Syncro / Haldex conversion questions

[Kloyvd]

I am doing a Syncro to Haldex coversion on my mk2 and have a couple of questions. Tried searching an looking for answers, but I couldn't really find any. So here goes:

1: Do the electronics in the Haldex diff need to be connected to a controller or anything for it to work? Will it work without connecting it? And what are the two hoses for?

2: I am going to be running a G60 engine. Will an angle drive from a VR6 engine work with a 4 cylinder engine or are the angles different? Can I use the angle drive from a G60 syncro with an 02M gearbox and Haldex diff?

3: What to do with the electronic speedo issue? Will a mk3 speedo or a digifiz do it?

4: Wich parts do I need in order to convert to a hydraulic clutch?

[Agtronic]

There are many guys on here who are more knowledgeable than I, but not sure how often they come on here.

It sounds like you still have a fair amount of research ahead of you still, 'cause some of your questions are not necessarily Haldex related.

Basic answers:

1) The Haldex coupling is normally disengaged until its controller has decided it needs to engage. The controller is mounted on the Haldex. It monitors wheel speeds, steering angle etc. via the canbus, and engages when it sees fit. If you want to keep this self regulating function, you will need to fit ABS electronics from a quattro car, and ideally all the sensors related to stability control (yaw, steering angle). You can skip these sensors and disable them with VAG-com if you know what you're doing.

Otherwise you can run a standalone Haldex controller such as the one offered by F-town streetmachines.

As for the angle drive, you cannot simply bolt one onto a FWD tranny. Ideally you would run a 4 cyl. 02M quattro box. You can get them in 5 or 6 speed. Installing one requires some work, but it is a definite upgrade from the 020, 02A or 02C.

Hydraulic clutch is the same as for any, just need to cut a hole in the firewall and use a reinforcement bracket, then bolt on a hydraulic master. Then you
Just need the correct line to hookup to whichever style slave you end up with.

Speedo is standard electronic VW. MK3 should work fine.

Hope that helps!

[Kloyvd]

Thank you verry much Agtronic! One more question though: Wich shifter box can I use for the 02M gearbox? Do only the 02M ones fit or could I use a nother one?

[VRT]

02m for a 02m tranny

[Kloyvd]

Will a 02M DXW gearbox off a Audi A3 Quattro work?

[polov8]

So long as it's from a 4 cyl car, it'll fit your engine, you will need to make a gearbox mount, or source one, but that will bolt to your engine, and has the right ratio for the haldex Diff.

[Kloyvd]

I am going to buy a new flywheel for the project, but dont really know what type i need. I am using a Passat G60 engine(PG) and a 02M DXW gearbox. Any ideas?

Right, found out that I will be needing a G60 flywheel. But not really sure wich clutch would fit bothe the gearbox and the G60 flywheel. Help please?

[d-bot]

I am going to buy a new flywheel for the project, but dont really know what type i need. I am using a Passat G60 engine(PG) and a 02M DXW gearbox. Any ideas?

Right, found out that I will be needing a G60 flywheel. But not really sure wich clutch would fit bothe the gearbox and the G60 flywheel. Help please?

Your flywheel needs to match the transmission you are using. Not sure if the G60 flywheel will work or not. If this will work then you need the clutch set-up that fits on the G60 flywheel (228mm) and matches the 02M transmission. If you had an 02C I could tell you that you could use a g60 flywheel and a mk3 vr6 clutch.

Also, whatever front gear box you use, it needs to match the rear diff as well to ensure correct gearing as some have alluded to.

[TBT-Syncro]

Your flywheel needs to match the transmission you are using.

what he said.

clutch needs to match transmission, flywheel needs to match clutch

PG/G60 228mm is not the correct answer.

[Kloyvd]

Does anyone know if the A3 flywheel would fit the G60 engine?

[TBT-Syncro]

Does anyone know if the A3 flywheel would fit the G60 engine?

4cylinder flywheel will fit 4 cylinder motor
6 cylinder flywheel will fit 6 cylinder motor.

[Issam Abed]

4cylinder flywheel will fit 4 cylinder motor
6 cylinder flywheel will fit 6 cylinder motor.

to expand on this 4 cylinder flywheel from a timing belt VW827 or EA113 motor will bolt up the G60 engine so any flywheel from an A3 built before 2007 will bolt up to your PG motor. The flywheel from the EA888 TSI motor is 8 hole and will not.

[stef 4x4]

The most simple way for you is to use a 02C gearbox together with the angle drive of a VAG 4 motion model with 02C gearbox.
You don't have to change anything in the front of your car if you use all the stuff from a rallye golf or G60-syncro.
If you are going to use a hydrolic clutch you should also use the pedal box out off a rallye golf or a corrado.

[Kloyvd]

Anyone know what the two hoses on the Haldex diff are for?

So far so good, waiting for the kit from Dutchbuild:

[rallye1.8t]

2 hoses are vent hoses.