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I'm actually over on the Polo 9N3 forum with a Polo Gti but figured I'd get more bites here. The Polo 5 speed is an 02R but shares a lot of 02J parts in the box.
So I have 3 02R boxes. One has an 02J wavetrac built into it, the second an 02J Kaaz and the third which is in my new car has an SQS 1 way in it. All these boxes have 100mm driveshaft flanges as they all use 8mm driveshaft flange bolts rather than the 10mm bolts used on the 108mm flanges.
So when I was under the car the other day I noticed that both driveshaft flanges in the box in the car had about 5-7mm in/out play. That didnt look right to me so I checked my two spare boxes and their flanges had zero. These are the flanges used on my two spare boxes:
doubtful that both of the springs could break I thought maybe they'd been installed without the centre bolt to hold them in against the diff. So I dropped a driveshaft off and found that the centre retaining bolt was in and tight BUT the flange could move in and out and also had a lot of lateral play. I removed the loose flange and was surprised to see that it didnt have the brass collar that seats into the bearing or the spring fitted over the shaft. they looked like this:
At first I thought they might be flanges I'm not familiar with eg 108mm ones but they are definitely 100mm at the flange, and have the 8mm bolts. They have just been fitted naked without any of the spring set up or the brass collar/bearing.
No prolem I thought, i'll just grab one of the complete flanges off the spare box and swap it in, but they would not go in. After a closer look, the bearing that the output shaft slides into is different to those of every other 02R box I've ever seen. There is no bevelled surface for the brass collar to fit in against, just a smooth bearing inner.
Soooooo.......any ideas what the go is?????
. Its pretty clear that to get the 100mm driveshaft flanges to fit the new cars box they have just stripped them naked and with no spring tension the flange can slide in and out a certain amount on the internal sliding nut that diffs have. I dont know if the lateral play is due to these shafts not running the brass bearing collar or the bearing designed for them OR if with the output shaft bearings that are in this box its actually fine to run the driveshaft flange without the spring/collar and the lateral play is just coming from shagged diff bearings. I dont know how the oil seals havent flogged out yet but they'll be leaking soon.
I think the 02A's had a completely different driveshaft flange design with cups that went onto internal output shafts. But could the box have 02A bearings in it somehow? 02Js used both 100mm and 108mm flanges and I thought the gearbox side bearings for these were common but figured you guys would know better. For all I know in 02J tuning circles what I'm looking at is a done thing but was hoping for a little help.
thanks for any help
sam
sam
So I have 3 02R boxes. One has an 02J wavetrac built into it, the second an 02J Kaaz and the third which is in my new car has an SQS 1 way in it. All these boxes have 100mm driveshaft flanges as they all use 8mm driveshaft flange bolts rather than the 10mm bolts used on the 108mm flanges.
So when I was under the car the other day I noticed that both driveshaft flanges in the box in the car had about 5-7mm in/out play. That didnt look right to me so I checked my two spare boxes and their flanges had zero. These are the flanges used on my two spare boxes:
doubtful that both of the springs could break I thought maybe they'd been installed without the centre bolt to hold them in against the diff. So I dropped a driveshaft off and found that the centre retaining bolt was in and tight BUT the flange could move in and out and also had a lot of lateral play. I removed the loose flange and was surprised to see that it didnt have the brass collar that seats into the bearing or the spring fitted over the shaft. they looked like this:
At first I thought they might be flanges I'm not familiar with eg 108mm ones but they are definitely 100mm at the flange, and have the 8mm bolts. They have just been fitted naked without any of the spring set up or the brass collar/bearing.
No prolem I thought, i'll just grab one of the complete flanges off the spare box and swap it in, but they would not go in. After a closer look, the bearing that the output shaft slides into is different to those of every other 02R box I've ever seen. There is no bevelled surface for the brass collar to fit in against, just a smooth bearing inner.
Soooooo.......any ideas what the go is?????
. Its pretty clear that to get the 100mm driveshaft flanges to fit the new cars box they have just stripped them naked and with no spring tension the flange can slide in and out a certain amount on the internal sliding nut that diffs have. I dont know if the lateral play is due to these shafts not running the brass bearing collar or the bearing designed for them OR if with the output shaft bearings that are in this box its actually fine to run the driveshaft flange without the spring/collar and the lateral play is just coming from shagged diff bearings. I dont know how the oil seals havent flogged out yet but they'll be leaking soon.
I think the 02A's had a completely different driveshaft flange design with cups that went onto internal output shafts. But could the box have 02A bearings in it somehow? 02Js used both 100mm and 108mm flanges and I thought the gearbox side bearings for these were common but figured you guys would know better. For all I know in 02J tuning circles what I'm looking at is a done thing but was hoping for a little help.
thanks for any help
sam
sam
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