Note: The second time I did this, I ground down the 3 arm puller some more and was able to fit it under. I could not fit my 3 arm puller between the case so I had to use a 2 arm, and grind down the arms a little bit. Using a 2 jaw puller, repeat the removal process for the 5th gear idler. 5th gear rides on the shaft over a needle bearing roller, so it should come right out. You have a good view of the brass syncro here. Don't forget to unscrew the bolt periodically as you are extracting the hub. It may take a lot of cursing and re-orienting the puller arms on the syncro hub, but eventually it will come out. This will give something for the puller to press against as you extract the syncro hub.
#Proper amount of fluid for an o2j vw transmission install
Reinstall the gear pullers, and loosely install the T60 bolt in the shaft. I heated mine for a good minute or two to make sure it was hot. Once you feel that you can get the pullers in, then heat up the synchro hub with a propane torch. I had to grind down the lower side of my gear pullers in order to fit them under the syncro hub. This is MUCH safer and won't damage the syncro. NOTE: I have found that you can also fit the pullers under the syncro hub if you grind them down a bit more. This is where you will need to get your pullers in. Notice the gap between 5th gear synchro hub and the brass synchro. I take no responsiblity if you damage your transmission. Make SURE you have heated up the gear to loosen it. (no picture included, it is the small silver clip)ĬAUTION: You MAY damage your syncro or your idler gear in this process. It should come out easily with a blade screwdriver. Lastly, remove the spring that is sitting inside the 5th gear syncro hub. Notice there is a washer under each bolt. I could not budge these with a breaker bar, so I ended up just impacting them off. Remove the T60 torx bit that is holding the 5th gear on. Carefully remove the 5th gear selector bits, and bag them along with the 5th gear selector. Remove the 5th gear selector, and set it to the side. Do not loose these or drop them in the case. Pull out very slowly, as there are 3 spring loaded selector bits that will come out as well. It should come out as one piece, but the pivots are loosely attached, so do not loose them. Remove the 5th gear selector fork retaining bolts with an 8mm triple square bit. When you fully remove the bolt, make sure you don't drop either piece into the case.
Notice there are 2 parts the bolt itself and the selector adjuster. Loosen but do not remove the 5th gear selector adjuster bolt with a T45 Torx bit. Remove the five 11 mm bolts holding the outer transmission cover. Some bolts are very specific in size and length. NOTE: Bag EVERY part you remove from the tranny. Bench grinder (to grind down 3 arm puller arms) ***If you are having problems getting this far, this DIY may not be right for you because you could cause serious damage to your transmission if not reassembled properly. Start by removing the transmission by using previously written DIYs and drain the transmission fluid. Let me know if you have any questions and I'll try to answer. This will help you split your O2J transmission case and remove all the components, either for cleaning, replacement, or if you want to install an LSD =) I haven't written one of these in a while and it was requested, so here it is.
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