The Dirty Carpet Series Presents:

The dirty and incorrect way to split open the 020 trans

 

These are the tools you'll be using... it is everything you should have handy. The small 5th gear, the 5th housing, and 2 of the long 5th housing bolts.

I'd suggest using a support bar across the bellhousing. This is the adjustable VW bar, you can use anything strong and straight. Just bolt it up to the bellhousing and add sockets or whatever is needed until the input shaft is supported. I've split them without the bar, but you should use it or try to make one...

Say your trans looks like this (imagine the shift fork tube in place)... drivers flange off, all case bolts removed, reverse bolt out, 5th gears off, the 4 XZN 6mm bearing retaining bolts removed...

If you put the 5th end cap back on and look down into the TO bearing bore, you can see the input shaft sits very close to the TO bearing bore inside the 5th housing. There isn't much space between the two...

Take the small 5th gear and place it on top of the input shaft...

Put the 5th housing back on and you'll find it hits the 5th gear you stuck in there...

This leaves a gap between the 5th housing and the gearbox casing. Install 2 long bolts opposite of each other and tighten them down evenly. If it works, the 5th housing bolts will pull the gearbox casing UP to meet the 5th housing. This will split the trans at the bellhousing.

If it doesn't work, something is going to break. That is the risk of not having or making the proper tools. That being said, I've done it before, but not a lot. It should work, but don't blame me if something is damaged. Just contact me for the parts, I have them in stock ;)

Good luck!