Consolidation of Information: Haldex into Corrado. (02m, Syncro)

[JamesS]

Well eventually I would like to have a mk2 rear crossmember and gas tank... wouldn't we all.

But first I have to finish up this 02m

[pileofredparts]

I dont have the time or money to try and source stuff from Europe. It is a pain in the ass and people are unreliable.

you will spend more time (which is =$) ****ing around with the wrong **** than if you just did it right

passat gas tanks and floor pans dont fit corrados. neither do the rear beam mounting plates. get the right parts, bolt them in and enjoy the car. rather than hack something together

[cata]

^thank you for confirming this. Deff not touching that Passat floorpan anymore.

[pileofredparts]

^thank you for confirming this. Deff not touching that Passat floorpan anymore.

golf 2 stuff is the only stuff that fits, and even that needs minor modifications.

[JamesS]

If I run vr6 hubs redrilled to 4x100 in g60 spindles I am assuming I would use g60 wheel bearings? From what I can see the wheel bearings themselves are the same but they mount differently- although this would probably be the difference between + suspension and normal suspension.

Just trying to make sure I order the right parts.

[MrDave]

Corrado syncro using Passat mounts, crossmember and fuel tank.








Build thread.

Located up in Edmonton, if somebody wants to take a closer look at how the parts don't fit togeather.

-Dave

[HavokRuels]

Damn son is that your fuel tank in the last pic??? Switch to a fuel cell.


Sent while sitting on my ass VIA my iPad

[JamesS]

Corrado syncro using Passat mounts, crossmember and fuel tank.


Located up in Edmonton, if somebody wants to take a closer look at how the parts don't fit togeather.

-Dave

And if you used the mk2 mounts you wouldnt have to do those modifications to the body... although Im sure you know this. For someone with your fabbing skills it doesnt seem like much to use the 4 bolt axle mounts compared the just bolting in the 3 bolt ones.

[JamesS]

Damn son is that your fuel tank in the last pic??? Switch to a fuel cell.


Sent while sitting on my ass VIA my iPad

Fuel cells are lame and put the weight too high IMO unless they are custom made.

[eodtech]

If I run vr6 hubs redrilled to 4x100 in g60 spindles I am assuming I would use g60 wheel bearings? From what I can see the wheel bearings themselves are the same but they mount differently- although this would probably be the difference between + suspension and normal suspension.

Just trying to make sure I order the right parts.

Yes the g60 bearings will work.

[MrDave]

To fit the rear diff and rear subframe, at an absolute minimum, the spare tire well needs to be removed.

To fit the mk2 syncro or the B3 syncro tank, the rear floor needs to come out. By the time you're doing that sort of thing, fitting the B3 4-bolt mount is really nothing.

I wanted to run a factory-type fuel tank, not a fuel cell. As it stands, to insure the car I had to have a safety inspection. I mentioned nothing about modifying the car for AWD, the mechanic mentioned nothing about the car being modified or anything looking out of place. I'd say that's a good sign.

The Passat tank is a hemeroid on the back of the car.
Here's another one:


He made it fit with the mk2 syncro floor.


And is running the Passat crossmember.


This thread:Corrado-newbie-and-another-AWD-corrado-build

-Dave

[HavokRuels]

To fit the rear diff and rear subframe, at an absolute minimum, the spare tire well needs to be removed.

To fit the mk2 syncro or the B3 syncro tank, the rear floor needs to come out. By the time you're doing that sort of thing, fitting the B3 4-bolt mount is really nothing.

I wanted to run a factory-type fuel tank, not a fuel cell. As it stands, to insure the car I had to have a safety inspection. I mentioned nothing about modifying the car for AWD, the mechanic mentioned nothing about the car being modified or anything looking out of place. I'd say that's a good sign.

The Passat tank is a hemeroid on the back of the car.
Here's another one:


He made it fit with the mk2 syncro floor.


And is running the Passat crossmember.


This thread:Corrado-newbie-and-another-AWD-corrado-build

-Dave

Your car is so clean, you should have just removed the spare well in its entirety.


Sent while sitting on my ass VIA my iPad

[JamesS]

Your car is so clean, you should have just removed the spare well in its entirety.


Sent while sitting on my ass VIA my iPad

Its not his car...


But anyways, I think that the passat tank could be overcome easily with thinking out of the box. What about just adding a rear valence to at least hide it?

Yes the g60 bearings will work.

Thanks

[MrDave]

But anyways, I think that the passat tank could be overcome easily with thinking out of the box. What about just adding a rear valence to at least hide it?

That's the plan, just not there yet.

I mounted my amps in what was left of the Passat's spare tire well.
Covered that with a shortened cover plate from a B3 wagon.

-Dave

[JamesS]

The more I look at it the more I just want to say FFFF it and put in a fuel cell (but mount it low):

[raddo]

Now your thinking like a fabricator. Fuel cells are easy to make so why not make one to fit since your going to all this trouble to make your car syncro anyway. That's my thought on the whole fuel cell topic anyway. I wish my house would stop falling apart so I can get my project underway

[JamesS]

I have finally finalized in my mind the plan for the rear end. Looking at PSUCorrado's syncro swap again I realized that grafting floor pans and trying to source european parts just isn't worth it when it is so straightforward to just do a custom setup. The passat setup is a compromise and offers no benefit compared to a fuel cell setup. I have decided that I would much rather have a fuel cell to fill up in my trunk then a tumour on the back of my car.

All I am going to do is remove my spare tire well, mount up the axle using the mk2 3 bolt mounts and then weld in the differential support. Then I will put in a 12 gallon or 15 gallon fuel cell but mount it behind the diff and as low as possible. Doing it like this will make it MUCH easier and straightforward. All I need now is a fuel cell, mk2 axle mounts, haldex axle conversion and differential support.

Doesn't mean much to other people, but I am pretty happy I finally have a definitive plan to work towards.

[JamesS]

Quick update of the original post, added some pics and info.

[VRT]

Any question You need to have answered? I think I have a good handle on it

[MrDave]

James,

the 3-bolt rear beam brackets from a Quantum Syncro Wagon can also be used on the mk2/mk3/corrado.

http://forums.vwvortex.com/showthread.php?4507939

-Dave

[JamesS]

Any question You need to have answered? I think I have a good handle on it

As of now I think I am good, but I do appreciate the offer. I'm sure once I get down to the actual swap I'll need to send you a couple PMs

James,

the 3-bolt rear beam brackets from a Quantum Syncro Wagon can also be used on the mk2/mk3/corrado.

http://forums.vwvortex.com/showthread.php?4507939

-Dave

Thanks for the info. Will add it to the thread. Anyone looking to do a syncro/haldex swap should definitely check out your thread on the CCC- you did a great job of the write up and I appreciate the documentation you did.

[MrDave]

For JamesS:
syncro install in mk3, bus fuel tank, scratch-built rear diff-hanger/crossmember.

http://forums.vwvortex.com/showthrea...yncro-to-a-MK3






I wouldn't want to install a fuel tank in the trunk like that, definately wouldn't in the hatch of a Corrado, but it is food for thought.


-Dave

[JamesS]

For JamesS:
syncro install in mk3, bus fuel tank, scratch-built rear diff-hanger/crossmember.


-Dave

Thanks! I love the way that setup was done minus the fuel tank. Makes sense... don't really need the crossmember and there is no need to fab the points to bolt it in when you can just weld it. I am thinking 2"x1" chromoly would do the job perfectly and stiffen the chassis considerably.

[JamesS]

Quick update with the difference between a 4 cylinder 02a axle and an 02m axle:



This is why if you are staying with 4 bolt hubs you need to have them machined:



And... should have some more progress in a couple weeks.

[JamesS]

Looks like the transfer case is going to have clearance issues.



Likely need to source a syncro downpipe... anyone have any insight?

[Sr. Karmann]

Likely need to source a syncro downpipe... anyone have any insight?

Make one.

[pileofredparts]

i have one for $200 shipped

[1956dub]

And the rest of my haul:

You know your sick when a picture like this gets you excited!!

[JamesS]

Have a question if anyone has insight...

First, I am looking at the internal slave cylinder of the 02m and my clutch line from USP. It has one female fitting and one banjo fitting... Im not sure how this is compatible even though it was specified for Corrado to 02m slave. It looks like I need a piece which fits between the 02m male slave and the male line


But, as far as I can see the Corrado master does not use a banjo fitting.


I would look up the part # but my pirated etka has been giving me troubles.


As far as an update I am very happy to get a syncro downpipe! Thanks to Dave for shipping it out to me quickly, really appreciate it.

Blurry pic but shows how it goes around the transfer case.

[dasbeast3.0]

My usp line had a female end and the clip-in male end. I'd send it back and get the old style, especially if it didint come with the banjo bolt u need. That piece you need is called a breather btw, just buy it new w/ new o rings, clips and bleeder, its cheap. They always leak, new wont give ya trouble.

[JamesS]

Thanks for the info. I do have the bango bolt, I wonder whether I can thread that into my master....


The bleeder block is PN 1J0 721 468 C if anyone comes across this in the future.

[hendrikbmx]

Hi. first of all Im from Europe, car is 94 vr6 , so I think I don't have too much trouble finding euro parts.
I would like to stay as OEM as possible.

When going the Rallye floorpan way, what cross member and what fueltank can I mount?
If the only OEM fueltank option is the rallye one and I cant find it , I will use the 70 liter ( please say which one ) and after I pass MOT I will fabricate a fuelcell , BUT other parts must be OEM.

Is there a difference between syncro rearaxle assemblys from different models mentioned here?

also, what is the p/n for the 3 bolt brackets that is a straight fit?

My plan is to gather most of the parts for the haldex swap, then do a documented/detailed plan, and ask for a permission from where we register our cars, and then start building it, taking photos of every step so when I go to get it registered as AWD I dont have any troubles, the laws are really strict here.

please copy paste this, so its understandable in one way

rallye floor pan OEM way:

crossmember from .......... /........
fueltank options : ........../........
syncro rear assembly: ........./.........
part number for 3 bolt brakcets :
and the spoonlike looking parts that bolt onto :

thanks.

[JamesS]

rallye floor pan OEM way:

crossmember from .......... /.......Rallye or other mk2
fueltank options : ........../........ syncro 50l MK2
syncro rear assembly: ........./......... Passat, All mk2 syncro
part number for 3 bolt brakcets : c191 505 129
and the spoonlike looking parts that bolt onto :c191 505 119

thanks.

[JamesS]

Did some more work this weekend. Mk3 subframe is in for test fitting.


This is where the mk3 subframe has to be modified to match up to the Corrado:


USP conversion line did work... just worried me initially since it uses a banjo bolt compared to the factory threaded hard line


Lottsa room for the driveshaft....eventually



Also began working on the rear output shaft which was damaged when the transmission was removed. I think whoever took it out took an air hammer to it or something Certainly has caused me some grief.


Luckily I was able to source a new cast piece for 70 bucks as opposed to the $500 my local VW dealer wanted for it But the radial seal is still stupid expensive at $80 for a piece of rubber

Finally, some people might be interested in my powder coating setup. Pretty ghetto but it gets the job done.

[sdezego]

This is where the mk3 subframe has to be modified to match up to the Corrado:

What I usually do with that rear Kframe strut is cut out a section and then weld it up. A little more work, but prevents you from having to use washers, etc.