#Aba o2j swap manual#

Now we can move further and with cylinder removed - bolt a pedal box to firewall: Have brushed everything, primed with an epoxy and painted matt black to get an OE look :)Ĭylinder moves as intended. Personally I have welded in hex nuts to serve as a thread: If it's ok, drill few more holes for cylinder bolts. Regarding flange you should end with something what looks like:Ī step back, put cylinder in hole attach to pedal and assure cylinder's pushrod is able to move and travel freely. In example I do represent everything comes tightened in one piece, I would say like a bunch of five. I strongly suggest to use more robust construction. As an outcome cylinder changes it's angle and brings problems using it. Firewall sheet is very thin and when you apply force by foot required to press cylinder - it starts twist with an entire firewall. Cylinder becomes bolted separately from pedal box. I've seen few examples where lads fitted cylinder straight to firewall. When requisite flange is welded and you know where center of longitudinal axis of cylinder is - cut a hole diameter 31-34mm. I won't describe measurements I did, but I honestly suggest you to do multiple measurements and multichecks so you can press clutch easily and nicely. Just take a glance to how pedal box came in:Ī flange. When you source pedal box it won't have a flange needed to bolt clutch cylinder to. If this is not granted you gonna kink cylinders pushrod what will cause difficulties to press pedal smoothly. That's an important moment as you must obtain place very precisely. Take a pedal box and try to 'install' clutch pedal cylinder to visualize where it should be located.

Another hose/pipe to connect clutch pedal cylinder with gearbox cylinder įirst of all make sure you have effortless access to places you gonna cut/drill.

A hose to connect MBC reservoir with clutch cylinder.

Master brake cylinder reservoir with outlet to source clutch cylinder with brake fluid.

Pedal box from a VW model using hydro clutch.

Clutch cylinder connected with clutch pedal.

Gear selector compatible with choosen gearbox.

02A, 02J gearbox with clutch cylinder in it, shift tower, i.e.

Since you know the way it's not hideous anymore. On the list of disadvantages I did not mention a fabrication needed to fit everything and make it work :D That's the reason I made this how-to. To be honest I never had any issues with that.

Some say that through cable operated clutch you're able to feel better when clutch's catching.

There gonna be unused hole left in firewall.

Like in any other situation there're pros&cons. I mean you may fit it inside, on the tunnel, not in the tunnel where it belongs. Personally for me, a great installation is a thing to consider about.

Gear selector in case of 02J is made of aluminum and it looks way better.

Internals like close ratio Syncro final drive still could by easily used.There're no problems to source LSD like for any other VW gearbox.Because of that, these sometimes even come at silly prices Nowadays there are diffuculties to source 020 gearbox in acceptable condition.Newer gearboxes are sealed better, my bet is All the 02J gearboxes I've seen are clean and not greasy like 020.Fitting gearboxes mentioned above won't require any of mounting re-fabrication.02J gearbox cable operated gear selector works 100x times more precisely comparing to 020 linkage operated mechanism.If you're planning to run ~250-300bhp I would not even think about an old 020 gearbox 02A or especially 02J gearboxes can handle significantly higher power output.Changes and upgrades ahead are not so tiny I must admit, but trust me, it's worth the effort. Why would I convert to 02A or 02J ? You may combine 20v engine with an old 020 gearbox surely, but I would not recommend doing it. Since major differences are known, probably next question which comes to the head is.

#Aba o2j swap manual#

In my case that's an AGU 20vT engine with 02J 5 speed manual gearbox. In this particular topic I'll assume we're talking about 4 cylinder engine and any 02J gearbox it came with. Other major circumstance is that 02A and 02J gearboxes when changing gears are operated using cable shifter. It happens because cars natively running ABF, AAA, ABV, AGU, AWW, AWP, AUE, BAM, APX you name it, came with gearboxes type of 02A, 02J where clutch is pressed using hydraulic cylinder instead of cable connected to clutch pedal like in Golf mk2 or Golf mk1. This question arises to all Golf mk2, in some cases Golf mk3 or Passat owners when doing conversions. It's been many times I was asked 'What should I do regarding gearbox when swapped my car with more powerful and newer engine?'.