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Inside a Kaaz Differential VW 020, and 02A, preload?

Posted by Tom B

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Tom B
Tom B
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Tom B

Inside a Kaaz Differential VW 020, and 02A, preload?
March 03, 2011 11:46AM

Registered: 02/27/2006
Posts: 780

Hey John and others, here are the guts to a Kaaz for an 020:

I don't think the inside of the 02A diff will be much different. Whadda ya think, bring down the 02A diff with a couple of drive flanges and set a pre-load?

Or wait a couple of months for KAAZ to ship parts from Japan?

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Tom B
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 03, 2011 12:05PM

Registered: 02/27/2006
Posts: 780

Quote
somebody else
In the kaaz book or manual they didnt have instructions for the vw so i called kaaz, he explained it to me like this, there are 8 disc's inside the vw 020 kaaz diff(4 on each side of the diff) and they have sides A and B, A has straight grooves from the inside to the outside and B has small to large circles or rings, 100% configuration is A,B,A,B and A,B,A,B 50% configuration you just flip the one disc so its A,B,B,A and A,B,B,A (basically so the 2 sides that are the rings face each other) tearing the diff appart is difficult because you need to press the stubs in and out to do the disc's.

50% is like 80 ft lbs of breakaway tq and 100% is approx 130 ft lbs of break away tq.

I was told to use 100% on asphalt and 50% on dirt or gravel.

And I can verify that the 50% lockup will not get you out of a stage when you break an axle, hence the post about pre-loading the diff.

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john vanlandingham
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 03, 2011 12:36PM

Registered: 12/20/2005
Posts: 14,152

Quote
Tom B
Hey John and others, here are the guts to a Kaaz for an 020:

I don't think the inside of the 02A diff will be much different. Whadda ya think, bring down the 02A diff with a couple of drive flanges and set a pre-load?

Or wait a couple of months for KAAZ to ship parts from Japan?

yeah bring 'em down

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fliz
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 03, 2011 12:39PM

Registered: 02/01/2007
Posts: 484

Quote
Tom B

And I can verify that the 50% lockup will not get you out of a stage when you break an axle, hence the post about pre-loading the diff.

I made it 3 seconds at 100% lockup after blowing an axle, although I can't say for sure that I had the plates or the spring washer 100% correct, but I did have them alternating (may have been B-A-B-A instead of A-B-A-B.

I still only get ~75lb-ft of breakaway torque on the diff.

Also, you don't have to press off the stubs to dissassemble, so it's not that hard to play around with.

My only problem was I stripped out those little hex head screws.

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Rallymech
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 03, 2011 12:43PM

Registered: 04/27/2008
Posts: 1,292

Grab JVL and come over to my nice, warm and well lit shop. We will clean and inspect that diff. Then we can shim it up.

Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

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Tom B
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 03, 2011 10:35PM

Registered: 02/27/2006
Posts: 780

here's the real bitch....kaaz just shipped up the right clutch plates today.....after three months.... grrrrrr!!!

anyhoo, I think I'll bring it down gents

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fliz
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 04, 2011 07:13AM

Registered: 02/01/2007
Posts: 484

Ouch. It only took a month and a half for them to ship me the right plates. The first ones they sent were Mustang plates.

Wish we could use those...twice the diameter.

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Cosworth
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 04, 2011 10:30AM

Registered: 03/15/2007
Posts: 721

Crap.... 75lbs of torque on yours? My kaaz is down to 35/40lbs. Gonna have to look into it!

Edited 1 time(s). Last edit at 03/04/2011 10:31AM by Cosworth.

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john vanlandingham
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 04, 2011 10:54AM

Registered: 12/20/2005
Posts: 14,152

Quote
Cosworth
Crap.... 75lbs of torque on yours? My kaaz is down to 35/40lbs. Gonna have to look into it!

If he ever shows up. I'll report.
Two ways I know (shim or spacer select fit ) and we'll see,OK?

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DexterVW
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 04, 2011 11:30AM

Registered: 11/20/2008
Posts: 290

Can one make shims for these, stuff another one in? I have the 100% lockup kit from KAAZ.. installed correctly and I'm only getting about 60ft/lbs breakaway and no drive with a broken axle... I do have a full machine shop at my disposal :-)

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john vanlandingham
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 04, 2011 11:41AM

Registered: 12/20/2005
Posts: 14,152

Quote
DexterVW
Can one make shims for these, stuff another one in? I have the 100% lockup kit from KAAZ.. installed correctly and I'm only getting about 60ft/lbs breakaway and no drive with a broken axle... I do have a full machine shop at my disposal :-)

On the diffs I've done in the past, I used Saab transmission end cover shims.

These are in select fit sizes from 0,05 to 0,3mm.

But hey knock yourself out but be aware it maybe no more than .020" that'll bump you up a shitlaod.

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fliz
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 04, 2011 11:54AM

Registered: 02/01/2007
Posts: 484

Quote
Cosworth
Crap.... 75lbs of torque on yours? My kaaz is down to 35/40lbs. Gonna have to look into it!

That's what I was at after I blew an axle. Disassembly showed all the plates on one side were mostly smoothed out.

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DexterVW
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 04, 2011 01:21PM

Registered: 11/20/2008
Posts: 290

Quote
john vanlandingham

Quote
DexterVW
Can one make shims for these, stuff another one in? I have the 100% lockup kit from KAAZ.. installed correctly and I'm only getting about 60ft/lbs breakaway and no drive with a broken axle... I do have a full machine shop at my disposal :-)

On the diffs I've done in the past, I used Saab transmission end cover shims.

These are in select fit sizes from 0,05 to 0,3mm.

But hey knock yourself out but be aware it maybe no more than .020" that'll bump you up a shitlaod.

Hey Rockin!! thanks JV! So where would one order some of these shims from? Not that I don't like making stuff... I just have too much to make right now :-)

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Pete
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 05, 2011 02:55PM

Registered: 01/11/2006
Posts: 2,022

Hell, just find a local repair shop and ask 'em if they have any spare rearend shims. Any place that has done more than two or three ring and pinion installs will have more shims than they know what to do with. They grow in boxes like coat hangers in closets.

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Cosworth
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Re: Inside a Kaaz Differential VW 020, and 02A, preload?
March 21, 2011 09:19AM

Registered: 03/15/2007
Posts: 721

Took my diff appart this weekend and all the clutches are still good as new. No abnormal wear or anything. Installing a thicker thrust washer at the end would definetely help with a higher break away torque but that might cause too much wear on the plates. I measured the stack inside the diff cage and then measured the whole assembly with the clutches, the gear carriers and the big belleville thrust washers(at the compressed height) and there's only a few 10th's on a militer to work with. But what exactly is included in the 100% lock kit? Thicker clutches or thicker washers? Also what oil do you use?

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