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

    1. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      10-05-2012 12:13 AM #106
      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

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      95 urS6, 92 golf, 84 rabbit, 09 hypermotard, corrados
      10-05-2012 09:14 AM #107
      Quote Originally Posted by JamesS View Post
      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
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    3. Member cata's Avatar
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      10-05-2012 11:42 AM #108
      ^thank you for confirming this. Deff not touching that Passat floorpan anymore.

    4. Member
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      10-05-2012 11:50 AM #109
      Quote Originally Posted by cata View Post
      ^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.
      Cleary Coachworks

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    5. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      10-05-2012 07:26 PM #110
      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.

    6. 10-05-2012 09:32 PM #111
      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

    7. Member HavokRuels's Avatar
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      10-05-2012 09:39 PM #112
      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
      Guru Motorsports / europeein

    8. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      10-05-2012 09:49 PM #113
      Quote Originally Posted by MrDave View Post
      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.

    9. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      10-05-2012 09:50 PM #114
      Quote Originally Posted by HavokRuels View Post
      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.

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      10-05-2012 10:31 PM #115
      Quote Originally Posted by JamesS View Post
      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.
      My R32 swap and shaved bay jetta coupe build
      http://forums.vwvortex.com/showthrea...ding-the-beast

    11. 10-05-2012 11:44 PM #116
      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

    12. Member HavokRuels's Avatar
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      10-06-2012 12:00 AM #117
      Quote Originally Posted by MrDave View Post
      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
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    13. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      10-06-2012 12:03 AM #118
      Quote Originally Posted by HavokRuels View Post
      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?

      Quote Originally Posted by eodtech View Post
      Yes the g60 bearings will work.
      Thanks

    14. 10-06-2012 12:35 AM #119
      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

    15. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      10-07-2012 05:17 PM #120
      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):


      Last edited by JamesS; 10-07-2012 at 05:30 PM.

    16. Member raddo's Avatar
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      93 Corrado VR6T Haldex 2012 Tiguan
      10-07-2012 09:02 PM #121
      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

    17. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      10-14-2012 05:57 PM #122
      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.

    18. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      11-02-2012 07:03 PM #123
      Quick update of the original post, added some pics and info.

    19. Member VRT's Avatar
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      90 corrado 20/20 haldex, 2003 jetta
      11-02-2012 08:28 PM #124
      Any question You need to have answered? I think I have a good handle on it

    20. 11-02-2012 08:42 PM #125
      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

    21. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      11-08-2012 12:19 AM #126
      Quote Originally Posted by VRT View Post
      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
      Quote Originally Posted by 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
      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.

    22. 12-17-2012 04:49 PM #127
      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

    23. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      12-17-2012 07:37 PM #128
      Quote Originally Posted by MrDave View Post
      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.

    24. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      12-24-2012 12:10 AM #129
      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.

    25. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      12-27-2012 11:13 PM #130
      Looks like the transfer case is going to have clearance issues.



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

    26. Member Sr. Karmann's Avatar
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      12-28-2012 12:14 AM #131
      Quote Originally Posted by JamesS View Post
      Likely need to source a syncro downpipe... anyone have any insight?
      Make one.
      Quote Originally Posted by crazynorweegian View Post
      Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
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    27. Member
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      12-28-2012 09:17 AM #132
      i have one for $200 shipped
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    28. Member 1956dub's Avatar
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      12-28-2012 01:29 PM #133
      Quote Originally Posted by JamesS View Post
      And the rest of my haul:
      You know your sick when a picture like this gets you excited!!
      Quote Originally Posted by Rento_VW View Post
      Needs a real Zender wing.... lower it.

    29. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      01-10-2013 09:47 PM #134
      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.

    30. Member dasbeast3.0's Avatar
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      01-10-2013 11:19 PM #135
      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.

    31. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      01-11-2013 12:27 AM #136
      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.

    32. 01-12-2013 07:47 AM #137
      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.

    33. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      01-13-2013 10:39 PM #138
      Quote Originally Posted by hendrikbmx View Post

      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.

    34. Member JamesS's Avatar
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      91 JDM Corrado, 98 Subaru Legacy
      01-13-2013 10:51 PM #139
      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.


      Last edited by JamesS; 01-13-2013 at 10:54 PM.

    35. Member sdezego's Avatar
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      01-14-2013 12:06 AM #140
      Quote Originally Posted by JamesS View Post
      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.
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

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