Comment from my mate as he inspected my spare 02M box, after splitting it. Apparently the cogs inside are HUGE and really chunky looking. I wonder what the torque rating is on them?

As you can gather - progress is being made on fitting of the LSD, and it's nice to have my own car to drive around still while it's happening!

The multi shaft gearbox is a very strong unit indeed (I have mentioned this before).

The multi shaft gearbox is a very strong unit indeed (I have mentioned this before).

Just been asked by another mate working on the box (more "gearbox" oriented skills) about shimming, as the diff is shimmed, so the gearbox should need doing too. To be honest, having never looked in a box I've no idea AT ALL what he's on about.

And to top it off he also says two of the supplied plates the diff came with broke when torqueing up the bolts as per the instructions - plates which attach the diff to the ring gear apparently. I'll be taking a look tomorrow.

Oh, and do you know if LSD fitted gearboxes require a different oil to the 85/90w (whatever stuff it is) that the standard boxes get filled with?

I told you the diff and casings need shimming.

The diff is shimmed already apparently - Unsure what shimming actually involves - It sounds like hardcore metalwork to me. My mate is off MSN now so won't be able to clarify until tomorrow. So glad this wasn't done with my current box.

The diff itself may well be shimmed but the output bearings will still need shimming up. This is done by pressing out the outer races and removing any shims. Refitting the bearings, building th box back up and then measuring the endfloat with a DTi and then stripping back down again to fit the required shims.

Do you know what the clearance should be?

There is a table of measurements and the available shims in the workshop manual, way to many configurations to know of the top of your head.

Ah problem there, we don't have a manual :(

I would say no matter how good techie you are unless you have a manual you are going to struggle rebuilding an 02M gearbox. Having done a couple on a course a few years back with all the correct pullers and press tools and all the correct shims it was difficult enough.

I thought Jason had the required manuals anyhow.

Been looking at the specifics of shimming and trying to understand the procedure.

Have gained further respect for true mechanics reading up on it....

Gary Peloquin recommends an absolute maximum of 0.35mm preload, the recommended factory value is 0.20-0.25mm (can't seem to find the 02M 6-speed gearbox number).

So you add that number to the amount of free play in mm measured with no upper (?)shim (using a DTI gauge and 5 bolts torqued correctly, diff rotated a few times to seat bearings correctly). Then open up things again, remove the upper bearing and put in the shim that measures the total calculated and re-seat the bearing.

Like I said, complex stuff, but that's the way I understand the procedure.....

Any chance of a few pics on how your mate opened up the box, Jase?

Cheers

Bas

I thought Jason had the required manuals anyhow.

Nope, don't think so. We are only splitting the cases and changing the diff, not touching the rest of the box. I've rebuilt many gearboxes and never needed a manual until now. Are the other shafts shimmed too out of intrest?

Yes and they should in theory be reshimmed when the box is opened but really only need to be done if the shaft bearings are replaced.

Any chance of a few pics on how your mate opened up the box, Jase?

Cheers

Bas

I expect jase will do some pic tomorrow, it's a very easy box to split.

Yes and they should in theory be reshimmed when the box is opened but really only need to be done if the shaft bearings are replaced.

Yup, thats what I figured.

A lot easier than the 02J/R I found.

Much the same as the DSG.

I expect jase will do some pic tomorrow, it's a very easy box to split.

Be really great if you and Jase can spare the extra time to take a few pics of the steps involved in installing a Peloquin diff.

They would make a totally brilliant guide - there's no detailed LSD fitting guide anywhere on the net that I can find.... And you two would be the first to post one.

Will keep my fingers crossed!

Cheers

Bas

Aha - I see my gearbox skilled mate has surfaced on here.

I suspect my box is a FJW code, but I'll confirm that tomorrow. I do appear to have a manual for it but it's missing some data.

Had a look today (Jason again) thw two plates which broke are what go between bolts on the ring gear - A bit like those things they put between the nuts on lorries/buses to keep an eye on them.