mk5 Jetta/Golf 4motion conversion findings

[Vegeta Gti]

mike i may be coming across an R32 to strip. gotta see if it's gonna get bought back. 04 R32, if so..the tank is yours. give me a couple weeks to find out if it's a go, cos i am gonna pretty much keep everything from the car. i will talk to you when you get here this weekend

[EL_3grab]

Wouldn't it be cheaper to source half Golf Variant and ship it?

I'm thinking this way; I've found a lot of wrecked TDI 4motion hatchback on the net

Whish you all the best

[maloosheck]

Quote, originally posted by Vegeta Gti »

mike i may be coming across an R32 to strip. gotta see if it's gonna get bought back. 04 R32, if so..the tank is yours. give me a couple weeks to find out if it's a go, cos i am gonna pretty much keep everything from the car. i will talk to you when you get here this weekend

Chris, the biggest PITA with the tank is it must be for DEEZHL... If I was sure both gasoline and diesel tanks are the some I would not bother and grab one from US-spec mk5 R32...

[maloosheck]

Quote, originally posted by EL_3grab »

I've found a lot of wrecked TDI 4motion hatchback on the net

Where?

[cb1111]

Cool!

[traderdesk]

Just curious on how you will activate your stock ECU to think it is now running the haldex? Have you compared the code on your stock ECU to a ECU that is 4motion/haldex on? If it almost the same and only a two digit change i.e. 03 34 23 4f 23 etc and you need only one number to be switch like 0F to be substitute to 07 will your ECU accept the change? I will be very interested to see if you have done this...

[Marshmallow Man]

Quote, originally posted by traderdesk »

Just curious on how you will activate your stock ECU to think it is now running the haldex? Have you compared the code on your stock ECU to a ECU that is 4motion/haldex on? If it almost the same and only a two digit change i.e. 03 34 23 4f 23 etc and you need only one number to be switch like 0F to be substitute to 07 will your ECU accept the change? I will be very interested to see if you have done this...

Interesting....didn't think about that one

[maloosheck]

Quote, originally posted by traderdesk »

Just curious on how you will activate your stock ECU to think it is now running the haldex? Have you compared the code on your stock ECU to a ECU that is 4motion/haldex on? If it almost the same and only a two digit change i.e. 03 34 23 4f 23 etc and you need only one number to be switch like 0F to be substitute to 07 will your ECU accept the change? I will be very interested to see if you have done this...

ECU has (to my knowledge) nothing to do with Haldex. Haldex has its own independent controller that uses signals from misc sensors over CAN-BUS. The ECU does not even have to know about the existence of Haldex. This is based on what I have read about Haldex. The reality might be of course different.

[rallydiesel]

You are truly insane.

[maloosheck]

Quote, originally posted by traderdesk »

Just curious on how you will activate your stock ECU to think it is now running the haldex?

I am trying to figure it out over here

[maloosheck]

Ok, here is few more shots and status update.

All the goodies collected so far (a starter is on its way):

Transmission:

Transfer case:

Haldex + Rear diff:

Rear subframe:

Rear axles:

[keisuke_z]

This is pretty cool - I've been asking around trying to get more information on this... definitely confirmed the 4motion setup from a MkV R32 doesn't mate up to the 2.0T GTI DSG... however, with the new 2009 Audi A3 2.0t Quattro... Anyone have ideas on whether this could be the ultimate "bolt-on" project?

[EL_3grab]

maloosheck, can you get me the DSG part# from the Audi TT-S

Starting parts hunting next week, aiming for whole R32 drivetrain, rear floor pan and fuel tank, minues the trans

I wish the FWD DSG can be tapped for the transfer case, hopefully I find out next week

[maloosheck]

Quote, originally posted by EL_3grab »

maloosheck, can you get me the DSG part# from the Audi TT-S

Is it already in ETKA? If so, I can probably try to find it.

Quote, originally posted by EL_3grab »

Starting parts hunting next week, aiming for whole R32 drivetrain, rear floor pan and fuel tank, minues the trans

Are you located in NA? So far I have heard about ONE totalled mk5 R32...

Quote, originally posted by EL_3grab »

I wish the FWD DSG can be tapped for the transfer case, hopefully I find out next week

If nothing has changed since my '05 FWZ transmission - you CANNOT tap transfer case to FWD transmission. The main reason is the AWD tranny has 2 separate output shafts on the right side: one for the front right axle (internal) and one for the rear drive shaft (external). Which means the case is most likely different and so is the differential.

[maloosheck]

Quote, originally posted by Audi4u »

I wonder how much it weighs

I will do the weight comparison when I will be installing all my parts.

[EL_3grab]

FWD DSG, you can see the casted 4 holes for the T-Case

AWD DSG, drilled holes

FWD DSG side view, grinding that bulge down

AWD DSG, side view

T-Case, side view,

I need to see whats underneath the right axle flange on the FWD DSG, a sticking shaft or a shaft housing like the AWD DSG?


Modified by EL_3grab at 6:24 PM 10-3-2008

[maloosheck]

Quote, originally posted by EL_3grab »

I need to see whats underneath the right axle flange on the FWD DSG, a sticking shaft or a shaft housing like the AWD DSG?

That I do not know. But if you remove the flange, you should see. However, I highly doubt the differential has that second shaft output.

[Vegeta Gti]

hey mike how is it comin?? can't wait to be back in DC to see this in person..we can compare projects :]

mis sya man!! looks good!!!!

[maloosheck]

Quote, originally posted by EL_3grab »

maloosheck, can you get me the DSG part# from the Audi TT-S

'09 TT-S 2.0 Quattro Gasoline (CDL) trannies:
DSG: KRF (02E 300 012 007), KNN (02E 300 012 CF 007
6MT: KNZ (02Q 300 011 CE)

'09 TT-S 2.0 Quattro Diesel (CBB) trannies:
6MT: KNW (02Q 300 011 CD)

Modified by maloosheck at 10:42 AM 10-3-2008

[maloosheck]

Quote, originally posted by Vegeta Gti »

hey mike how is it comin?? can't wait to be back in DC to see this in person..we can compare projects :]

It is going pretty well. Tracked the flywheel/clutch kit, now looking for front axles and shaft (found some, negotiating the price ). Everything is in EU, so I am looking for some inexpensive transportation options. If I get the axles/shaft next month, I will try to send everything to get it before Xmas. And swap the tranny asap.

Man, I am going to need you here to help me out with all that crap when I collect everything.

[EL_3grab]

Quote, originally posted by maloosheck »

'09 TT-S 2.0 Quattro Gasoline (CDL) trannies: DSG: KRF, KNN 6MT: KNZ '09 TT-S 2.0 Quattro Diesel (CBB) trannies: 6MT: KNW

Thanks, any part# to check how much

[maloosheck]

Quote, originally posted by EL_3grab »

Thanks, any part# to check how much

Added above. But the part no. are different depending on the market. I would go and ask about KNN. This is the one used with 2.0L CDM engine (265HP).


Modified by maloosheck at 10:50 AM 10-3-2008

[EL_3grab]

Finally!!!!!, the 200hp 2.0TFSI is available with 4motion and DSG

Check the 09 Audi TT, they list it as an option on Audiusa.com and Audi.de

Can't wait to see a salvage one

Modified by EL_3grab at 8:25 PM 10-3-2008

[maloosheck]

Quote, originally posted by EL_3grab »

Can't wait to see a salvage one

It will be as rare as totalled mk5 R32... I am waiting for 200HP Diesel version .

[maloosheck]

I know it does not have anything to do with the 4M, but here is some info: 5MT starter is different than 6MT starter. Plus 6MT diesel starter is different than 6MT gasser starter. Diesel starter needs twice as much juice to start the engine...

[DHill]

Quote, originally posted by maloosheck »

Ok, here is few more shots and status update. Haldex + Rear diff:

Wow they really cleaned that up and made it clean and modular. The bolt-on transfer case seems like a no-brainer. That splined shaft adaptation for the axle output is a great idea.

Cars are destined to become as self explanatory as Legos.

[maloosheck]

Update:

Just got few bolts today and attached Haldex to subframe. Over the weekend I will try to attach the rear axles and what is more important transfer case to transmission. There is only one problem: there is one bolt attaching right axle flange to the differential that requires super long Allen M6 bit: 10-12 inches long. I need to ask at local VW if I could borrow one for few minutes.

[volcomska]

'scribed..

[SBAtdijetta]

Quote, originally posted by maloosheck »

Update: Just got few bolts today and attached Haldex to subframe. Over the weekend I will try to attach the rear axles and what is more important transfer case to transmission. There is only one problem: there is one bolt attaching right axle flange to the differential that requires super long Allen M6 bit: 10-12 inches long. I need to ask at local VW if I could borrow one for few minutes.

You should be good friends with the local dealers by now... Hopefully they will oblige and let you borrow it so you wont have to buy it for one time use...

Keep us posted, and good luck

[maloosheck]

Quote, originally posted by SBAtdijetta »

You should be good friends with the local dealers by now... Hopefully they will oblige and let you borrow it so you wont have to buy it for one time use...

I really wish, but it is not that easy. I am not a frequent visitor at the dealership

[maloosheck]

Quote, originally posted by Audi4u »

Is it just me, or R32 uses rear subframe made of steel instead of alloy? I order the brake pipe from R32 that goes over the subframe from the left side to the right brake, and it does NOT fit. Fortunately, I can replace it for the one I need, so there is no problem, but I wonder why they changed subframe from alloy to steel: costs? safety?

[maloosheck]

Here is a reason why you cannot count on ETKA:

2 years of production, the recent update, and still nothing ...

[SBAtdijetta]

Agreed, they told me the BRM PD TDI turbo and CEBA CR TDI turbo were the same part #, I even saw it with my own eyes... but you already knew that!

[R32dreamer17]

due i live in centreville and my father's office is in sterling, any way i could see this some time. real impressed. would love to do a conversion on my mk4

[maloosheck]

Quote, originally posted by R32dreamer17 »

due i live in centreville and my father's office is in sterling, any way i could see this some time. real impressed. would love to do a conversion on my mk4

Mk4 is a complete different story. I am still not 100% sure I can complete my swap. Apparently, the chassis part over the fuel tank is different in FWD and 4WD Golf Variant. It bothers me a bit, but as long as do not have to touch the part where subframe is attached, I am fine.