VW 5 Speed 02J Transmission Problems

What can be done?

Spider Gears/Side Gears-There are 2 styles of gears, cast and standard sintered steel. The cast gears fail at least 5 to 1 compared to the sintered steel gears. So we only install standard sintered steel gears.

Cross Shaft Breaks- There are two diameter cross shafts available, 16 & 18 MM. The 18MM shaft stands up to much more punishment and is the only size we use in all our o2j rebuilds.

Cross Shaft Roll Pin Breaks & Cross Shaft Punctures Case-This is the most common failure for all o2j rebuilds that come into our shop. There is a single 5 MM roll pin retaining the cross shaft. We double roll pin the shaft with an SAE type pin inside the metric pin. Next we grind a small "V" groove between the cross shaft and differential. Then a small root weld is applied. We haven't had a roll pin failure since using these procedures.

Rivet(s) Breaks and Punctures Case-We remove all factory rivets and replace them with a better than OEM bolt kit made by Peloquin.

Most O2j Mrk IV rebuilds come to use because of a differential problem. These are the 4 main issues we see. Each issue usually ends up in catastrophic failure puncturing the case. Spider Gear/Side Gear Failure Cross Shaft Failure Cross Shaft Roll Pin Failure Ring Gear Rivet Failure
What can be done? Spider Gears/Side Gears-There are 2 styles of gears, cast and standard sintered steel. The cast gears fail at least 5 to 1 compared to the sintered steel gears. So we only install standard sintered steel gears. Cross Shaft Breaks- There are two diameter cross shafts available, 16 & 18 MM. The 18MM shaft stands up to much more punishment and is the only size we use in all our o2j rebuilds. Cross Shaft Roll Pin Breaks & Cross Shaft Punctures Case-This is the most common failure for all o2j rebuilds that come into our shop. There is a single 5 MM roll pin retaining the cross shaft. We double roll pin the shaft with an SAE type pin inside the metric pin. Next we grind a small "V" groove between the cross shaft and differential. Then a small root weld is applied. We haven't had a roll pin failure since using these procedures. Rivet(s) Breaks and Punctures Case-We remove all factory rivets and replace them with a better than OEM bolt kit made by Peloquin.		Customer returned VR6 02j 5 Speed Core. The big hole in the case allows the ring and entire pinion gear to be viewed. A simple $1 part sheared and allowed the cross shaft to puncture the case. Cast gears on left, steel on right Cross shaft, broken roll pin, & replacement double roll pins Upgraded O2j Differential Steel Gears 18MM Double Pinned Cross Shaft W/ Weld Ring Gear Bolt Kit
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