4Motion Project Begins

[lour32]

Yes, the Haldex is a unit that does get connect into the cars Can-bus system. The Haldex takes signals from certain modules to active the clutch pack to engage the rear wheels when any slip is detected.. I also got the final pieces to the puzzle today, my rear aluminum sub frame and the trans/bevel case. Here are some pics:

Aluminum Rear sub frame:


Trans\Bevel case (some call it transfer case or angle drive)

[SDbirdman]

Subscribed!

[Cranford803]

[v b chil-n]

Good luck with the swap. Are you planning on swapping the front brakes over to the 4 motion larger brakes?

[lour32]

No, I am trying to save weight, since I am added the rear Haldex which is not lite. I am using the Aluminum rear subframe instead of the steel version that the V6 Passat comes with to save more weight. Maybe later I will get a upgraded front brake setup, like Forge 14" kit or Stoptech's kit. We will see. I just cant wait to launch this K04 sucker from 4-5k rpms at a light, LOL

[Bill6211789]

No, I am trying to save weight, since I am added the rear Haldex which is not lite. I am using the Aluminum rear subframe instead of the steel version that the V6 Passat comes with to save more weight. Maybe later I will get a upgraded front brake setup, like Forge 14" kit or Stoptech's kit. We will see. I just cant wait to launch this K04 sucker from 4-5k rpms at a light, LOL

you need gopro footage!!!! Bc of you Lour32 i gave another $$$$$ to spend on my car next yr ill be joining you with 4Motion. Have you looked into the haladax control units from NAM?

[Wolfpack Noob]

Good luck!

[PSU]

This looks promising.

[Incrementalg]

No, I am trying to save weight, since I am added the rear Haldex which is not lite. I am using the Aluminum rear subframe instead of the steel version that the V6 Passat comes with to save more weight. Maybe later I will get a upgraded front brake setup, like Forge 14" kit or Stoptech's kit. We will see. I just cant wait to launch this K04 sucker from 4-5k rpms at a light, LOL

Any risk using the aluminum rear subframe instead of steel? Will the addition of the 4mo setup create flex in the rear subframe? Aluminum doesn't flex very well....it breaks.

Is the aluminum subframe used in the non v6 4mo offered in other countries?

[lour32]

I think you are confused a little bit. This rear sub frame is only used on the 4motion setups. The FWD rear sub frame is totally different. Yes the aluminum one is used on certain models thru out production years... Like on some Audi S3, Passat B6 TDI (EU), Audi A3 used the aluminum version. I think they are all steel ones now, just because the aluminum one is just so much more expensive. If you went to buy the aluminum version its like $600-$800 more than the steel version + the aluminum one is stronger and a lot lighter....

[lour32]

you need gopro footage!!!! Bc of you Lour32 i gave another $$$$$ to spend on my car next yr ill be joining you with 4Motion. Have you looked into the haladax control units from NAM?

Yes, a friend of mine has the Gopro and I will definitely being filming some take-offs, LOL

[lour32]

Bill6211789, the hardest part is finding all the right parts... This was a real challenge and took me a couple of months to gather all the right pieces. Also shipping from over seas and having to go thru US Customs is a nightmare when the shipment is traveling by cargo ship.

[maloosheck]

I see you have started your 4M swap. Good.
BTW not sure why you cannot use the alloy rear subframe.

[Incrementalg]

I think you are confused a little bit. This rear sub frame is only used on the 4motion setups. The FWD rear sub frame is totally different. Yes the aluminum one is used on certain models thru out production years... Like on some Audi S3, Passat B6 TDI (EU), Audi A3 used the aluminum version. I think they are all steel ones now, just because the aluminum one is just so much more expensive. If you went to buy the aluminum version its like $600-$800 more than the steel version + the aluminum one is stronger and a lot lighter....

Oh..Ok. I was thinking the aluminum subframe was from a fwd car. I wasn't aware that an aluminum awd subframe existed.

[maloosheck]

Oh..Ok. I was thinking the aluminum subframe was from a fwd car. I wasn't aware that an aluminum awd subframe existed.

A5 Jetta/Golf + B6 Passat/Tiguan 4Motion details:
http://forums.vwvortex.com/showthrea...rsion-findings

[lour32]

I hit a little bump in the road. The rear Passat Differential front busing mount sits out more than on the R, S3 etc.. So I had to order another rear aluminum sub frame that uses the same mount location as on the Passat. Take a look at these pics:

First pic is the wrong sub frame with diff mounted up. You can see the front diff bushing can not connect to sub frame.


This pic is of wrong connection circled in red:


This pic is the right bracket connection(the subframe I just bought today):


So, it looks like there will be a very expensive aluminum 4motion rear sub frame on the forums for sale (already in classifieds). But I priced it pretty cheap compared to what a new one goes for from dealer ($1100.00) This sub frame will work if you buy a rear differential from a R32, S3, A3 and even a Passat TDI (EU) as these have different rear diff than I do... Someone by it, LOL

[maloosheck]

Good to know, I was looking at Tiguan parts at some point and they are probably the same as in Passat.

[lour32]

Yes, you are correct Tiguan and Passat have the same rear sub frame. Good that you did not get that time..

[maloosheck]

Try selling the alloy subframe on mk5 R32 forum. The US-spec R32s use steel ones as far as I remember and maybe there will be a person interested in lowering the weight of the rear.

Speaking of alloys/steel the rear hubs are also available in both alloy and steel. I picked the alloy ones and I see your left one is made of alloy too.

[lour32]

True, I will try on the MK5 R32 classifieds.. Also I will try and sell my rear FWD bearing housings as they are also made of aluminum and the MK5 GTI and even MK6 FWD rear bearing housing are steel and about 3-4 pounds heavier each side

[Berish]

A very interesting project

[lour32]

Bolted the diff up to my 2nd rear sub frame and it fits perfect. Also got the cross over brake line clipped on...

[lour32]

Well, I got every part that I need to do the swap. It was a little time consuming to get all the parts because not all parts from 3.6 4motion work on the 2.0t Passat. Like the front passenger side drive shaft, you must buy a Passat B6 TDI European front passenger drive shaft version. The front driver side drive shaft that my 2.0t came with originally will work on the awd 6speed manual transmission so no need to buy different one. You also must use a Golf R bracket, this is the bracket that's supports the angle drive that attaches to the rear drive shaft. Golf R oil return line from turbo, front 3.6 4motion (R32 or Golf R will work also) sway bar and rear sway bar. Another hard part to find was a good working center drive shaft. All the ones I found had torn center bushing and if these are torn you can not just replace the bushing you have to buy the entire drive shaft which is way over $1200 new. VW does not sell this part separate from the drive shaft. I bought my drive shaft from Germany (used). I will be starting the swap the first week of July. I will take pictures and detail everything on here. Overall, this will be a great add-on to my build. It was just very hard to find all the right parts.

[SickTRed08FSI]

Hmm...this looks epic. Maybe I need to swap to M/T and then do this.

[TyrolSport]

Your PM box is full.....I replied to you regarding the spindle machining.

[Nikos_GR]

I can't wait to see it happening!

[bonestockgtx]

I'm loving the look of this! Could you help me out by posting part numbers for the two aluminum sub-frames? I looked at the tiguan and A3 p/ns and they seem to be the same as the one listed for the TDI 4motion passats in the EU. Not sure what I'm missing. Also, any possible way you could weigh the alu sub-frame? I'd be interested to know what sort of weight could be saved!

Thanks!

[filipinodawg]

does somewhereville mean somerville? if so i live like 20 minutes if possible i'd like to come take a look at this with my 4Mo because this is incredible! car looks sick too, GL

[lour32]

I'm loving the look of this! Could you help me out by posting part numbers for the two aluminum sub-frames? I looked at the tiguan and A3 p/ns and they seem to be the same as the one listed for the TDI 4motion passats in the EU. Not sure what I'm missing. Also, any possible way you could weigh the alu sub-frame? I'd be interested to know what sort of weight could be saved!

Thanks!

Audi A3/S3 has this rear Aluminum subframe part # 1K0 505 235 N

Passat 3.6 4motion subframe part # 3C0 505 235 L

[bonestockgtx]

Audi A3/S3 has this rear Aluminum subframe part # 1K0 505 235 N

Passat 3.6 4motion subframe part # 3C0 505 235 L

I'm looking for the part number on the second aluminum one you got. You said the S3/R one doesn't fit, so you went with the euro tdi passat one. That's the the p/n I'm looking for. I can't quite make it out in your picture

[lour32]

The part # for the Passat would be the 2nd part # listed. You can use the S3 subframe but you would need to use a S3 diff. It so happened that I bought a Passat 3.6 rear diff which uses a different casing so that is why I had to buy a Passat rear subframe..

[bonestockgtx]

The part # for the Passat would be the 2nd part # listed. You can use the S3 subframe but you would need to use a S3 diff. It so happened that I bought a Passat 3.6 rear diff which uses a different casing so that is why I had to buy a Passat rear subframe..

Perfect, thanks a lot.

Any possible way you could weigh and aluminum subframe? I'd be really interested to see what I can save. I have a 3.6 4mo so I'd be great to save some weight

[lour32]

I will try and get a weight of the Passat Aluminum rear subframe but it must weigh like 15 #'s

[lour32]

Might be selling the whole project. I just got a new Job and will have company car. So I might not even start project. Anybody interested in the whole setup PM me or email me at Lriquito@ulmaforms.com

This is a complete 4motion kit. It consists of all new bolts, nuts & harness for the project. Just in the mentioned bolts, etc. I spent well over $850.. I have all the listed parts needed for this direct swap, an Audi S3 6 spd. manual trans with angle drive (41000 miles on it) bought in UK, Passat 3.6 4motion complete center drive shaft, Passat 3.6 4motion rear aluminum subframe, Passat 3.6 4motion rear Diff (32000 miles on it), both rear drive shafts, both rear 4motion aluminum hub spindles, Passat 3.6 4moiton rear complete gas tank with new fuel pump and new 2nd fuel sender unit (installed already) and fuel tank straps, new drive shaft heat shield, new rear cross over brake line, new front passenger side drive axle as the driver side axle from my fwd 6spd is the same used on the 4wd trans so no driver side axle needed, also have the front and rear sway bars as they are different then the ones on the fwd cars and new Scorpion Golf R DP. I have every new nut & bolt for this project (JC@Douglas) can attest to this claim, as I have spent well over $850 just in wires and bolts... This is a true direct bolt on to any Passat 2.0t with a 6spd. manual already installed. No cutting involved what so ever.

[lour32]

Well I had some spare time today and decided to start the project. Removed rear fwd subframe, gas tank and rear exhaust. Next week I will remove fwd trans. Removing the parts actually was very easy. Only took about 2 hours. Here is a pic of progress: