mk5 Jetta/Golf 4motion conversion findings

[maloosheck]

I would like to start this topic to keep all my findings regarding the Mk5 Jetta/Golf 4motion conversion. I am going to focus on the TDI engine, as this is what I currently drive.

It appears it should be way easier to make the conversion in mk5 then in mk4. Here is a comparison of FWD and 4motion rear suspension:

This is FWD rear suspension:

And this is 4M rear suspension:

It appears the bolts attaching the whole thing to the chassis are in the same location. What is more important I can confirm there is a cavity over rear suspension in my Jetta that should allow Haldex to fit in. In other words: the FWD and 4Motion chassis APPEARS to be the same. Which should make any potential conversion really easy.

Here are two pics of the rear side of the drivetrain with the rear drive splitter (or whatever proper name of this thing is). One is from Passat B6 (most likely BMM engine code - Passat B6 shares lots of components with A5 Jetta/Golf), the other one is from mk5 R32.

Passat B6 4motion:

Mk5 R32:

The BRM engine that is in US Jetta TDI has a similar turbo setup: over the exhaust manifold. Again, this means there should be enough space to fit in the splitter.

Here are three pictures of the rear suspension: Passat B6, Mk5 R32 and Mk5 Golf TDI 4motion (available in EU and Mexico AFAIK):

Passat B6 4motion:

Mk5 R32:

Mk5 Golf TDI 4motion:

In addition here is the picture of the FWD Mk5 Golf suspension:

As I mentioned: there is a cavity in the Jetta chassis that should fit in Haldex.

One thing that also needs to be changed is fuel tank. I still look for the pictures of fuel tanks in Jetta, Golf and Golf 4motion.

I would be grateful for any info regarding 4motion conversion in mk5 Jetta/Golf, especially from the EU forums.

[O2VW1.8T]

wow that sure does LOOK easy if it will bolt up. The lower trailing arms arm the same. If thats the case everything else will much 100 times easier then a Mk4 AWD swap... I would give it a shot

[O2VW1.8T]

checked etka and the 4motion trailingarm and the regular FWD arm are the same..

[maloosheck]

Here is something that I am not sure. This is a picture of the 4motion 6-speed tranny with the detached splitter (anyone knows proper name?):

As you can see there are 4 holes to attach the splitter and there is no diff flange (most likely the whole part is different).

I found several pics of the 6-speed trannies that were in the FWD vehicles:

Only the last one does not have the holes for the splitter bolts.

My question is: will the FWD tranny with the holes work with splitter, say after making sure that the diff flange from 4motion? Or are there any other differences between 4motion and FWD trannies that will not allow to attach the splitter to the FWD tranny?

[jettaboy_gtx]

the spliter as you call it is transfer case. And im not 100% sure but i think you cant put a transfer cas on a FWD tranny. why wouldnt you just find an AWD tranny and use that instead of trying to put a transfer case on a FWD tranny?

[maloosheck]

Quote, originally posted by jettaboy_gtx »

why wouldnt you just find an AWD tranny and use that instead of trying to put a transfer case on a FWD tranny?

how easy is it going to be to find a 6-speed 4motion tranny with TDI engine gear ratio in NA that I can use in mk5 Jetta?

[TBT-Syncro]

Quote, originally posted by maloosheck »

how easy is it going to be to find a 6-speed 4motion tranny with TDI engine gear ratio in NA that I can use in mk5 Jetta?

You arent going to find with in NA, you need to look overseas.


Modified by TBT-Syncro at 2:58 PM 9-23-2007

[maloosheck]

Quote, originally posted by TBT-Syncro »

Yyou arentt going to find with in NA, you need to look overseas.

Any idea how to easily bring it here, once I find it?

[TBT-Syncro]

Ever imported a large/heavy item before?

Its all going to depend on the seller/shipper and what they're willing to do for you at their end. Bringing it through customs once it's here is easy.

[boner]

purely unscientificly, i'd say that the pics look close enough that you can bolt the transfer case on a fwd trans. if i had to guess tho, you'd probably be looking for a different front diff cuz it's got to engage the transfer case. also, what about the axle seal on that side? is the OD of that gonna be the same OD as the part of the transfer case that goes into the box?

looks to me at first glance that were you to establish that you CAN infact attach the transfer case to the fwd trans, the rest of the car will more or less fall together, and for relatively cheap too i mean, looks to me all we're talkin about is the transfer case, rear suspension, custom exhaust and probably some misc electrical gizmos to control the haldex (are there any?)

the electrical scares me though. i mean, even the wipers on my gti are connected to the brains so that they go to intermittant when you are at a stop light.....

[farfrumslow]

there are also holes for fluid transfer in addition to the four bolt holes

[maloosheck]

Quote, originally posted by farfrumslow »

there are also holes for fluid transfer in addition to the four bolt holes

Heard about it. Any pics/other resources to validate this info?

[maloosheck]

Quote, originally posted by boner »

the electrical scares me though.

AFAIK it should be the easiest part. Haldex is connected with 5 wires: power, ground, CAN-H, CAN-L and brake switch.

The only problem I can see here is that there might be different Haldex programming for Diesel and Gasser.


Modified by maloosheck at 5:50 AM 3-7-2008

[tranceporter]

bump?

[shortshiften]

nice......

[Audi4u]

This is what I need! Makes my Rabbit even more valuable!

[shortydub]

these parts can be easily sourced in america..
ecodeparts will import thus fer shur

[mujjuman]

wow sweet.

[wuznmeTT]

Wow, I was just talking about this. I'd love to do it.
Looks like it may not just be a pipe dream.
Thanks for making the info available.

[Audi4u]

Does anyone have pics of how the mkv r32 exhaust is routed?

[Audi4u]

nm

[Audi4u]

Bump

[jetta9103]

Quote, originally posted by jettaboy_gtx »

the spliter as you call it is transfer case. And im not 100% sure but i think you cant put a transfer cas on a FWD tranny. why wouldnt you just find an AWD tranny and use that instead of trying to put a transfer case on a FWD tranny?

the "splitter" is NOT a transfer case...it is referred to as an "angle drive" or more commonly a "power transfer unit." it performs the same function as a t-case, but t-cases are usually used in longitudinal setups (and also where the transmission does not house a final drive of some sort), and power transfer units are typically used in transverse setups.

btw, cool pics in the OT. and cool topic. im interested in the answer...

[Issam Abed]

Quote, originally posted by maloosheck »

Any idea how to easily bring it here, once I find it?

Will cost you about 450-600US in shipping alone.Better to do it in a bulk shipment or have 1 of those specialty people (ecodeparts,etc) import it for you.

I guess VW finally got smarter and made both chassis the same.Andre you want to do this?

[Audi4u]

Quote, originally posted by Wizard-of-OD »

Will cost you about 450-600US in shipping alone.Better to do it in a bulk shipment or have 1 of those specialty people (ecodeparts,etc) import it for you. I guess VW finally got smarter and made both chassis the same.Andre you want to do this?

I was thinking of use using a audi tt 225 trans.

[trastrim]

What is the estimated cost and workload associated with the possible swap of a 4motion drivetrain into the MK5 chassis. I'd love to do this one the Rabbit, especially if it's about the same price as a turbo (without labor)

[Issam Abed]

Quote, originally posted by Audi4u »

I was thinking of use using a audi tt 225 trans.

Same bell housing as the inline-5?
Wow VW is getting smarter

[abeMKvGLi]

inteerrestttinggg . .......

[bwzimmerman]

any more info? What about us 2.0T owners? We got the Audi A4 2.0T Quattro to part from... right?

[jetta9103]

Quote, originally posted by bwzimmerman »

any more info? What about us 2.0T owners? We got the Audi A4 2.0T Quattro to part from... right?

no, not "bolt on," because you are still dealing with completely different drivetrain setups. Audi A4 = longitudinal (w/ a center diff)
your 2.0T = transverse (w/ PTU & Haldex)

[maloosheck]

Quote, originally posted by Wizard-of-OD »

Will cost you about 450-600US in shipping alone.Better to do it in a bulk shipment or have 1 of those specialty people (ecodeparts,etc) import it for you.

Do you have any more details on how to ship anything from Europe? I found the transmission I want and I need to find out how to bring it.

[mercury26]

I am very interested in this thread and hoping I see a DIY come out of it. I purchased a DSG GTI, with hopes that it would be easier to source US parts to do the conversion. Looking forward to someone giving this a shot.

Cheers,

Chuck

[maloosheck]

Quote, originally posted by djsaint »

I am very interested in this thread and hoping I see a DIY come out of it. I purchased a DSG GTI, with hopes that it would be easier to source US parts to do the conversion. Looking forward to someone giving this a shot.

With DSG gasser all you have to do is to save some money and find the totaled mk5 R32 (one was already in the mk5 classifieds)...

[Marshmallow Man]

whats the orientation of the tiguan 2.0t?

after all is said and done probably better just buyin the tiguan

[EL_3grab]

http://forums.vwvortex.com/zerothread?id=3842257