02J tranny part pictures was: Re: 350hp with 8vTransmission?02A/02J longevity?

[jdbubb at ix.netcom.com (Dan Bubb)]

Thoughts within.

----- Original Message -----
From: "Ron Pieper" <rapieper@yahoo.com>
To: "Dan Bubb" <jdbubb@ix.netcom.com>; <scirocco-l@scirocco.org>
Sent: Thursday, February 12, 2004 6:41 PM
Subject: Re: 02J tranny part pictures was: Re: 350hp with 8vTransmission? 02A/02J longevity?


> I thought it was interesting, and just to let you know Dan, I *coulda* done that with the pictures
> if I wanted to...(nya nya) because I too am doing my first 02A.  I kinda liked the two-cone
> synchro arrangement, the factory parts look great.  I replaced only the brass rings and left the
> intermediate steel cone alone.

Ron's the tranny meister! I would never pretend to the throne! But, I had the pictures......
The three part synchros are interesting. The parts don't seem to sit down tight on each other like a
one piece synchro does. Wonder if that has anything to do with them being not so effective?
>
> Other parts are beefier, but I hear that 02A's have their own sets of problems and that 020's are
> as strong?  Know anything about this?  Wouldn't think so looking at the parts side by side.

I just know that some people with alot of HP are running the 020's. (and some people with not so
much HP manage to break 020's regularly!) Every part of the 02A/J looks lots stronger so I don't
know. Maybe it's the tooth count thing. There are 02A/Js that have gear ratios with high tooth
counts just like the 020. Or maybe people just think it's normal to drop the clutch in 3rd to see if
they can get scratch!
>
> One thing that bugs me is that on an 020, the small end pinion bearing is always shot.  It's the
> same bearing as one of the rear wheel bearings.  For whatever reason, VW failed to upgrade this
> part - the 02A uses the exact same bearing - and in the tranny I'm doing (supposedly 65K miles)
> you guessed it - it's shot.

Yeah, I noticed this too. The good news is I already have the adjustment shims for this bearing from
working on 020s. The bad news is I need to use them!

>
> Not in love with the flange arrangement either - the flanges on this box have pickup on the shaft
> that fits into the diff.

OH! the 02J (and some 02As) have a really sweet flange arrangement where everything is retained by
an 8mm bolt down the center torqued to a massive 20 ft-lb! No circlips and crap seals!
So, what's the plan for the 02A??
Dan
>
> Ron
>
> --- Dan Bubb <jdbubb@ix.netcom.com> wrote:
> > For those that are curious some interesting 020/02J tranny part comparison pictures. (at least I
> > think they're interesting!)
> > In all cases the bigger parts are the 02J.
> > http://www.funksoulkitty.org/02jtrannybuild/tranny/parts.html
> >
> > Dan
> >
> > > >
> > > >
> > > > > Also, if anybody cares, the 02J (and presumably the 02A) is way stronger. The
> > > > > gear center to center
> > > > > distance is bigger which reduces tooth loading, the gears are all wider, the
> > > > > gear splines are huge
> > > > > compared to the 020, the engagement sleeves are much stronger and best of
> > > > > all, first and second
> > > > > gears have really cool triple cone synchros ;^)
> > > > > Dan
> > > > >
> > > >
> > > > I was told by German Transaxle in OR, that the 2nd gear synchros on the 02A
> > > > and 02J are especially weak...
> > >
> > > Well, the engagement teeth on 2nd gear were a little beat up on this tranny. I assumed it was
> > abuse
> > > since the clutch was also toast.
> > >
> > > >They mentioned that this is the same design
> > > > that Porsches had (I am assuming past tense), and that they are more expensive
> > > > to replace if, and when they wear...
> > >
> > > I'm pretty sure they would cost more simply because there are three pieces and they have more
> > > extensive machining. Interestingly, despite the obvious wear on the engagement teeth, the
> > synchos
> > > still measured just about like new parts.
> > >
> > > > I am curious what your take on this
> > > > design is, as I plan to have an 020 in each of my A1s.  Eventually I hope to
> > > > have about 225-250 hp on one of those, and if you have a different take on it,
> > > > I might do well to ask you...  ;-)
> > >
> > > My personal car is going to get an 020 and I hope to be in the same power range as you, so
> > we'll
> > see
> > > how the 020 can handle that.
> > > The 02J is going to be mated to an AWP, the engine it originally came with, but it will be
> > > interesting to drive it and see what I think about the synchros. There's no question the rest
> > of
> > the
> > > tranny looks a hell of a lot beefier. I hope it's not just appearance.
> > > Dan
> > >
> > >
> > >
> > > _______________________________________________
> > > Scirocco-l mailing list
> > > Scirocco-l@scirocco.org
> > > http://neubayern.net/mailman/listinfo/scirocco-l
> >
> >
> >
> > _______________________________________________
> > Scirocco-l mailing list
> > Scirocco-l@scirocco.org
> > http://neubayern.net/mailman/listinfo/scirocco-l
>
>
> __________________________________
> Do you Yahoo!?
> Yahoo! Finance: Get your refund fast by filing online.
> http://taxes.yahoo.com/filing.html