btw I am not saying that it won’t work, just that it wont work for very long, one day in the not to distant future you will drop the clutch at the traffic lights and there will just be a big bang & possibly a spreading oil pool,
also the 02C gearbox has a 230mm clutch while the 020 box only has a 210mm plate,
please don’t forget that most of our parts are at least 20 years old with who knows how many miles on them,
realistically its no wonder that they fail when we use/abuse them by putting far more power through them than the original VW spec and long after their original design life expectancy !
how many Fords or Vauxhalls of this age do you see? [
] yes, exactly
with my car I have a chiptuned & cammed 8V GTI motor with about 125/130 bhp & personally I consider that to be very near the limit for a 4wd 020 rodchange box, in the past 10,000 kilometers I have had to be low loader recovered when I broke the transfer box and recently I lost 5th gear, (which I am not even going to repair) as at the moment I have a set of VR6 gears & shafts and a cast iron (original Rallye) transfer box & internals just waiting for me to build them up into/onto an 02C Syncro bellhousing
I was watching beetle crisis on discovery channel last night, when one of the guys said of rebuilding his Beetle
“This is such a big job that you only want to be doing it once, even though it may take a bit longer it makes sense to do it right first time”
Also it is torque and not power which destroys gearboxes & clutches and the diesel motor is not to different in the torque department than the G60 motor,
Golf 2 G60 has 225 newtonmeters of torque at 3800 rpm, while the
Golf 4 1900 diesel has between 210 and 320 nm at 1900 rpm depending on motor code
and as torque is also calaculated by the engine revs it is produced at, this actually makes even the lesser powered diesel nearly twice as torquey as the G60 motor! []
all figures in this post are from here
http://www.doppel-wobber.de/wbb2/jgs_portal.php?id=119