02M 6 speed DIY rebuild help

Leon20vt4

Active Member
Oct 21, 2018
939
683
Hey everyone so the 3rd gear on my 20vt 4wd has gone kaputo... actually i bought the car that way. regardless i think its 3rd gear the symptoms point to 3rd.

Every gear engages just fine except 3rd gear, and whenever you drive the car no matter what gear you are in the transmission makes alot of noise... so obviously im not driving it alot. only to diagnose and to the mechanic shop.

So the question starts with this... what do i do!?! I have a few options. The mechanic is a friend of the family and he will help me and open up shop on saturday to allow me to use the lift and necessary tools.

He gave me the option we can either take out the old broken tranny and swap in a used 02m quattro off of an S3 or TT or something. i would install a new clutch kit from LUK at that point with a new central slave cylinder. Then in my free time i can open and repair the old tranny to sell it and make some money back.

option 2 is to take the tranny out and then I have to open it up and repair it all on my own. then we put it back in. he could help me order all the parts etc but as far as the transmission rebuild is concerned im on my own.

Has anyone here tackled the 02m rebuild? if so are there any tips or tricks of the trade or anything i should do while I have it out anyways? (i wont replace the flywheel unless its necessary) the car has 83k miles.

My worry is if im swapping in another used tranny for lets say 450 euros or so with 40k miles who says that i wont run into another problem rather quickly ... i mean ive heard the 02m tranny is one that often has defects or problems.

on the other hand i just had a baby so time is now not my friend to do a rebuild on my own and i would have to wait maybe another month or 2 to get it done but not so bad.

Any advice on the matter would be great!

Thanks in advance!!!
 

Sparkie

Angling Adict.
Sep 25, 2009
2,541
779
Middlesex
Usually it’s a specialist job.
Most mechanics won’t open them up, just removal.
That tells you loads.
Good luck.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.
 

Leon20vt4

Active Member
Oct 21, 2018
939
683
Usually it’s a specialist job.
Most mechanics won’t open them up, just removal.
That tells you loads.
Good luck.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.

Would most mechanics do an engine rebuild? honing the block new rods pistons etc? because I've done that... okay it was on a 4 cyl iron block e36 bmw... but its not the easiest job in the world.
 

Leon20vt4

Active Member
Oct 21, 2018
939
683
Usually it’s a specialist job.
Most mechanics won’t open them up, just removal.
That tells you loads.
Good luck.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.

I got an estimated quote from a 02m specialist ... if i bring him the tranny out of the car he can repair it for around 500 euros. its a 1 hour drive each way to him but i think its not a bad price. whatya think?
 

Leon20vt4

Active Member
Oct 21, 2018
939
683
I would also like to know how to rebuild/repair these boxes.


Sent from my iPhone using Tapatalk

For anyone else interested in how to repair these trannys i have 2 links that have been pretty frikin helpful!!!

They are for the Golf mk4 but we all know its the same part numbers under the hood.

https://workshop-manuals.com/volksw...gearboxes_through_gearbox_date_1853/removing/

https://forums.vwvortex.com/showthread.php?7019564-02M-split-open-how-to-get-gears-out-and-off
 

Sparkie

Angling Adict.
Sep 25, 2009
2,541
779
Middlesex
I got an estimated quote from a 02m specialist ... if i bring him the tranny out of the car he can repair it for around 500 euros. its a 1 hour drive each way to him but i think its not a bad price. whatya think?

I think you should give him a Quaife LSD to fit too.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.
 

Leon20vt4

Active Member
Oct 21, 2018
939
683
I think you should give him a Quaife LSD to fit too.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.

OH SHHIIITTTEEEEE how did an LSD escape my mind ... that would be great to have for the hockenheim and Nürburgring come summertime!
 
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mty12345

Active Member
Jun 17, 2011
3,728
451
bristol
I would pay the guy to do it as well, either that or buy one that's already been reconditioned. You can usually get them on an exchange basis. Like sparkie says, they are so complex it's not worth trying to do it yourself.
 

Leon20vt4

Active Member
Oct 21, 2018
939
683
I'll post an update on my decision when i get there in a week or so. first thing is the tranny for sure needs to come out. Which i will tackle that task on Saturday April 6th.
 

Leon20vt4

Active Member
Oct 21, 2018
939
683
Has anyone here done a write up or anything? I tried searching but no luck. Or are the VW guys the only ones dumb enough to try to DIY this tranny ;)
 

Leon20vt4

Active Member
Oct 21, 2018
939
683
Well my pops visited me over here in germany from the US and him and I got to talking. I will be attempting this DIY as long as i can get some garage space to work with the tranny in my free time.

Tranny comes out in April... stay tuned

I'll be sure to make a thread and post alot of pictures so the next poor ******* can get some help.
 
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