CaiosG60 PWR

I forgot to mention while I was waiting for the crown wheels bolts from pelequin I got bored and polished my gearbox casing. (sad I know :lol: ) I didnt do an amazing job of it but its pritty shiney. I'll post some pictures in a bit when I find my data cable.

No worries benji! If I break my engine, the bottom end could be used by you to go 16vG60. Well I think it can be done that way! Anyway, I stripped my charger this morning and found that the scroll was knackered. The outside edge with the seat for the apex seal had a massive chunk out of it and loads of cracks. Its definetly hit the casing when the chargers got out of sink. But it looks like the damage has been building there for a while. When Steve and Darren rebuilt my charger last they did point out some repair work on the edge of my scroll as a weak point of my charger. The few chargers that I've seen open have shown wear on the scrolls where the apex seals sit. I think that seat gets thin over the years. :-( There was grease/oil present in some of the cracks on the scroll which makes me think they where there before its went. Its likley that a peice broke off and jammed somewhere causeing the belt to loose some teeth and the hole thing go out of sink. Resulting in the loverly picture on the previous page. I've got some pictures of the damage on the scroll I'll try get them off my phone and put them up. Right I'm off to Las Vegas tonight for a week, so I'm gonna forget about chargers and dubs untill I get back!!! Hopefully I'll hit the jackpot and can build the dub of my dreams when I get back! See-ya :lol: :lol:

Well, I wacked them in with a hammer before puting the nuts on them. ;-) :-) (probably not the best way but it worked) The spline on them drives into the diff and then stops them turning while you tighten the nuts. Very tought botls to score the diff like they do!

Update! Its all sorted!! The problem I'm describing above is only relevant on very early 02a boxes. The diff bolt size was increased 8 months into 02a production. So on most 02a and 02j the diff bolts holes are the same. (same part number for replacements I think) I ended up geting some special bolts from Gary Pelquin in the US. Didnt have to drill the crown wheel or anything (o2a moddified he called them). I would recomend geting you diff/crown wheel bolts from him, VAG ones are £109 and Quaife ones £111!!! Gary chargers $30 to $44 depending on which ones. Mine arived in just two day all the way from the US aswell. Cost $90 including 2 day air shipping. Not bad. ALmost went back togther without any hassle except the bolt that holds in the reverse shifter snapped while I was tourqeing it up. Took me about an hour with a drill and little screw driver to persuade the broken bit to come out with out knackering the thread!! aaargh Well happy with the gear ratios I chose! There spot on! (just wish my charger hadnt broken so I could enjoy it some more) FIN :D

Yeah, I was doing about 45 to 55mph in some road works when I turned the music down to hear what sounded like a blown boost pipe. I was even still geting some boost as the boost return was hissing. I know Kev, I spent a couple of 12 hr days rebuilding my gearbox only for this to happen. What ever I end up doing the gearbox is a keeper. I'd probably keep it even if I sold the car. Lot of work and worth quite a bit. ;-) Never know kev, VR6 engines are quite cheep now, could put one of them in instead. :lol: aarggh! Chargers are still expensive! It looks like £400 or so then maybe a rebuild on top of that. Bugger!! Thats quite a bit to spend on something that could just blow up a couple of months later. :-( My mates got some intact outercaseings, so at the moment if I can find one I only want a scroll.

cheers for replys and encouragment! If I do go the 20v route it wont be untill Ive finish the camper van I've currently got in about 100 pieces all over the shed!

Nice one Ben!!

My chargers gone on the way back from tatton park! :cry: :x Typical charger damage, (see pic) cant really tell if the little belt lost some teeth or a bearing sezied. The belt has half its teeth missing and a bearing in the little shaft (syncronising shaft??) feels a bit notchy with one particularly bad click. :-( :-( :-( Whats the going rate for a charger thses days? I'm not prepared to spend much. If it costs to much I'll go for a hole 20v engine and break my g60 engine. :cry: :cry: :roll:

Nice one Ben, I'll come around for a spin on your RC. I've tried the gears back in the case today and it seams good. They line up well and with the case on it looks like there spot on. I've also got the final drive gear off my old diff. Had a local machine shop drill the studs out, cost me a tenner. The problem I've got now is that the holes on the o2j diff are much bigger than that on the final drive gear. So either there are some suitable bolts or I get the final drive and diff drilled to take an m12 bolt. (would have to drill the diff too as the holes are 11.5mm, so would need to be drilled to fit 12mm bolt) I think I'll give vince at stealth a ring to see if he can sell me some suitable bolts.

Really! I had trouble getting that many wheels and tyres in my golf.

Got any more pics for us to oggle ben? (this page didnt want to load for me , anyone else having touble?)

If a little cheeky! :-P I had a copy but I lent it to someone. Then reinstalled windows so have lost it!! grrr grrrr Need to get it back!

While someones got etka open could then take a screen shot of the lower flywheel cover plate for a CZM 02j gearbox. I need to see what one looks like before ordering. Thanks

Reverse is a little shaft on its own. I think it matched with 1st or 1st and 2nd on the input shaft. I've got a box in pieces so I'll check it out for you tomorrow.

EDIT* Think I'll have a gearbox specialist take a look at that fifth. Its a bit border line I reckon. I really want to use a fifth like that and I hate to think what a new one from VW would cost. If I use it and it fecks up it wont break anything else because of its possition in the case. I could also probably replace it without removeing the gearbox from the car. aaahh, I'll probably just risk it! :lol: That was my intention with this build, first and second quite long for good traction. Then I used the shortest third and fourth to make the most of the traction and give good mid range acceleration. Finally a long fith for fuel ecconemy and less motorway cruising RPM for charger health. When I worked out the ratios of the gears from counting there teeth, they all matched the info I'd found on the internet. Here's the final pictures taken today! Need to get the diff bolts drilled tomorrow at a local machine works. Then reassmeble in the case and check it all with a dial gauge. :-P

What a day I've had! I've stripped both output shafts and both input shafts. Had a bit of a nightmare because I got all the third and fourth gears mixed up. :lol: :lol: Had to get the calculator out and work out what gears matched with what and gave the correct ratios. Eventually worked it out though!! :D I've rebuilt an output shaft and input shaft with the gear ratios I wanted. I hadnt realised at first that to change the third to a G60 one I'd need to change the input shaft as well as output shaft. Dont know if it was really worth it as I've only changed from a 1.31 third to a 1.34. A little shorter! :wink: I needed to strip the hole output shaft anyway to get half of the final drive and the input shaft was easy compared to the output shaft. I've got some pictures below, a kind of mini how too. Unfortuanatly after mixing up the gears a bit I had to concentrate and stoped taking pictures. So the assembly isnt pictured sorry. Pictures arnt that good as there with a phone.

Here's some of the places I've seen gearbox ratios; http://www.techtonicstuning.com/TransRatios.html (american codes??) Rallye http://www.dubforce.net/forums/index.php?showtopic=2385 There more on dubforce somewhere but I cant find them now. If VR second was 2.12 you wouldnt be able to do 60 in second with the 3.68 final drive you have. Think with a 1.94 it means you can do 60 to 65 mph. Depending on wheels and rev limit. Check it out on you way home tonight? I may have to use the 0.84 5th as my 0.74 fith has some wear showing on it (shown in first pic on this page). Dont know if its to warn to risk using again or not??

that looks sweet mate. Nice colour and I like those wheels too. :-) :-) EDIT* Just noticed the rear lights. Are they sprayed like that? If not can you tell what make they are? Know someone whos after a set like that.

Nice one Ben. I'll be up a grahams tomorrow, you working? Bring your RC car up! Yeah its feels a bit wrong not to fit an LSD while I've got the gearbox stripped. I've got no credit cards to max out though. I'll just have to strip it again some time when I've got more money. Need a new interior, coilovers and wheels first! This pic remind you of anything! I'm starting to get the hang of taking gearboxes off! :cry: :cry:

Just watched the vid from donny of your mates 1.8t. Nice tt dash, and 6 gears? Got any pics of it from the outside? You can see the roll on yours. :lol: Looks like still holding the road well though. The drive your getting out the corners is leaving him standing!! 8) :lol: Cant quite make out what he's saying.

If it doesnt start misbehaving as it hits a certain temperature and its problems seem more related to distance. Then could if be there's something wrong with your fuel pump and its playing up when its been operating for a long period of time. Or possibly your lamba is being effected by exhaust heat and failing when it gets really hot. Welcome to the forum and goodluck! Sounds like you know your stuff!

I dont know if anyones reading this but I may as well finish the thread off now its gone this far. I've learnt loads in this thread so it should be pritty good when people are searching the forum for gearbox info. I've now got the 02j box off my car and striped down. I can see plainly that I need the cog at the very bottom of the output shaft (arrow in pic) to match up with the ring pinion (final drive). Unfortuantly this cog/gear is part of the output shaft so means striping and rebuilding the hole thing. You can see the difference in size of the output shaft bottom cog on the picture below. The final drive around the diff isnt that different in size, although I havent measured it precisely. Another thing I've noticed is that although the two diffs are slightly different (flanges bolt into 02j and it has more teeth inside the diff) the 02J diff is still labeled as 02A. odd? So tomorrow I'm going to see a mate who has a hydraulic press and strip and rebuild the output shaft. Wish me luck! I think I'm gonna need it! :lol: :lol: I'm thinking the following gear ratios, 1st. 3.30 (same as vr) 2nd. 1.94 (same as vr) 3rd = 1.34 (same as G60) 4th = 1.03 (same as vr) 5th = 0.76 (Golf G60) with 3.67 final drive (Golf G60), 02j diff, 02j shift mech and 02A case. EDIT* Which means at 6500 rpm; 1st = 36.23mph, 2nd = 61.62mph, 3rd = 89.22mph, 4th = 116.07mph, and 5th = 157.3mph (according to http://fatboyraceworks.com/gears Gear Ratio Calculator) The gap in ratios between 4th and 5th may feel a bit weird but 5ths only for saving petrol on the motorway! ;-)

Here you go, just found this; http://www.techtonicstuning.com/TransRatios.html

These are American vr ratios, 1st = 3.30 2nd = 1.94 3rd = 1.31 4th = 1.03 5th = 0.84 Final Drive = 3.68 Think the uk vr has a 3.4 final drive but same gears. Kev, I think that site's wrong. Look it lists 1st 3.78, 2nd 2.12 which are G60 ratios I think.

I reckon thats pritty good.