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Old 21-04-18, 14:19
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T4 Post Icon Stripping and rebuilding an O2G gearbox

If its ok with admins, can I do a bit of a how to thread on the VW t4 02g gearbox?

Mainly because Ive been searching for info for mnths and there isnt a lot out there. Hopefully it might help some others to understand them a bit.

Theres plenty of info out there on the 02b gearbox on youtube but the 02g seems to be overlooked.

If anybody wants to add to the content or correct any mistakes please feel free.

So, in my quest and from personal knowledge I have established the following.

The VW t4 came with one of two gearboxes.
The 02b -Used in the 1.9, 2.4 and 88hp 2.5tdi.
The 02g - Used in the 102hp and 150hp 2.5tdi.

The 02b is rated up to 250nm and the 02g up to 350nm.

Both gearboxes are similar 5 speeds.
The easiest way to spot the difference is the 02b has a removeable plate/cover on the end of the box which will expose the 5th gear when removed.
The 02g does not. Its a solid case.

So here is the 02g box I'm going to strip down



Its filthy but not oily.
It came from a Caravelle with about 160k on it. I cant feel any play in the input shaft but I want to strip it anyway and change the bearings.

I'll take loads of pics and detail how I do it.
I'm not a gearbox expert by any means and this is the first Ive stripped.
I have done so much research that I'm not afraid of it anymore.
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  #2  
Old 21-04-18, 14:20
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dub warrior3 dub warrior3 is offline
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Default Re: Stripping and rebuilding an O2G gearbox

First of all remove drive shafts.
The driverside has a small output stub and an intermediate shaft.
This was removed with a small plate and slide hammer-



Leaving this

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Old 21-04-18, 14:21
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Default Re: Stripping and rebuilding an O2G gearbox

Passenger side driveshaft hub is pretty easy to remove.
Its pushed into splines and has a spring clip half near the end.





The easiest way to remove this (as I read on the net) is to wind in 2 or 3 m10 bolts into the holes. They will push on the outside of the case and draw the shaft out.
Bolts need to be over 80mm long and all thread. I used 3 bolts to even it out a bit. Took a bit of force on the bolts but it worked slowly.
It might be possible to do this with a slide hammer but, after the struggle with the bolts, I'm not sure a slide hammer would be easy. It would certainly give the differential bearings a pounding to. Not too much of a problem as they will be changed.
Just waiting on a bearing splitter then I'll remove the other stub shaft and get on with spliting the case
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Old 21-04-18, 14:22
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Default Re: Stripping and rebuilding an O2G gearbox

For anybody else thinking of taking their 02g box apart, this link has proved to be invaluable so far -


http://www.realoem.me/Volkswagen/RDW/TR/2001/230/R

Its a link to an online version of the VW parts system. I find it easier to understand how things work when I'm looking at exploded parts diagrams. It shows every item in the gearbox and lists part numbers for anything that you need to replace.

These links are useful to anybody not sure how a syncromesh gear system works.

https://youtu.be/N5Tn106J-cI

https://youtu.be/wCu9W9xNwtI

Until I watched these, I never realised that all the cogs in a box are permanently engaged with another cog, just not locked to the shafts
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Old 21-04-18, 14:25
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Default Re: Stripping and rebuilding an O2G gearbox

More progress while I'm waiting for a bearing splitter.

The speedo sender screws into the case just above the driverside stub shaft like so-

The switch part can be unscrewed by hand.

On top of the earlier 02G boxes is a cable operated lock for reverse gear. It looks like this



The casing splits to reveal this



Which then just pulls off. Sadly, the guy who removed my gearbox cut through the reverse selector cable rather thsn remove it. They are no longer available from VW so I'll have to get another made up or find a way to delete it. Its just to stop you accidentally going from 5th to reverse.

So here is the selector unit


3 bolts, a bit of a tap and a struggle and it came out. The gear selector must be in the neutral position to remove it.

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Old 21-04-18, 14:26
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Default Re: Stripping and rebuilding an O2G gearbox

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Old 21-04-18, 14:31
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Default Re: Stripping and rebuilding an O2G gearbox

Still waiting on buying a bearing splitter to pull out that other stub shaft. I cant see any other way of doing it. It is a small smooth shaft about 4 inches long and the only thing to get any grip on, is a small O ring groove near the end. I dont want to chew it ip with a pair of mole grips
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Old 21-04-18, 14:43
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Default Re: Stripping and rebuilding an O2G gearbox

Just as another disclaimer, Im not a pro, but these gearboxes arent the pandoras box that a lot of people think they are.
They use the same syncro-mesh system as most other manual boxes and, from my reading of the VW parts diagrams, seem to be a lot simpler than the 02b boxes with a lot fewer moving parts.
I'm stripping it because I want to look inside and see how it works.
I will change the bearings and seal.
In all likelieness, I may end up paying a pro to put it back together as setting the pre-load with shims and a dti seems a pain in the butt.
But, at least I'll have saved him/her the job of stripping it ( assuming I dont break anything).

So two more facts for today.
1) - The 02g gearbox weighs a bloody tonne and I'm trying to lift it as few times as possible.
2) - The smell of transmission fluid is on a parr with cat/dog s**t for me. I truly hate it. I made the mistake of spilling a Subarus gearbox fluid on me once and was having chest problems for days.

Sadly, the guy that removed this box never drained it first. I think, before I drain it, Im going to put a litre or so of white spirits or similar in the box to thin the transmission fluid down a bit and help it drain a bit easier. Everything will be cleaned once stripped.
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  #9  
Old 21-04-18, 15:06
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Default Re: Stripping and rebuilding an O2G gearbox

Nice work. Keep the up dates coming.
I like the smell of transmission oil. But for the seller not to drain the oil before palleting it is a bit off. IMO

You don't have to grow up. You just need a bigger bike.
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Old 21-04-18, 17:19
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Default Re: Stripping and rebuilding an O2G gearbox

The shifter tower/mechanism cleaned up quite nicely so far. Looks like a piece of machined billet. Too nice to refit😂 -






In "resting" position, you can the shifter is in neutral with peg (at the bottom) in between 3rd and 4th gear. Pushing the stack down engages 1st and 2nd and its lifted for 5th and reverse.
The small protruding peg only has to move about 10mm to engage the next set of gears. Quite simple really
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