o2A gears into 02J trans

[dieselherb1]

I have some TDI 02A trans. I'd like to swap gear sets into the 02J cases. Anyone familiar with this?

[bbob203]

internally I belive they're identical. all I got.

[theman53]

From what I gathered too internals are the same. The case has different mounting points. You could contact peloquin or somebody like that to see for sure. Or at least if the diffs are the same they would know.

[CRSMP5]

myturbodiesel.com has copies of a 02a and 02j tear down.. in pdf submitted by me too... they cannot "host/discuss" as the one looks like vw scan off so i had to submit them...

in the mk4 section is the thread..

[rodpaslow]

I think if you can do that, you'd want to replace the input shaft bearings with new and set to proper end play, and replace the output shaft roller bearings and preload, along with proper preload for the diff.  Seems like a lot of work. 

I replaced all the bearings in the current 02A I'm running.  All new bearings are about $300 or so, the bearing to set input, output and diff for proper settings would be alot less.  The teardown and swap of the gears is the time-consuming part.

Why not just run the 02A.  I do believe they are interchangeable, as far as 4 cyl MK3 and MK4 are.  The one trans mount, mounts differently on the MK4, but its the same case as the MK3.

[dieselherb1]

02J has a dogbone mount on the bottom. I'm looking into making a mount to weld to the 02A case for the dogbone. maybe cheaper overall.

[rodpaslow]

I imagine you could probably just change the one case, but again there's lots of work to that if you want to do it properly to have a lasting trans...

[andy2]

I'm currently running 02A CTN guts in my MK4 02J can't remember having any issues.

I have also used the 02A VR6 gears in my other 4cyl 02A as well.  

The only issue that I'm having and it not likely related is hard shifting. It is hard to select gears from a standstill or on the move.s.If I double clutch it seems to help.I'm also wondering if my clutch disc is dragging too much and not letting the input shaft slow down enough for shifts.I'm using a soutbend clutch that has an aggressive material on the disc.I have seen this issue before with clutch disc's and hard shifting.


Edit: only thing different is the differential o2a vs o2j.I remember now as I have LSD's and they are different regarding the drive flange.

[bbob203]

I have the same issue with my CTN 1 and 2 aren't as smooth shifting as id like them to be. I have all mk4 shifter stuff installed w/ it and 42dd shifter bushings as well as an audi tt short shifter. Ive tried adjusting the linkages and have it set the best i could get it. It shifts good sometimes but that 1 and 2 gate just isn't what id like 3,4 and 5 are fine but maybe its normal i have nothing to compare to.

[dieselherb1]

I got a complete printout of the disassembly (02J) from Alldata. I may try it soon

[CRSMP5]

now that theman's ol lady popped the one i have to strip will be commin when he can sneek away for some mancave time.. ill get some nice tear down pics/instructions made up..

[dieselherb1]

I don't want to swap gears and not have something set right then not know until done in car and making noise or worst!