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Flywheels ??

Discussion in 'A4/S4 forum(B5 Chassis)' started by Bradderz_1988, Sep 19, 2011.

  1. Jason.s
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    Jason.s Active Member

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    [Sep 30, 2011]
    To be honest the machine shop i originally took it to to get a quote told me that it`d be fine to touch the starter ring and it wont cause any problems as its pressed onto the fly good and proper so drilling into it a touch wont really disturb it.

    I never did see how deep my mates work that i eventually got to do the work went. Pretty sure i told him all the info i`d been told and let him get on with it. He would have just kept going until the bolt could screw far enough in. I didnt have the need for washers so. My mate gave me some antirattle washers but working in a race gearbox firm they all use them but on a road car something like that isnt needed lol.

    The measurement on ETKA for the bolts are M8x16
    #41
  2. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Sep 30, 2011]
    Cheers mate just gotta see if I can get my mate to do it for me now or have a scout about, in the trade so shouldn't be hard lol
    #42
  3. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Sep 30, 2011]
    Drilling into it a touch is fine, but the original holes run right thru the flywheel, and drilling 6 holes right thru the ring gear is likely to weaken it to the point it either shatters or simply falls off!
    #43
  4. Jason.s
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    Jason.s Active Member

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    [Oct 3, 2011]
    A random point but the clutch/fly combo held up very well at shakey yesterday. Took everything that i threw at it with ease launching at 4-4500. Ok im 150bhp on FWD so a little less strain but still did a very good job!
    #44
  5. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Oct 3, 2011]
    Nice one. I've not really given mine any stick yet. One slightly aggressive launch worked quite well as evidenced by an almighty bang from the rear diff (that'll probably need new mounts then!). A second attempt at a roundabout just had it bog down :p

    Some practice required i think, but i'm trying not to thrash it too hard until i pressure test the inlet and work out if my odd weeeee noise is a quirk of the turbo or a leak somewhere. Sounds leaky to me, but i've been round and checked every pipe.

    Also dont think my DV is working, i get nice chavtastic compressor stall if i give it some throttle then let off at low speeds around town, so i might replace that for peace of mind.
    #45
  6. adamss24
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    adamss24 Well-Known Member

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    [Oct 3, 2011]
    The flywheel will hold just fine but it's the clutch that wont hold more than 450-500Nm. I have seen pics of a finish twin turbo AFN which tore the clutch hub down on one of them clutches. Should hold just well if you keep the max torque under 400Nm at 2000rpm's !
    #46
  7. Jason.s
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    Jason.s Active Member

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    [Oct 3, 2011]
    S2 3B clutch can take around 300ft-lbs. A diesel is going to put more strain on it than a petrol as most of the torque comes in a bigger lump and lower down than the petrol. So i read on club TDI
    #47
  8. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Oct 3, 2011]
    Well I've got the flywheel and bolts.

    And spoke to my mate and he said he's going to have a look at it if he can do it he'll do it I asked him how much he said now't bargain.

    Now just an S2 clutch is needed, but sadly had a minor bump at the weekend toying around with a mate and the adrenalin was pumping my mate in his seat cupra R said try and keep up he says it's 180hp but Im sure there 156hp standard which his is just subtle mods (dv, air filter, exhaust) and pulled out of a junction after him a bit to quick and he had to stop at the pelican and braked but unfortunately hit his rear end so have to pay for his to be repaired first at least it's not going through my insurance lol
    #48
  9. Jason.s
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    Jason.s Active Member

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    [Oct 3, 2011]
    Even basic sports and cupra`s are 180bhp on the MK1 platform.

    Sucks to hear about the shunt. Hopefully wont cost too much.
    #49
  10. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Oct 3, 2011]
    Interesting as on autotrader they say there 156hp.

    Not to bad of a shunt my bumper bar is bent slightly and my pressed plate is ruined as the screws of the number plate holder punctured his bumper and my plate :( just got a quote from bodyshop round the corner for £130 so not to bad compared to my £250 excess.
    #50
  11. Jason.s
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    [Oct 3, 2011]
    lol Autotrader lies! My gf has a Sport 1.8t. Has 180bhp but still only has a k03 but just has a factory remap. Cupra`s were 180bhp k03s.

    yeah not too bad. Much better than dealing with insurance and getting bent over!
    #51
  12. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Oct 3, 2011]
    If its a Cupra R it has 210 or 225hp from the factory...

    AFAIK All transverse cars after ~2001 were fitted with the K03s, irrespective of 150 or 180hp tune. I would expect a Cupra (non-R) to have 180 though.
    #52
  13. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Oct 22, 2011]
    Will any off these part numbers do for a 1Z conversion ???

    1.Part Number: 074141025CX. 2.5 Litre 5-Cyl Diesel engines. Engine Codes: AGX. 240mm. Pressure plate.

    2.Part Number: 074141032BX LT 2.5 TDI / SDI ENGINE CODES - AHD, AGX, APA, ANJ 240mm CLUTCH FRICTION PLATE

    3.Part Number: 06B 141 031 M Audi A4 Brand 1.8 and 2.0 litre models years 2001 to 2005.

    4.Part Number: 06E141031AX AUDI A6 C6 3.2 FWD CLUTCH PLATE
    #53
  14. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Oct 22, 2011]
    #54
  15. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Oct 22, 2011]
    Where would I get the pressure plate from what models are they fitted to and what part numbers are compatible ??

    What about this one.

    Clutch Pressure Plate.
    2.5 Litre 5-Cyl Diesel Engine.
    Volkswagen Transporter 1996 - 2004
    Engine Code: ACU
    Part Number: 074141025MX

    Or this one
    GENUINE VW LT 2.8 AGK ATA 240MM CLUTCH PRESSURE PLATE *
    Part Number - 062141025BX
    Last edited: Oct 22, 2011
    #55
  16. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Oct 22, 2011]
    The ATA/AGK one is what i'm using.
    #56
  17. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Oct 23, 2011]
    How can I look up/cross reference genuine part numbers to luk/valeo items as the ones Aragorn says I need are remanufactured and I'd prefer new or at least price and see what the score is between them and an S2 item.
    #57
  18. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Oct 23, 2011]
    Those partsdepo bits are genuine audi parts mate.

    Audi themselves do recon parts and they're perfectly good quality.

    Either buy those bits i mentioned above, or spend the money on a LUK kit for an S2.
    #58
  19. jcb
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    jcb Active Member VCDS Map User

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    [Nov 21, 2011]
    can someone summarise this in a single post.
    What flywheel/friction plate/pressure plate combo is required to get a 1.8tqs onto a SMFW with either same size or bigger friction plate?
    is it:
    any S2 pressure plate
    any s4 friction plate
    and a SMFW from flywheel from a B5 petrol engine?
    #59
  20. Jason.s
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    Jason.s Active Member

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    [Nov 21, 2011]
    1Z flywheel from Audi 80/early Passat for example part number 026105269LX
    1Z flywheel bolts (shorter than 1.8t bolts) N90206103 x6
    S2 3B engine code clutch kit

    Or you use the LT pressure plate ATA/AGK and V8 disc Aragorn found to be suitable.
    Last edited: Nov 21, 2011
    #60
  21. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Nov 21, 2011]
    SMFW from an Audi 80 era car with a big 4 cylinder engine. Audi Coupe/100 also have the same flywheel, and its used on 1.8, 2.0 and 1.9tdi engines.

    Friction plate can come from any 240mm longitudinal car i guess, so long as it has springs. I'm using an B6 S4 V8 one, you could also use a B5 S4 one, or one from an S2/RS2, or any number of newer V6/TDI engines, so long as the central spline is correct.

    Clutch cover can come from either a 3B engined S2 (not the later engines, as they changed to dual mass) or a VW LT Van with an ATA/AGK engine.

    The flywheel needs redrilled by a competent engineering shop to take the larger cover though.
    #61
  22. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Nov 21, 2011]
    The friction plate needs to have 23 splines and have a springed hub.

    Also you can use a normal 1z clutch as I think der techniker(rconn) is using the standard 1z 228mm clutch iirc.

    Mine will be going for machining next week.
    #62
  23. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Nov 21, 2011]
    Yeh i put a standard 1Z clutch on our old FWD, and it still seems happy 10k later with a basic remapped engine, but its designed for a 90hp TDI motor, so i've no idea how it would take to having a big turbo 2.0 motor behind it.
    #63
  24. AR-rkon
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    AR-rkon AllROOOOOOOOOAD!!! Staff Member Moderator Regional Rep

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    [Nov 21, 2011]
    Yep I'm using the std 1Z clutch. Holding up lovely against my heavy driving and up to 30psi of boost :)
    #64
  25. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Nov 21, 2011]
    30psi?! on a K03?!
    #65
  26. AR-rkon
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    AR-rkon AllROOOOOOOOOAD!!! Staff Member Moderator Regional Rep

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    [Nov 21, 2011]
    "S" now, and to be fair... It's a VERY rare peak lol
    #66
  27. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Nov 21, 2011]
    Exactly what I was thinking lol
    #67
  28. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Nov 21, 2011]
    it isnt an "S", unless you've got it from the 190hp B6 model.

    The -029 on DBW A4's is the same size as the standard K03 on an A3.

    The -005 on earlier A4's is smaller than the standard A3 turbo!
    #68
  29. AR-rkon
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    AR-rkon AllROOOOOOOOOAD!!! Staff Member Moderator Regional Rep

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    [Nov 21, 2011]
    It's an 073 which I was told was the "best thing without forking out for a k04" and apparently from a B6

    I'll hold my hands up and say I know wires not so much mechanical lmao
    #69
  30. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Nov 21, 2011]
    ah cool, 073 is an "S" then :)

    Good for 220-230hp, but it wont last long if you keep pushing it to 30psi lol.
    #70
  31. AR-rkon
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    AR-rkon AllROOOOOOOOOAD!!! Staff Member Moderator Regional Rep

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    [Nov 21, 2011]
    Lol like I said its a very rare peak. I may see it every few weeks, it's usually sat around 25/26psi

    I'm thinking maybe the actuator or wg is sticking or the 75 is playing up.

    Could be the map though
    #71
  32. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Nov 21, 2011]
    who mapped it
    #72
  33. AR-rkon
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    AR-rkon AllROOOOOOOOOAD!!! Staff Member Moderator Regional Rep

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    [Nov 21, 2011]
    A mate at work, though he's used to writing/modifying maps for 5.0 SC V8s lol.

    It was basically a clone of his passat 1.8t that was tweaked one quiet evening in the power train rr workshops lol **shhhh don't tell*** haha
    #73

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