[Audi Doody]

Hi Gareth, to limit your options as they stand, you have to keep the original reverse switch as it controls the rear diff freewheel.
I would suggest you check your existing rallye gearchange, mine is original rallye and is easily as good as a late mk4 change.

I would suggest you check everything is in top condition before trying other change setups, I’m not even sure the throws are exactly the same.

Have you checked the cables are easy to move when disconnected and the end connections are not worn? could posibly be seized or worn selectors in the box or even a dragging clutch, seized clutch release arm or leaking clutch hydraulics. these will all cause problems changing gear. changing the gearbox oil for sythetic can help a lot too.
the only mod I can suggest is fitting the weighted shift arm as fitted to the later G60 Passat, it makes the change a little slower but much smoother.

cheers Mike

[Audi Doody]

I noticed that both transfer boxes are alloy, would the iron one be any better?.
BTW how does the VC unit fair with this level of torque?

[Audi Doody]

Hi everyone,
I would like to add my views to those of LD50.

I am in the unique position of being one of the people that went to the Nurburgring, know what went on and what was said, also I consider myself a good friend of Chris.
Regardless of the rights and wrongs relating to the ring trip, both parties had the decency to keep their dispute off site (well this one at least)
Chris was so upset by what occured, his lack of activity on site was an understandable reaction and thankfully the syncro bug bites so deep that he could not stay away for too long.
The disagrement/misunderstanding that occured at the Nurburgring was such that both parties felt wronged and neither was going to appologise to the other.
The subsequent dispute over supply of parts/money not paid is only a continuation of the Nurburgring dispute.

So come on guys, you are never going to be mates…do the right thing, sort out who owes what, send it back or whatever, pay up and spend the rest of your time never talking to each other.

The real shame of all of this, is both parties contributed to the site with advice and supply of parts and any loss will be to the detrement of us all.

With regard to bringing this dispute onto site Diamond hell is well out of order…a private dispute has no place on here, so I agree completely with LD50 to barr DH. what I do not agree with, is barring Chris.

The problem is..if their dispute is never resolved how long do you keep both of them off site?

I know from speaking to Chris on many occations, the last thing he would do was start a war on site, the tempatation was strong but he is determined to keep the dispute and site seperate and rightly so.

Regardless of the eventual outcome, the sad fact is the site will be the poorer for it….a real shame

 

[Audi Doody]

Thanks guys, typical vdub then, any idea what It looks like…std type or long, connections on end or long side etc. Thing is I can’t find anything on the relay plate and don’t remember seeing any relays behind the centre consul when I did the heater matrix.

I may also try and wire up the spare connection on the rear diff for a lamp to indicate if the freewheel is on or off. wiring diagram shows a spare contact, not had time to check the diff yet, so we’ll see.

[Audi Doody]

Ok for a start where is the oil coming from? Get under the car and check the offending output for up and down play. if it seems ok then get the oil seal for it. swap it over and see..might be worth it.
As to the best way, the thing is, for everyone you ask you will get a different answer…so which one do you choose?

If I was in your position, I’d try the seal thing first but if either of the bearings are worn then the rest of the transfer box is most likely in the same condition.. so get another one. I would take the engine out of the car and most likely replace the clutch at the same time (VR6) clean the engine bay, paint the engine, waxoil the chassis etc.

You pays yer money and takes yer choice.

[Audi Doody]

Hi Richard, I have never had any success with removing the transfer box from below on my rallye, i’m not even sure it can be done.

I’ve tried 3 times, gave up each time and ended up removing the front of the car and dropping the entire engine/gearbox on the subframe.

Sounds a lot of work but I have changed a gearbox this way and completed it in a day.

Tip….if you do it this way, label all the wiring so you know where it goes, makes life so much easier for reassembly.

Hope this is of some help

good luck Mike

[Audi Doody]

Cheers for that Dale, the tubular manifold sounds a nice idea, shame my welding isn’t up to it. My plans will be scat rods first, bigger injectors then turbo, trouble is I’m running near 300bhp now and have already trashed one gearbox so if I go for more power then I guess its either quaife internals or Haldex!
My Rallye is a real hoot now and still a *****cat around town and I don’t want to lose that, so I might do a syncro track car with rallye running gear and a 16v turbo and do all my playing with that.
BTW what injectors you are running?

Mike

LOL the preview won’t let me use the word P..U..S..S..Y…

[Audi Doody]

Hi, any chance the 6 spoke alloys that were on your current car are for sale?
Also are you sure the air filter is big enough for 300+bhp? looks a bit on the small side to me, be a shame to strangle the power from that mahoosive turbo. Your’e dead right about getting used to the power, I want more (saving up for a IHI +bits)

Mike

[Audi Doody]

Yet again Chris came to the rescue with a replacement gearbox switch, so all I need now are the front air ducts

[Audi Doody]

Chris what do I say to that offer….nah no thanks!!! not likely…
seriously,one availible and delivered almost to my door what can I say…
how much do you want for an asu box, bearing in mind you can have the gear clusters out of my old box…

My plan hopefully is to get back on the road with another gearbox and use my original casing (if ok) and install a 20vt gear cluster at my leisure, with photo’s of the old one with the damage then the install of the turbo cluster. ( i think I’m going to need lots of advice when I do it.
cheers mike

[Audi Doody]

Thanks for the offer Chris, I have a feeling the price might just be out of my league, I will see what the dreaded ebay has to offer. the ironic thing is 2 weeks or so a guy was selling a rallye box with 20vt internals….sods law again!
BTW can you still get hold of the 25mm passat synco estate anti roll bar? if so can you sort me out a price please?

[Audi Doody]

Hi Chris,
the box code is ASU30069,
I was having a good time with a carrera turbo, some XXXX pulled out in front of us and we had to slow, I dropped into 4th, waited for the idiot to pull in and floored it,then bang I thought the turbo boost pipe had come off…..I had to drive the car about 20 miles after the incident in 5th expecting the box to lock up, I guess I’ve stripped the gear, I’m sure the selector is ok from the feel of it.
I live in Dover Kent. depending on what the outcome is you are welcome to the internals.
I’m tempted to install a different ratio set so I can get to 60 in 2nd gear just depends on if a gearbox turns up or I have to strip it down ….
Mike

[Audi Doody]

As far as I know it’s an 02A, the code on the box is ASU. don’t know exactly what has gone wrong only I have no 4th gear. It feels as if its going into gear, just no drive. all the other gear are ok but the box sounds terrible. any ideas?

mike

[Audi Doody]

I’ve got one out of a Rallye.
I don’t know if they are the same, the good thing is its for sale

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