They’re very expensive to replace with new, and it’s very likely not necessary. If they look good (no chips, no visible scratches or scoring, no heat discoloration), they probably are good. The final tally for bearings, 14 (for one transmission). There are 5 of them, one under each gear. So, it was back to parts hunting because the rebuild kit didn't have any of these needle bearings. Maybe bearings that visibly look good actually are good, but this first transmission has 320,000 miles and the second has 420,000, so I made the call to just replace all these needle bearings. But, some may look good, like the needle bearings underneath the gears on the output shaft of my first transmission. Some things may be visibly damaged or worn, so that's easy. The decision on what to replace is yours. I’ll talk more about some individual parts later. Then, I bought 2 of everything expecting I'd need them again for my second transmission. So, I've had to go parts hunting several times as I got into this first transmission and found more parts that I decided to replace that weren't part of the first "rebuild kit" that I bought. I naively thought that a "rebuild kit" would have everything I would need. This was especially the area where I wish I had more information as I got started. I had to trim one of the hooks down a bit with a cutoff wheel to give clearance to get under the gear, but it worked great once in place. What worked for me was the middle-sized 2-jaw puller from a 3 puller set from Harbor Freight. The hub was on there good, so I did resort to a gear puller. While I was able to use pry tools to remove the 5th gear and hub from the output shaft on transmission #1 following the Andrew Lewis video, I was not able to do this on #2. Metal supply shops usually have an area of cut-offs and remnants, and you may be able to find small pieces of tubing in the right sizes for cheap. Not everyone has a scrap metal pile, so it could be challenging to find things to use as drift tools for this job. In the background of image 4440 in the previous post, you'll see a couple pieces of tubing that came in handy. The scrap pile was solid gold for this project as I found tubing of the perfect sizes that I could use. I've done a number of metal fabrication projects, so I've got a small pile of scrap metal that I've saved over the years. From the later post: One thing worth mentioning is you'll need to improvise for the various factory drift tools that you don't have for pressing the gears, sliders, and bearings onto the output shaft. Rebuilding the transmission becomes very difficult without items to use as drift tools. I wrote this section in the post on output shaft assembly, but drift tools for pressing on the bearings and gears are really important and should be mentioned up front. Various diameters and lengths of tubing for drift tools. Less detailed than the Bentley but a quicker read to get the gist of things. Worth it.Ī rebuild document that I downloaded from the below link. Note this is for the 02A transmission, which is very, very similar to the 02J internally. 218 pages on the manual transmission alone. I have consulted a number of documents, web pages, and youtube videos.ī4 Passat Bentley manual. My intention is to provide some up-front information and fill in the blanks on certain parts of the rebuild showing methods that worked for me.įirst, Resources. I won’t guarantee that this is comprehensive as there may be other issues other people may face with their transmissions that I didn’t. So, I’m going to start a thread documenting most of my rebuild that, hopefully, will give folks a single place to find all or nearly all the information needed to rebuild an 02J. Now, partway through, I’m finding there’s a number of things I wish I had known from the beginning from parts and tools that I would need to techniques for accomplishing specific tasks without special VW tools. I started a few weeks ago, and I thought I might document things from the beginning, but then I thought, nah, there’s enough out there already that it probably wouldn’t be helpful. This is my first time inside a manual transmission. I’m in the middle of my first of two back-to-back 02J rebuilds.
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