mk5 Jetta/Golf 4motion conversion findings

[maloosheck]

Two more items crossed out of the list: ABS pump/controller and ABS multi-sensor.

Bonus feature of the ABS controller I found is Hill-Holding. Not that I really need it, but it will be nice to have it (I wish I had it in San Fran ). I need to check if it requires additional button as in Tig or it works straight forward (as in my wife's MCS).

[YoungMedic]

so was it determined that the transfer case could be bolted to the US FWD 6MT? or would the input shaft not work?

im glad i found this thread, i have been mulling an AWD conversion through my head for the last week or so. would the 02M 121C 4WD from the 2.0t S3 work on the GTI?

also also you completely clarified the ?'s i had about how the Haldex controller works with the ECM.

cheers! and good luck!

[maloosheck]

Quote, originally posted by YoungMedic »

so was it determined that the transfer case could be bolted to the US FWD 6MT? or would the input shaft not work?

AFAIK no.

Quote, originally posted by YoungMedic »

would the 02M 121C 4WD from the 2.0t S3 work on the GTI?

That should work just fine.

Quote, originally posted by YoungMedic »

also also you completely clarified the ?'s i had about how the Haldex controller works with the ECM.

No, this is still open. If my ECM will not work, I will grab 2.0L TDI CR 170HP from EU Tig 4M and swap the engine .

[YoungMedic]

haha, way to work the problem!

thanks

[XM_Rocks]

Subscribed...

[Pelican18TQA4]

Skimmed through this very interesting thread and didn't see this mentioned, but another reason the R32 rear pan is different is becasue the battery is in the trunk. Not sure if this is the same with other 4Motion MkVs.

[maloosheck]

Quote, originally posted by Pelican18TQA4 »

Skimmed through this very interesting thread and didn't see this mentioned, but another reason the R32 rear pan is different is becasue the battery is in the trunk. Not sure if this is the same with other 4Motion MkVs.

2nd page:

[Pelican18TQA4]

Saw the pic, didn't see any reference to the battery. My mistake!

[TGZ]

Good luck on the project! I'm looking forward to seeing the finished product.

[Berlinetta Boxer]

Wow, I remembered this thread from when it started, but I'm glad that you've been finally making progress!

So why are you going with a dual mass flywheel instead of a single mass? If there isn't a difference in flywheels and clutches between FWD and AWD transmissions, then you should be able to use a G60 flywheel and VR6 clutch. Most people over at tdiclub.com would probably suggest this over a dual mass flywheel. I'm mostly curious, as these would be easier and cheaper to get than the ones from a PD170, though it looks like you've already got them.

[maloosheck]

Quote, originally posted by Berlinetta Boxer »

So why are you going with a dual mass flywheel instead of a single mass? If there isn't a difference in flywheels and clutches between FWD and AWD transmissions, then you should be able to use a G60 flywheel and VR6 clutch. Most people over at tdiclub.com would probably suggest this over a dual mass flywheel. I'm mostly curious, as these would be easier and cheaper to get than the ones from a PD170, though it looks like you've already got them.

The mayor reason is PD170 (and all PD100, PD140) in mk5 Golf/Jetta paired with 6MT tranny use 240mm clutch. G60/VR6 is 228mm.

The other reason are vibrations from SMF.

I am planning to keep my G60/VR6 setup just in case I decide to go back to it, but at this point I want to try PD170 DMF/clutch.

[rallydiesel]

I admire your DIY-ness but if I was looking for an AWD TDI, I would wait for an xdrive BMW 335d or a 4motion 170 hp Passat CC.

[maloosheck]

Quote, originally posted by rallydiesel »

I admire your DIY-ness but if I was looking for an AWD TDI, I would wait for an xdrive BMW 335d or a 4motion 170 hp Passat CC.

And I would wait for R8 V12 TDI .

Not sure if 335xd will ever come to US. Plus it will most likely be in auto only. Same with CC: current gasser vr6 is sold with auto (not-DSG) only. The stupidest configuration ever invented.

But I would love Audi A4 Avant with V6 TDI 6MT AWD. The day it hits this shore, I wrap up my Jetta and let it go.

[R32dreamer17]

hey i'm the dude who lives in cville and asked about a month ago or so if i could come see your project in sterling. looks really cool just wonderin you'd still be down to let me see it.

[maloosheck]

IM sent.

[R32dreamer17]

saw you im'd me. not quite sure when. I can let you know tomorrow probably and then I guess we'll also see when would be convenient for you.

[ShadowGLI]

Wow, this looks great, I had thought about this on my GLI but did not have the money or time, can't wait to see this finished.. great work so far.

[maloosheck]

I was able to locate the 4M TDI fuel tank real cheap. The problem is this thing is big, so my carrier will not be able to bring it here. Any leads for how to have it shipped here in the least expensive way are highly appreciated.

Anybody stationing in EU, who plans to come back soon and could help me with that?


Modified by maloosheck at 9:38 AM 12-31-2008

[Gotsol]

any updates? Great project!

[maloosheck]

Quote, originally posted by Gotsol »

any updates? Great project!

Not much. Have a bunch of stuff to ship from EU and looking for the most inexpensive option. Once it all is here, I should be able to start tranny swap.

[Hello Bob]

A+++ on this project. You should get a PhD in Volkswagens when you're done with this. I was thinking of doing a 4-motion GTI myself, and your thread has encouraged me even more. Anyway you can post a gathered list of all the parts you would need? Also, how are you setting the coding? With a normal ROSStech VAG cable?

[maloosheck]

Quote, originally posted by Hello Bob »

Anyway you can post a gathered list of all the parts you would need?

As soon as I finalize the project, the parts will be listed. At this point it is hard to determine if I still need anything else.

Quote, originally posted by Hello Bob »

Also, how are you setting the coding? With a normal ROSStech VAG cable?

Now, this is an excellent question, but I do not know the answer. Everything can be coded with VCDS, but the list of modules that need to be recoded is still unknown.

[Hello Bob]

Bro- you're my hero. I will reward you with my hot asian wife after this project is over.

[maloosheck]

Quote, originally posted by Hello Bob »

Bro- you're my hero. I will reward you with my hot asian wife after this project is over.

If my wife reads that, the project will never be finished, because she will kill me first .

[Hello Bob]

Quote, originally posted by maloosheck »

If my wife reads that, the project will never be finished, because she will kill me first .

If MY wife reads that, I won't be able to read the rest of your write ups!

[Teknojnky]

any updates?

[maloosheck]

Quote, originally posted by Teknojnky »

any updates?

Hopefully by the end of March I should have all I need for tranny swap in my hands.

[jaah]

Hi..

I found some weird oil leak (maybe) from bevel box.
http://tos.pp.fi/images/album/vuoto/
^It needs / to the end, and then the adress should work.

Did you have any pictures; if there is some kind of breather tube or something in bevel box or gearbox?

I checked oil levels: normal
Thanx

ps. I also updated my front bumber:
http://tos.pp.fi/images/album/puskuri//

Modified by jaah at 9:00 AM 2-26-2009

Modified by jaah at 9:00 AM 2-26-2009


Modified by jaah at 9:25 AM 2-26-2009

[maloosheck]

Quote, originally posted by jaah »

I found some weird oil leak (maybe) from bevel box. http://tos.pp.fi/images/image/vuoto/DSC00104.JPG

What is this wire connected to? Oil level sensor in the oil pan?

[jaah]

Quote, originally posted by maloosheck »

What is this wire connected to? Oil level sensor in the oil pan?

Yes thats it

[jaah]

I found this from etka, 5B

There is a breather.
Maybe I have just a little hope, and it was frozen and then just a few oil comes out.


Modified by jaah at 7:42 PM 2-26-2009

[maloosheck]

Update: ok, I found a fuel tank and a shaft. And Rich from oempl.us offered his help with shipping everything to US. The last parts missing are rear hubs, which I can source here.

So hopefully next winter / snow driving will be easier with a little help of 4Motion...

[EL_3grab]

All the best

[Zupek]

sorry if this is common knowledge already, but you'll need the front diff out of a AWD car and if you use a FWD bell housing, you'll need to rip it all down and swap the AWD front diff in....

Again sorry if its common knowledge I just ran through this with my syncro... I put O2J gearset in my 02c.

[not SoQuick]

pm sent