Adding some info here as I go along.
"rebuild" of 02M quattro gearbox (not the later type with the plastic cap on the casing for the input shaft)
These are the tapered bearings needed for the gearbox rebuild.(No pics of the diff bearings)
From the top..
Input shaft bearings, 02M 311 124A (clutch housing side) & 02M 311 123B (gearbox housing side)
1st - 4th output shaft bearings, 02M 311 220 (clutch housing side) & 02M 311 123B (gearbox housing side)
5th - 6th output shaft bearings, 02M 311 124 (clutch housing side) & 02M 311 123B (gearbox housing side)
2x Differential bearings - 002 517 185M ( the quattro diff uses the same size bearing on each side) not in the picture.
All bearings are marked so I don't get the bearings and races mixed up, as I'm doing this rebuild piece meal.
Very important not the mix the races up between the bearings.
Since I don't have a hydraulic press at home, I have been man baking.
So far I have had the diff in the freezer and the diff bearings in the oven and the same goes for the input shaft and bearings.
I have also had the clutch housing part of the gearbox in the oven and all the bearings races for the clutch housing, in the freezer.
This way the hot bearings just slip onto the cold shafts.
I did manage to mess it up when doing the bearings on the diff. One side went straight on, but I think I waited too long to do the other side and the bearing cooled down too much. So it got stuck. I had to go use a press at the machine shop to get the bearing on all the way.
Pressed on now.
After that I torqued up the ARP bolts on the LSD and that was the diff done.
Next up was man baking the clutch housing part of the gearbox, while the bearing races chilled in the freezer.
FYI - make sure you clean all the gearbox oil off the diff, that stuff smokes A LOT. My kitchen looked like a smoke machine just went off in the night club.
Before dropping in the cold bearing races into the hot clutch housing, I had to determine which races needed a shim installed first.
With the help of the Elsawin workshop manual and the link below, I managed to work out what was required
(Broke is a legend),
http://forums.fourtitude.com/showthread.php?5690818-02M-preload-info-for-Dub-Nub
http://forums.fourtitude.com/showthread.php?5690818-02M-preload-info-for-Dub-Nub
All the below info is to do with the clutch housing side of the gearbox.
The Diff race requires a 0.65mm shim installed in the clutch housing side before the race is fitted.
The 5th & 6th output shaft requires a 0.65mm shim installed in the clutch housing side before the race is fitted.
The 1st - 4th output shaft does NOT require a shim, instead it has an "oil deflection plate" dont forget to install the plate before the bearing race.
The Input shaft does not require a shim in the clutch housing side.
Ensure you line up the notch in the input race with the notch in the housing. This allows the locking bolt/tab to be fitted
Clutch housing with new bearings races and the diff.
Next up, was the input shaft.
I pulled the old bearings off the input shaft using one of these.
Then the input shaft went into the freezer while the bearings went into the oven.
This time I left one bearing in the oven while I fitted the other end. They both slipped straight onto the input shaft without an issues. Don't mix the bearings up as each end is different.
New bearings on input shaft - (make sure to install the bearings with the tapered side away from the gears)
retainer C-clip to be installed still.
LSD has a friend, input shaft with billet insert.
Next step will be to attack one of the output shafts, pull the old bearings off and get the new ones one.
to be continued.....
