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Discussion in 'A4/S4 forum(B5 Chassis)' started by Broken Byzan, Mar 26, 2008.

  1. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Mar 26, 2008]
    Ok after my baby feeling sorry for herself while i saved to buy her what she needed, well the clutch arrived on Tuesday but needs special bolts so have ordrered them and the new gearbox mounts for the 6 speed :hubbahubba:
    [​IMG]

    While the engine bay was empty i thought i would install the gear linkage,

    old one
    [​IMG]
    new one
    [​IMG]

    Linkages side by side
    [​IMG]
    Only pitfall is i lose the Quick shift, ahh well !!:wtf:


    Differences between boxes, not a lot in length but the six speed must be at least 20kg heavier
    [​IMG]

    The reverse switch was different so i hacked it apart to access the connectors to mount the old wiring on.
    [​IMG]
    [​IMG]

    Now i am stuck as none of the 3 sets of shafts will work and i have no idea which ones would go straight in if any, so i am going to try to get the 130mm inners that fit the box machined to fit my original shafts. Anyone help here??:sos::sos:
    [​IMG]
    #1
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  3. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Mar 27, 2008]
    seems like its about to stop here, it seems its impossible to get shafts remade for decent cost etc etc, and tbh i cannot afford to just keep buying shafts till one fits.

    Anyone please??
    #2
  4. macca
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    macca Member

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    [Mar 27, 2008]
    are using a fwd a4 1.8T clutch with the 6 speed box? also std flywheel?

    is it worth using diesel gearbox, driveshafts and then changing the hub carrier to match? would that match up to the rest of the suspension? just a thought?
    #3
  5. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Mar 27, 2008]
    simon, 1.8t LWFW and clutch.Diesel 'box and i was gonna use the inner CV's from the v6 box i have but they wont fit the shafts etc .

    So i either get 2.5tdi uprights,bearings,flanges and shafts or set fire to the bloody thing,lol

    On a good note i stripped and cleaned the APU engine and it does have a new oil pump fitted as hoped and i made sure all of the gunk was as clean as it could be. Also found out it has an AEB head on it, only the guy i bought it from spent a small fortune buying "the right" head for it,and all someone did was smooth out the AEB marking, he he
    #4
  6. docurley
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    docurley Moderator Staff Member Moderator

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    [Mar 27, 2008]
    Can you not swap over the 1.8T flanges on the boxes?
    #5
  7. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Mar 27, 2008]
    tbh i dont know. I know the ones in the 1.8t box are a press/push fit and the 6 sp looks like it has an allen screw in the centre. I can get custom shafts made for 187 each, thats not too bad as i guess it means i done lose my new wheel bearings and the like.

    I have a phone call to make tomorrow to see if the all seeing eye can help point me in a different direction before i take the plunge
    #6
  8. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Mar 27, 2008]
    I found out waht the rattle was on my old engine

    Bits of shell in sump.
    [​IMG]

    Shells welded to journal
    [​IMG]

    State of the journal
    [​IMG]

    Number one journal is the best one and that has picked up slightly so i suppose the "rattle" i had was bottom end . My head was telling me it was, i just thought it cant be etc etc etc
    #7
  9. macca
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    macca Member

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    [Mar 27, 2008]
    good news about the head then. not so good news about the old engine. but hey you have a spare block to build up.

    let us know how you get on with gearbox stuff, this i maybe interested in as mine is past best and clutch and flywheel need doing as well.

    not convinced gearing is going to be suitable though.
    #8
  10. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Mar 31, 2008]
    If the gearing wont work its too late now,lol

    I believe we have overcome the shaft problem, after various conversations it would appear there are some 108mm output flanges available that will fit this 'box.

    Just to see where i need to re mount the box mounting point i shoved it in the car ( my back now broken)

    Whole box
    [​IMG]
    Passenger side, see how the gearbox mount is too low, i aim to get a drivers side subframe mount cut off and weld it to my frame in the right place. Any spare subframes kicking around?
    [​IMG]
    Drivers side
    [​IMG]

    On a positive note, i can select all of the gears with the linkage loosly assembled and it looks like my slave cylinder will fit also
    #9
  11. macca
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    macca Member

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    [Mar 31, 2008]
    so what was the gearbox out of again?, would it not be better to make a custom bracket for the mount, instead of chopping subframe?
    #10
  12. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Mar 31, 2008]
    2003 Passat 130 TDi. 01E box,
    If i had not just spent a fortune buying brand new OEM gearbox mounts maybe i would have done, but i think i could weld a new mounting point onto the subframe easier than making a mount to bolt to the box ect
    #11
  13. sitrials
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    sitrials Member

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    [Apr 1, 2008]
    can i ask what are you actually aiming for from all of this?
    #12
  14. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 1, 2008]
    I dont really understand the question, but i hope to have a working gearbox, all be it a six speed and a working engine as mine self destructed. All on the smallest budget possible
    #13
  15. Markey
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    Markey Active Member

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    [Apr 1, 2008]
    He is swapping his 5 speed original gearbox for a 6 speed from a VW Diesel.
    #14
  16. Siena
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    Siena Active Member

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    [Apr 1, 2008]
    I don't understand - why is the gearbox mount on the passenger's side sitting underneath the subframe, or is that how it's meant to fit?
    #15
  17. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 1, 2008]
    its not supposed to be there, its hanging from that long bolt to just see where things lined up. I aim to use a drivers side subframe mount and weld it to the pass side in the correct position for the box to sit on. At the mo it wants to sit on top and forward of the mount as it stands.But i would be unable to use the mounting rubbers etc properly so i am going to cut it off and weld a new one in place as soon as i get one ;-)
    #16
  18. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 2, 2008]
    Subframe moddified with the same type of mount thats on the drivers side. I thought this was easier to do than trying to make a gearbox mount seeing as i had just bought an OE one anyway,lol
    [​IMG]
    #17
  19. billybravo
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    billybravo MODERATOR

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    [Apr 3, 2008]
    i tell you now your going to have fun with that clutch mate :)

    mine isnt even a paddle but **** me its hard you need big legs if you running a single mass flywheel

    im on the stage 4 DXD with flywheel also you get a lot of judder in gears if your not going fast or if you down gear.
    #18
  20. macca
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    macca Member

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    [Apr 3, 2008]
    wahhoo, i gotta get one, it feel like i'm driving a track car. j/k :)
    #19
  21. Markey
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    Markey Active Member

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    [Apr 3, 2008]
    So where you able to buy the mount for the subframe or did you get another right leg and cut it off ?
    #20
  22. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 3, 2008]
    bought a used subframe and cut it off,lol

    Updates later, need a bath
    #21
  23. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 6, 2008]
    Ok she is running and driving now, i ended up getting V6 uprights and shafts ( although one is wrong, more in a min) So the APU engine seems to pull strongly and the box changes cleanly, but you guys were right about yhe clutch, its a right pain !!!!

    Ok i was given the shafts and one was about 4 inches shorter, so i went back to the breaker and got a replacement, it was longer and seemed to fit ok. I found out by looking that its the same one as is already on the car, so puts pressure on thye flanges causing a grumble, so i have not driven far. I have on the right 8d0 407 272 bb (dt)
    and the same on the left,i think the left should be 8d0 407 271 bb (DT) But i cannot be sure as i have no way of checking the lengths. I need the left one to be slightly shorter as per OE i think anyway. Anyone have a spare V6 Drivshaft set kicking around they can measure?
    Oh at 80 in 6th its running 25:puke2:00 ish but dont want to push it till i am sure of this shaft etc etc
    #22
  24. Markey
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    Markey Active Member

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    [Apr 6, 2008]
    Nice one thats wicked news mate, im going to rip all the info and part numbers from this for when i do it :)
    #23
  25. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 6, 2008]
    You welcome matey, i just gotta sort this driveshaft thing out and i will list everything i can think of that i did etc etc

    EDIT : Just checked the old shafts and although its not much difference its obviously enough, If i was OE ride height i bet i wouldnt notice
    [​IMG]
    #24
  26. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 7, 2008]
    Thats it i am going to cry !!! I got the right shaft, fitted it to the passenger side ( left??? ) Assuming i have that right. And the Whine is still there when driving, its full of oil, anyone any tips?

    Trust me to buy a dud !!

    I will make a recording later for shits and giggles, but am am proper pissed off. Does anyone here rebuild boxes??
    #25
  27. sitrials
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    sitrials Member

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    [Apr 7, 2008]
    no are you aiming for any big power increase at all after your engines decided to blow up??
    #26
  28. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 7, 2008]
    I do not understand your comment, I have an APU engine with an AEB large port head,K04-15 turbo, decat, 3 inch stainless exhaust, Custom remap, coilovers etc ect so I do not aim for any more power than that why do you ask?????
    #27
  29. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 7, 2008]
    My car is being used as a Guinea pig to try different things and i have learnt a lot that i was trying to share with anyone thats interested,if you are not interested go post elsewhere
    #28
  30. farmerq
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    farmerq New Member

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    [Apr 7, 2008]
    Are you sure. It seemd very high revs for a 6 speed box. My 5 speed sits at 60 at 2400rpm
    #29
  31. farmerq
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    farmerq New Member

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    [Apr 7, 2008]
    Thanks mate for taking the time to post everything you have done. Especially the pictures. This is what forums are all about:friends:
    #30
  32. Broken Byzan
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    [Apr 7, 2008]
    My bad, i forgot to stick it in 6th,lol

    I am gonna upload a video of 4th.5th.and 6th with evidence of the whine
    #31
  33. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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  34. Siena
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    Siena Active Member

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    [Apr 7, 2008]
    Couldn't really hear much from the video.

    Is the whine present in all gears? Does it reduce / stop on overrun?
    #33
  35. Markey
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    Markey Active Member

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    [Apr 7, 2008]
    What are the correct part numbers now for the drive shafts you used ?

    Also there is a very loud noise there dies it go up and down with the revs etc? Does it dissapear when the clutch is depressed?
    #34
  36. Broken Byzan
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    [Apr 7, 2008]
    gets louder with speed, no difference on overrun. maybe a very slight difference when full acceleration. It doesnt dissapear with the clutch sadly. Now i have either damaged it myself by driving 2 miles with the wrong length shaft fitted, and that in turn put pressure on the output fanges of the box.

    I have the right side as 8d0 407 272bb and the left as 8do 407 171 bb, i also took right to be drivers side and left passenger, thats right isnt it?
    Oil is full, i will be draining and changing tomorrow anyway just to be 110% on that.

    At the end of the video the noise is most prevelent, she drives ok just has this annoying noise,lol
    #35
  37. Markey
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    Markey Active Member

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    [Apr 7, 2008]
    Any chance you have killed your wheel bearing with the longer shaft?

    Cheers for the above i so want to do this to my car :)
    #36
  38. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Apr 7, 2008]
    Nah, its not that kind of noise, shame as that would be easy to fix,lol
    #37
  39. macca
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    macca Member

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    [Apr 7, 2008]
    stick with it good buddy, we are all learning here. bit or moral support needed???
    #38
  40. Markey
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    Markey Active Member

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    [Apr 7, 2008]
    Indeed, you so close mate to having an awesome car just how you want it stick with it :) you are the pioneer for us.
    #39
  41. docurley
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    docurley Moderator Staff Member Moderator

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    [Apr 8, 2008]
    Mate this has been a great project costly at times but great. I would carry on using the car till box gives up the gost and look for a spare in the mean time.
    #40

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