02m broken shift fork

TDI s : Several. Well I'm finally installing MY lsd and figured I'd post up a good how to since there aren't really any out there. I've done tons of 02M lsd installs and this is the first one I've seen like this. Onto the pics; The paitient Remove speed sensor and all bolts you can find. The first clues that this was something different was that the case bolts are aluminum and the black cap that most 02m's don't have.

Next, remove the shift tower by pulling straight out and then put the trans bellhousing side down. Use a very small screwdriver to remove the cap that covers the rear input shaft bearing.

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Notice the snap ring on the outside of the bearing, remove it. If you have an old style 02M, this step doesn't apply to you. On mine, I also had to remove this guy to get the tower out Now, use a rubber mallet to break the adhesive bond between the halves and lift the top of the case off.

All the gears will be stacked nicely looking at you. I pulled the bellhousing side off first because I wanted to make sure I removed the shift tower correctly since I've never done a "new" style 02M before. I couldn't be happier to see how clean this transmission is on the inside. There can't be more than 20K on it tops. Here's all the gears Here's the forks with offending rivets that must be removed.

Notice the cushions on the end of the shift rails, old style 02M's don't have those. Please email or call only for business inquiries. PM's are not for business communication. Last edited by Whitbread; March 2nd, at Here's some interesting bits I noticed on this particular trans: Input shaft is supported by one straight roller bearing and one giant ball bearing. Normally, it's a tapered roller bearing at each end of the shaft on the older 02m's.

Now, I question whether this is a change made to increase strength, or a change because this is somehow cheaper than tapered roller bearings.

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It seems surprising to me that they deemed that the axial thrust loads generated by the helical gears could be handled by straight bearings with no thrust bearings. Another oddity is the shift rail bushings this trans has. In old style 02m's they use little ball bearings in plastic cages. This trans just has bushings.Bad Behavior has blocked access attempts in the last 7 days. Welcome, Guest. Please login or register. Did you miss your activation email? Author Topic: Who has done Gear shift fork repair weld?

Read times. So who has repair welded gearshift forks? Posts: 14, A critical part. There are many like it, but this one is mine…". Of course its kind a gample.

But i grind the forks back to specs and checked all clearences. And everythin looks good to me. Curious to see how well this works, subscribed. Really Old Timer Posts: 12, Northern Virginia. Same here, better to replace it than fix it. Posts: 19, I refuse Quote from: kranta on November 09,am. Posts: 7, Some of the boys racing in Italy have hardwelded then re-ground them straight.

Should be better than new. Quote from: 70CB on November 09,am. Ah so! Now it makes sense. I had this vision of broken fork, brass welded together. Quote from: 70CB on November 10,am. No no no A mystery how the circular wear marks would be there if the forks were not bent and the fork ends were above wear limits. Thats mystery.

02m broken shift fork

And circular marks are both sides of fork. Or is that marking just normal wear because of normal gear change? Because i have checked several times the clearence of the fork to gear.Log in or Sign up Close Panel. What's New? You're currently browsing VWvortex site as a guest.

How to Repair a Bent Shift Fork

Please sign up or sign in and take part in the conversation. Take a minute to sign up to enjoy all the features of VWvortex. Page 1 of 2 1 2 Last Jump to page: Results 1 to 25 of I have done engine swaps and stuff before but never taken apart a transmission. Anything special required to swap the forks?

Sponsored Links Remove Advertisements. Just remember the transmission case is made of soft materials and is easy to strip due to over torquing bolts.

Slide axle cup assembly out. Remove the gear selector rod x 13mm bolts on top of the trans case. There is a plastic bearing with rubber seal in this cap. When reassembling do not force this part on. You will break the bearing. This secures the lower half of the gear selector in place. You need to remove the two short bolts on the outside. The middle bolt should be loosened then tapped with a hammer until the cap pops out of the transmission case. See picture below.

Shift forks are bronze in color in this photo.

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My advice would be to bribe two friends to come over at this point with promise of alcohol and loose women. I've never just tried to pull a shift fork out but I get the feeling you're going to have to lift the gear stack up a little bit.

02m broken shift fork

Wear gloves. I would strongly consider replacing them at this point. Before reassembly clean the surfaces of the case and use your oil resistant sealant of choice. RTV black seemed to work for me.

Last edited by Doooglasss; at AM. Thanks Doug. I will be doing it alone unless my girlfriend is willing to help slide the forks out.Ever been stuck in gear and need to pull apart the tranny?

Chances are your factory shift fork is broken and needs to be replaced. This happens because the stock shift fork is constructed of weak brass, and is riveted together. Don't replace your broken transmission parts with the same junk that is going to break again, upgrade it and resolve the problem.

These steel transmission forks replace the brass failure points, and the problematic riveted assembly is upgraded with a much stronger and more durable welding process. If your fork is still holding on, and your dropping your transmission for a clutch or differential upgrade, it is the perfect time for preventitive maintenance.

By replacing these while the transmission is already out, you will save yourself hundreds of dollars in labor, and countless hours of your own time. Check out the images below to see how these steel forks will hep fortify your transmission.

Available for 1st-2nd gear and also 3rd-4th gear.

02M & 02Q Upgrade Gear Shift Fork Kit BAR-TEK®

We recommend doing them both while you have the opportunity! You can add to your order with the drop-down menu below. Product description. Customer feedback. There have been no reviews.

VW Shifter Adjustment When Tranny Locking Pin is broken--6 Speed

Add your own review. Select Your Vehicle. Read Full Description. Free shipping. Add To Cart. Recommended by the experts!

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Ask a Question. Add to wish list. Full description. Cars This FitsMany have experienced the failure or are scared of that happening. The brass fork failure is by far the most common issue on those transmissions and result in a car being either stuck in gear or unable to select a gear with a sloppy shifter. If yours is already broken or just want to upgrade, this is the solution. Do it once and be done with these upgraded steel forks.

No brass, no rivets, just welded steel. Oem parts therefore quality is not an issue either, these will last longer then the life of your car. Please verify rear case seal, not all transmissions have them, and those that do have 2 different sizes, approx.

If you have the later style with the clip there is a chance your trans may already have the steel forks. Full diameter all the way through and First, a newly machined billet We imagine this wont matter to a racer but just wanted to put it out there. Race Spool for the 02A Gear box.

Ideal for drag, rally, This is a upgraded gear set made of superior materials and tooth design over stock Through countless years of professional racing, APR Motorsport identified the factory shifter cable bracket system as a source of sloppy Sign in Create an account.

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Please also note that the shipping rates for many items we sell are weight-based. The weight of any such item can be found on its detail page.What's new New media New media comments Latest activity. Media New media New comments. What's new. JavaScript is disabled. For a better experience, please enable JavaScript in your browser before proceeding. Latest: Okiewan Today at PM. New Member? Go here first. Yamaha 2-Strokes.

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Latest: Mohawk Warrior. Mar 30, Apollo cc gas in oil Latest: Rich Rohrich Mar 28, Rmz leaking oil out of head bolt Latest: Pete Payne Mar 27, Thread starter Cannon00 Start date Jun 20, Cannon00 Member. Jun 20, Joined Jul 20, Messages 22 Likes 0. Hi, I've got an 05 yz that had tranny troubles. Found out two shift forks were worn so I'm replacing them as a set, but in the manual it says if you replace a shift fork to replace the two gears each adjacent to the shift fork.

What do they mean by this? Do I need to replace all gears contacting a shift fork and all mating gears associated with them?Steel is stronger than brass, and nowhere is that more evident than inside your VW 6-speed manual transmission.

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VW uses shift forks with problematic brass parts. Under enthusiastic use brass forks can — and do — break, and when they fail, your car is likely to be stuck in gear. A broken shift fork see the photos on this page means opening your transmission to replace the broken part.

Why invite a second failure by installing an identical part that falls short of your needs? Instead, install USP steel shift forks. A USP steel fork is available for the 1 st -2 nd and 3 rd -4 th shift in your 6-speed manual transmission.

Perform this transmission upgrade now to fortify your transmission, preventing breakage at the worst possible time. That saves even more time and prevents duplication of some work. Add them to your order before checkout. Product description. Customer feedback. There have been no reviews. Add your own review.

02m broken shift fork

Select Your Vehicle. Read Full Description. Free shipping. Add To Cart. Recommended by the experts! Ask a Question. Add to wish list. Full description. Kit Includes. Cars This Fits Related products. Customers also bought.


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