02A Transaxle Swap Guide for VW Mk2 Chassis

This write-up does not discuss the differences in procedure for cars currently using an automatic transaxle. This is a basic guide to the process – not a step-by-step detailed how-to. The assumption is made that the person doing the swap is mechanically inclined, intimately familiar with the mk2 chassis, and has access to a Bentley service manual.

Needed 02A swap parts:
– 02A Transaxle (g60, passat 16v, vr6) (coordinate version with motor type)
– Mk2 axles with 100mm diameter inner cv joint
– G60/passat 16v speedometer cable
– Corresponding 02A Starter
– Corresponding 02A Flywheel
(Match to motor: 6-bolt 02A flywheel is 4-cylinder, 10-bolt for vr6)
– Corresponding 02A Clutch Kit
– Recommend new throw-out bearing and guide tube kit
– New transaxle fluid (Redline MT-90 is the performance upgrade for the 02A)
– NEW flywheel & Pressure Plate Bolts for 4-cyl. (not necessary for vr6)
– Shifter box & cables
– Pedal Cluster
– Clutch master cylinder
– Clutch master cylinder bracket
– Clutch master cylinder supply line
– Slave cylinder
– Slave cylinder supply line
– 02A brake/clutch fluid reservoir

Removal of existing pedal cluster
• For better access to the pedal cluster area; remove the center console then remove the dash parcel trays/knee bar setup depending which year the car is.
• Disconnect throttle cable from accelerator pedal.
• Disconnect wiring to the switches mounted on the pedal cluster above the brake pedal and clutch pedals. If you do not have cruise there won’t be a switch mounted there. If you have cruise there will also be a vacuum line to detach.
• Disconnect clutch cable from actuating lever on transaxle and then disconnect the other end from the pedal cluster. Remove the clutch cable completely from the car.
• Remove the speedometer cable from the transaxle as well as the speedometer.
• Remove the nuts holding the pedal cluster to the firewall. There are also nuts below the carpet and nuts straight up below the dash cluster. Look at the 02A pedal cluster for locations for clarification.
• Disconnect steering column from the pedal cluster near clutch pedal.
• It may be necessary to detach the steering column for ease of pedal cluster removal. Unbolt if necessary.

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