Gearbox rebuild options

[jsws3]

Hi guys I'm looking for some advice on having my s2 gearbox rebuilt.

I want to build it so it will take 700 odd hp but don't want to go down the dog box route as its still a road car and to keep its carertristics.

And I also want to put the longer 6th gear in from the Audi 100 box so it brings the rpm down when on the motorway .

Has anybody used a rebuild kit from Jhm with carbon coated synchro's ?.

And is a b5 s4 or rs4 box a better option to rebuild and use .

[Error404]

B5 S4 & RS4 box will already have a slightly longer 6th and also external oil cooling which might not be a bad idea on your beast.
I think the JHM parts are all OEM so will be as good as any.

[diesel des]

I have rebuild a few now. My thoughts are that if it ain't broke don't fix it. Does it crunch into any gears now? The carbon syncros are faster shifting. And the new revised first to second collar is a slacker fit so less likely to gall up.

It's easy enough to change 5th and 6th ratios and I have v8 gears in one of mine.

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[jsws3]

I have rebuild a few now. My thoughts are that if it ain't broke don't fix it. Does it crunch into any gears now? The carbon syncros are faster shifting. And the new revised first to second collar is a slacker fit so less likely to gall up.

It's easy enough to change 5th and 6th ratios and I have v8 gears in one of mine.

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Hi mate it's started crunching second gear now however if I change from first to second slow it drops in ok and the same for 3ed to second nice and slow it's ok .

My gearbox has around 140k on it so it's due a rebuild I'm sure .

What's the difference in the v8 5th and 6th ?

[diesel des]

The v8 5th and 6th are taller than the s2 gears so you get slightly less rpm while cruising on the motorway. The Tdi gears are even taller but I feel they are too tall unless your wanting to do over 200 mph.

Yea it sounds like yours would benefit from the upgraded shift collar and syncros. You ideally want a box with wide first gear and flex input shaft so check yours has that if your building it up and spending the money. As stated some boxes have the oil cooler setup which can be bypassed like I did on mine or ran to a radiator. But it's more pipes and coolers....

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[Thuppu]

When you guys rebuild your 01E transmisions, do you usually change any needle bearing? There is a whole bunch of them inside, every gear has one + few others... I have now collected info of prices and if I change all needle bearings it won't hurt the wallet too bad. Only the big main roller bearings cost a kidney, so I wouldn't change them. Will also change the 3:rd and 4:th syncro ring and spring + the shaft seals.

[diesel des]

When you guys rebuild your 01E transmisions, do you usually change any needle bearing? There is a whole bunch of them inside, every gear has one + few others... I have now collected info of prices and if I change all needle bearings it won't hurt the wallet too bad. Only the big main roller bearings cost a kidney, so I wouldn't change them. Will also change the 3:rd and 4:th syncro ring and spring + the shaft seals.

Nope the gear needle bearings see very little stress so if after an inspection they look OK I leave them alone. I just changed what was needed in terms of bearings. Some looked and felt as good as new with others having obvious wear marks or rough spots. Change those only.

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[terrybullwon]

A proper clutch and flywheel will help with your gear changes. Less rotating energy, a full size clutch just won't work the same a smaller 7.25" also a 10kg flywheel will be the death of your gear box.

[Thuppu]

Ok. All needle bearing makes about 145e in total so they are not badly priced, but the big roller bearings are 160e/pcs.

[Thuppu]

A proper clutch and flywheel will help with your gear changes. Less rotating energy, a full size clutch just won't work the same a smaller 7.25" also a 10kg flywheel will be the death of your gear box.

Yes, 7.25" twin disc clutch and billet 4.7kg flywheel gona been used.

[Thuppu]

Yesturday my friend and I took one 01E apart to fit custom gearing. Other wise everything was smooth and easy, but the 5th gear was just so tight to pull that our bearing pullers started to bend, and broke a couple of small pieces of the gear tooths. The gear was missing the c locking ring, so we suspected there was locktite used to secure it, but couldn see anything when we finally got it out after pulling, heating and hammering(all at the same time). Is it normal that it is so tight? Everything else was easily pulled apart.

[diesel des]

All 4 or 5 01e boxes I have stripped have been OK with nothing too tight. You were just unlucky.

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[Error404]

I think a hydraulic press is the way to go - much more controlled!

[diesel des]

I think a hydraulic press is the way to go - much more controlled!

I agree but from memory I think you need to use pullers for 5th and 6th. Some of the other gears took about 5000kg on my press to shift.

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[Thuppu]

Thanks chaps. We strip soon another box and we see if it as tight as this. I will do a proper puller tool for that gear.