CaiosG60 PWR

£50! Thats a good price! dazzyvr6, that cant be from john roberts? :lol: (vw, bosch garage near wrexham) 64 split, brake lines can be a problem. Some times when replacing the rubber ones. The metal pipes that they attach too can snap because of corosion. If this happens you then need to replace the metal pipe work aswell. Which can be time consuming and a bit expensive. It doesnt always happen and if it doesnt its a pretty straight forward job.

You dont need to drop the rear sub frame. Once everythings all undone lift if from the under the diff (from the back so your tilting it forward) and waggle it about. Its should drop out like this although it involves a lot of swearing and knuckle scraping! :lol: :lol: Its not easy but it will go! If you still have trouble, remove the right hand side drive shaft with both the CV joints still attached. Gives you more room to play with.

Good read! At least you had fun in it for most of the day!

I've got the diff and final drive out of my old box now. Found a few teeth missing from reverse and the input shaft which explains the problems I had with it. The broken teeth had made there way to the little magnet inside the box that collects any metal fileings. If you look closely at the picture you should also be able to see the wear on my 5th gear. I did make it worse with the puller but it was definetly there before I used the puller. I've put most of it back togther as well. Minus the diff, flanges and fith gear. Just to check I could get all the gear selector bits working correctly again. It all works okay selecting gears. :) Need to press the final drive off the diff with the help of somebodys press. Then start striping the 02j! :wink: Is the final drive definitely only the cog attached to the diff? Will I not also need the cog on the output shaft that works with the big cog thats attached to the diff? (if that makes any sense!) :lol: Also, the diff has a bolt missing. I didnt find one in the caseing so it looks like it always had one missing. Is that normal?

Cheers Kev, just trying to sort a suitable puller now and hopefully I'll finally start making some progress!

Cheers for puting that more tecnical explanation up Kev. I was only speaking from my own personal experience with the two boxes. ;-) You mention that the 02j has "diff preload springs". Does that mean I dont have to preload the diff with shims when rebuilding my 02j box? (like shown in the linked G60renshaws gearbox rebuild thread)

Think the problem with the 6 speed is clearance. Its to long or bulky to clear the chasis rail I think. The rest of the tools I need to start on my gearbox have arrived today. Cant wait to get home and start taking it apart!! :lol:

The problem I have is because I was sold a 20v non-turbo box by mistake. So the final drive is 4.25, but the gear ratios are the same as a VR6. Just make sure you check the gearbox code not just the 02j bit. Think mine is a CZM or something. One from any turbo 20v should be okay but check its ratios on google before you buy. The diff in the 02j is a lot better than the one in the 02A. Apparently they’ve reverted back to a similar design to that used in the earlier 020’s. I get better traction even though the gears are shorter. I also think the torque steer is improved. You should be able to get an 02J box for £150 to £220. I'd give it a try on the car before you spend £500 on an LSD and then £300 fitting. 216bhp is very similar power to what I have and the 02j diff performs very well. Perhaps in the future if more engine mods are done and the powers raised I’ll change my mind. Also I think the benefit of an LSD is felt quite a bit in cornering, I’m only talking about wheel spin during acceleration with the improved 02J diff.

Sweet!! :-)

Hi, if you want me to check anything or measure it on my car PM me.

I'm just interested; a friend and I have just fitted a lyshom to his car. So we have been reading quite a bit about boost return, etc. Had to choose whether to use a recirculating dump valve (like BBM do with there silencing kits) or the standard G60 setup. So g60dave your G60 throttle body has the boost return sealed up in some way? Do you know how this has been done? Welded closed or modified the linkage so it no longer operates? Also, what boost are you running?

Henny, don’t you get recirculating dump valves for turbo’s?

Welcome! What’s the deal with your boost return? Is it venting to air or recirculated into the intake pipe?

Chris, they've got a massive range of tools too. I stand corrected on Jawel paints, they couldn’t beat justoffbase.co.uk’s prices. Odd thing is I just phoned justoffbase and they couldn’t take my order because they where just leavening for the afternoon to go wakeboarding. Is that good customer service? :lol: At least they where honest and said even if they did take my order now it wouldn’t get posted until Monday anyway. Looks like striping my gearbox will have to wait until Tuesday!

I've found an 8mb 218 pages Bentley official factory repair manual PDF for the 02A box. It’s too big to post here though. Its go every step illustrated and described! (Attached screen print of its instructions for removing fifth gear) Just need to order a couple of tools today and I’m away! Will a 150mm puller be big enough? Think its maximum size is 173mm.

Did you use that quick air drying hardener? Have you bought a respirator system or did you just use a good two filter mask?

Snap-On and Mac are a bit expensive for me. I usually buy Halfords pro or draper expert. Not had a problem with either so far. I've recently bought a Sealey compressor which is the dogs. So I'm going to order some of there tools to see what there like. I could do with a good quality 1/2” drive ratchet though. I’ll keep an eye out on eBay for a good quality snap-on one I think. I can recommend Jawel paints as they sold me my Sealey compressor for about 1/2 of the recommended retail price. They'll beat any price that you quote them too. Mail order number – 0121 558 6193

billinjahg60, where do you get your snapon and mac tools from, eBay?

The cheapest I can find are Jawel paints (eBay shop) and justoffbase.co.uk. Neither is very convenient to use because there websites are terrible. But there cheaper than anyone else I can find. They sell mainly Sealey and Draper tools which do me fine. Where's the best and cheapest place to buy tools online?

Thanks VEEDUBBED. How do you select 5th and 1st?

I wave at most Mk2, Mk1, Rocco, Rados and some campers. I tend to get a response from most around where I live. I also wave, beep, flash and shout at fit birds...............but never get a response. Its worth a try though, eh? ;-)

You’re not wrong! :lol: I'm gonna be lost tomorrow when the striping downs finished. Fun with rust and scraping the knuckles next!

WICKED!!! Thats just what I need! Cheers Jay

Nice one kvwloon, got any pictures of the progress on yours?

You've done it again Andy! Mint! What sort of paint are you using?