Group buy / order: 0.65 / 0.643 5th for TDI

djmachin said:
Cheers for the replies. How much did the 0.659 gear "kit" cost then? I think I'll get my local garage to fit them to save Skipton doing it as he seems to have his hands full at the moment ;)

Cheers
Dave
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Well i think the price of vat upped the price a little so you'll be looking around the £160/170 mark plus the oil and gasket and then the labour. I think Mike can still get the kits at dicount, if your not in to much of a rush to get it done see what Mikes diary's like and get it done with him cheaper by a long shot;)

Phil
 
I would also recommend waiting until Mike can do the work. it's not just the finacial savings but all the other little benefits of Mike looking at the car with his A2 knowledge your local spannerman will not have.
 
Hi all

I’ve just bought the 0.659 gears from Dan B in his recent ad. I have read the full 49 pages of this thread (well scanned a lot of it as I lost the will half way through) and I noticed one post from Mike (Skipton) as follows

“there are 2 additional parts needed, which add another £2.50 to the costs!!!

It's the dished washers that secure the 2 cogs and the originals are too big after the swap and would foul in the teeth.

The needle roller bearing that holds the synchro gear. It's necessary to heat up the gear to remove it from the shaft and as the cage from the bearing is made from nylon, this could get damaged.”


Can anyone shed any light on the above two items i.e any part numbers or further information so that I can obtain the parts before attempting to have them fitted.

Many thanks

Steve
 
A2Steve said:
Hi all

I’ve just bought the 0.659 gears from Dan B in his recent ad. I have read the full 49 pages of this thread (well scanned a lot of it as I lost the will half way through) and I noticed one post from Mike (Skipton) as follows

“there are 2 additional parts needed, which add another £2.50 to the costs!!!

It's the dished washers that secure the 2 cogs and the originals are too big after the swap and would foul in the teeth.

The needle roller bearing that holds the synchro gear. It's necessary to heat up the gear to remove it from the shaft and as the cage from the bearing is made from nylon, this could get damaged.”


Can anyone shed any light on the above two items i.e any part numbers or further information so that I can obtain the parts before attempting to have them fitted.

Many thanks

Steve
Click to expand...

Even an indication of where the part is fitted would be really helpful so I could perhaps discuss it with a parts guy at a VW commercial dealership.
 
Hopefully Mike will be along soon to advise. Although I watched the process it is too long ago for me to remember the details. Two issues I do recall: make sure your gear puller is heavy duty and if possible have access to a spare. The gear was so tight on mine it broke Micheals! Another issue is refilling the gearbox oil is a pain.
 
Thanks Adrian. The process itself is covered on quite a few TDI forums and I'm assuming that the process is similar for all 02J gearboxes, its the mention of the different sized washers that may be needed to make it fit on the A2.
 
The A2 parts list shows the std belleville washer size as 24 x 52 x 2.65 thick and for the VW Transporter it's 24 x 46.5 x 3 (p/n 02Z 311 324)

Not 100% sure if this is the actual smaller washer they use so it's worth checking this out if you can

Cheers Spike
 
spike said:
The A2 parts list shows the std belleville washer size as 24 x 52 x 2.65 thick and for the VW Transporter it's 24 x 46.5 x 3 (p/n 02Z 311 324)

Not 100% sure if this is the actual smaller washer they use so it's worth checking this out if you can

Cheers Spike
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Thank you so much spike. You really are a legend :)
 
I had Mike Skipton01 fit my 0.659 ratio gears in 2010. I'm just sorting through my A2 bits & bobs and came across the original 2 gears. I want to label them but I'm struggling to identify their part numbers. I found this parts diagram https://audi.7zap.com/en/rdw/audi+a2/a2/2004-248/3/311-311038/#30 and believe one is part #30 02A 311 361 Q (I have a GPK gearbox). Could someone confirm this and identify the other part please.

Here's a photo of similar https://www.a2oc.net/community/inde...65-0-643-5th-for-tdi.11914/page-11#post-96746
 
Thanks Spike. I'm a bit confused as I thought I would see both cogs on the same diagram (not on different diagrams) and according to the posts they are immediately accessible when the gearbox end plate is removed.
 
Hi Alan, the 2 diagms are for the main and layshafts, with the mating 5th gear cogs shown on the end of each shaft - where they would be accessible just by removing the end cover
Even though its just a schematic, those 2 cogs do resemble the pictures you posted

Cheers spike
 
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