The counter weight seemed a little stiff and I'm not really good with imperial measurements and being a guy I have a hard time working out what a 1/4 inch looks like My L shaped lever must be snapped as I couldn't lock it in place and I found it difficult to find that little sweet spot in the 1st/2nd gear gate. I replaced that with an OEM one at around £9 uk sterling. Oh yea, I should mention I've already tried to adjust the selector using your handy video, found a weak spot, one of the fingers of one of the cable ends disintegrated as soon as the knurled end was pulled back. I guess it's bad there with this whole VW diesel scandal Well maybe now that "silly season" or marching season is over it's better, but I'm just fed up with how our circus of a government are fighting over an alleged IRA murder and have practically stopped working leaving all our health services and stuff like that with no money, but hey, enough politics. VW did a lot right on the MK4, but the gearbox, not so much. There is side-side slop built into the selection mechanism within the gearbox, so anything outside the box (bushings, ball cup, etc) will help greatly, but you're never going to get rid of some slop. I find that if I grab the "golf club" (or the flat piece that replaces that in the Sigma), I can move it up and down while a gear is selected. I don't have any extra aluminum/McD's receipts, nor the FIGG, but that bushing looked OK at last glimpse. I have the new ball cup from the MK5 as linked above. If anything, I shift slower with it because I can feel when the gear doesn't want to engage yet, whereas before by the time that feedback came to the lever with the stock setup, I already had put too much pre-load to the rubbery cable-ends and the syncro was over-stressed.Īs for side-side slop, the DG shifter made it proportionally smaller, but it's still there. The throw-length isn't the limiting factor with the 02J, it's the syncro rings. The Sigma greatly improves the tactile feel of the shifting (no flexy rubbery bushings in flimsy plastic cable-ends, no weight to cancel feedback from the syncros), and it changes the throw of the lever to a more comfortable distance which reduces arm strain, but it won't "speed up" gear engagement. That's not a criticism of the Sigma product per se - any short shifter would have the same effect. If you shorten the throw, it becomes even easier to crunch the shift, so you have to be concious to either go extra-easy (two-fingers easy) on the lever. It must be said that I find that the 02J gearbox in general likes to grind/crunch shifts from rushing the lever (maybe I'm just extra ham-fisted?). GASDAG, Jim's (corrado_tdi) DG short shifter does allow you to feel the shift engagement more precisely. I see we really have healthy options to improve the ball cup lol! Didn't do squat for me, and from what I've read one or two other people have tried with the same poor result.Coke cans and McDonald's receipts. Oh yeah, someone was dead sold on heating up the tower in the oven and that the bearing would just about fall out. I was transferring it to a new (rebuilt) transmission and thought that now was the time to do this. There wasn't anything apparently wrong with this shift tower. The rubber washer actually installs over the shaft. The ordering top to bottom of the bits: seal, bearing and then rubber washer. Used a screwdriver and hammer on the top lip (once it was exposed enough) to get it the rest of the way out. I used a chisel from the top to catch the slight lip (lip on either end to keep bearing cage in place) and was able to start driving it out. I used a Dremel sanding drum (small), three of them, to cut away enough material that I could bend and snap off some of the shell metal: this is from the bottom edge. Not going to look back on this job! What a PITA. This missing bearing might be why 5th gear disappeared. There was a rubber washer in the kit I got. Is that lever called the "shift adjustment pin" in post #16 of this thread? I didn't know what the little right angle lever was for so I pulled the tower off separately. I stuck my magnet way down inside trany and nothing came back with it.
There was no sign of the old bearings or cage when I opened it. It was in there so good the tacks would break off and take some race with them. Nothing to grab so I tacked some welds to the inside. Might get an answer to my rubber washer question.ĭamn that was just as nasty as some of the pics I've seen. I posted some of this in my first TDI project thread.īut it seems like the info would be better placed here.
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