Looks like I'll be doing some fab work then. How much does Polo boxs run anyway?
~$110.00 and WAYYYYYY easier to do than the MK4 box.
JamesS has the assembled unit. I know of a few others with it too.
You can buy the pieces from ECS. That is where I bought mine.
Although this isn't really a build thread I have some updates on my own awd conversion
Have haldex mount and rear o2m mount coming from Europe (couldn't pass up a deal for things I would need eventually).
Also, bought an eastwood powder coater and a ****ton of powdercoat for little brackets (toaster oven or less in size).
Finally, I am still having trouble sourcing a reasonably priced rear pinion carrier casing that is damaged on my o2m. Might go ghetto on it and use JB weld just to stay on budget.
I have three key things left:
1. Front o2m mount ( hoping to order this from sdezego in the next couple weeks)
2. Clutch, flywheel etc
3. Shortening o2m axles (this is going to be impossible to get done reasonably locally, does anyone have any suggestions of where to send them out? I could get tig welding done for me, but I'm clueless on the process of shortening the axles properly.
If you are wanting to keep the standard mk2 track and 4 lug then you could get your stock hubs resplined to the bigger vr splines. That is what is being done to mine as I type this. No redrill and I can run the bigger splines.
I'm not talking about shortening of the driveshafts, Im curious about the hub combinations and interchangeability using the o2m driveshaft. From what I have read so far I am using:
Shortened O2M driveshafts, o2m innter CV, 4x100 spindles/hub, G60 outer CV.
But I haven't looked at the physical pieces to know if it works. All I know is I need narrow track and 4x100 to keep my borbets.
actual Axle spline is different on 02m vs MK2/3, so you can't do what you are proposing.
Just the Outer CV spline on outer 02m CV = 5 Lug C/MK3 Vr which is why you can use 02m axles in VR hubs
Damn, never even really thought of that. Sucks that all the machine shops in my area are either incompetent or expensive as ****. I think that welding and redrilling hubs would be a lot easier to get done then resplining. Too bad no one sells blank vr hubs... or that adaptec doesn't make dual pattern big spline hubs.
You don't really "have" to weld to add 4x100 (provided you are not running the ABS rings), although it would be my pref. If you are ABS, then you do have to weld and redrill.
Adaptec sells (or used to) "Doubled up Hubs" that have both patterns drilled. Not sure if they are 4 cyl spline or 6 (seem to recall 4), but you may want to check with them as another potential option.
$100 per hub to have them resplined properly does not seem like a bad deal.
I really need to do some physical mock ups of the cs/hub/ axle situation.
Some sources say I can use the stock g60 hub and g60 outer cv with the 02m axle, whereas other sources say I need to use the vr6 outer cv and resplined hub.
I haven't personally looked at it yet but it is on my to do list. Seems like the more I read the less I know.
02m Axle Spline <> 02a Axle spline, so you can not just use a G60 outer on the 02m axle
...unless you machine and weld the end of the 02a axle onto the 02m axle to form a hybrid merge.
The 02m outer CV does have the same outer hub spline as the VR, but the physical axle splines are different where the CV attaches to the axle.
Last edited by sdezego; 10-03-2012 at 04:38 PM.
I would have honestly let you have it haha, but I could deff not stand to see all that get wasted at the crusher. So I guess it was meant to be lol.
Initially I was thinking synchro with upgraded diffs for simplicity, but then again, I don't know that much beyond the basics with this stuff, ultimate power capabilities, etc. If it's some way possible to get the Haldex controller to communicate with a Lugtronic SA, then it's O2M VRT or bust
My main concern is the fuel tank, I want to plan for a low key oem install, so I'd like to source a 45L euro tank for it. But I don't know if it'll for sure bolt up to the Passat floor pan.
Last edited by cata; 10-04-2012 at 01:38 AM.
Since you have a vr6 my advice to you would go the route DUBZAK wants to take. Cut out the rear spare tire well, weld in the syncro passat beam and use the larger tank. Sure you will have to deal with the tumor out the back but I am sure it will be worth it.
I was also considering myself doing a passat syncro install and trying to section the tank and plastic weld it back together. I think this would be possible with some creativity.
Finally, on the syncro vs haldex route if I were you I would go haldex. 1st of all the syncro transmission has a 4 cylinder housing to begin with so you cannot use it without sourcing parts. Do what I am doing- an 02m swap first and let the rear shaft spin free til you figure out the rear end. This is the easiest and will allow you to limit down time. As far as haldex management you can cheap out and get a knob that controls power to the rear or go all out and have some cool electronic standalone to manage launches etc.
If you do it in stages you can limit the upfront hit of the conversion and also not get discouraged by parking your car for a couple years.
1)When will you put this to the test? Wouldn't have to try it on a unicorn tank, could prolly do it with any VW tank from that era
2)By changing its shape to hide its bottom-end, you might have difficulty mounting it, as the straps wouldn't work the same way.
Is there any advantage to using this setup over the Euro stuff? I might just turn this into a dece support vehicle