools, some of which I had to make. Special thanks to Brian of brokevw (not sure if you read this forum) who answered my many questions on the ACN prep (bought from a junkyard) before I felt confident installing it.

My flange tool I fabricated made installing the flange and circlip with tranny in car a snap. I made a circlip install attachment to the flange tool where cir-clip pliers is not needed and it literally was tapped and snaps into the groove.

usually when 5th pops out, its because there is a problem with 5th gear, not the linkage..