Rallye Gearbox Fitting

[blue95]

On the final leg of the Corrado syncro! I have decided to use the 2.0 16v 9a lump for a while, as it has the all essential mounting lug.

My Q is can I fit the rallye gearbox without removing the engine?

FYI: I will be removing the driveshafts, exhaust system & manifold.

[no such user]

Yes it’s possible, to make your life easier it would suggest fitting the gearbox with the transfer case removed and fit the transfer case when the gearbox is on the engine its a bit fiddly but a hell of a lot easier than trying to get box and transfer case in at the same time.

[blue95]

Thanks for your reply.

Only prob is that I have the rallye gearbox with shared oilways. Would this mean I would need to replace a gasket between the gbox and tbox?

Also does anyone know the torque settings for the bracket that goes on the end of the tbox and the engine block?

Thanks

[Chris S]

According to the VW manual

1) Tighten all 6 bolts finger tight
2) Tighten the 2 bracket to engine block bolts to 8NM (Newton Meters)
3) Tighten the 4 transfer box bolts to 25 NM
4) Tighten the 2 block bolts to 40 NM

Job done
btw the transfer box arm bracket is 40 NM both ends

[blue95]

Cheers fellas.[8D]

I was under the car last night, I have big block of metal attached to the subframe (just in from of where the diff will go) that will needs to be removed. Think its some kind of balance or vibration damper. Looked on VAGCAT and the Rallye does not seem to have one.

Can also confirm the 16v 9a lump has the mounting lugs for the tbox bracket, as I attached the bracket last night []

[blue95]

Job finally done!

Was easier just to split the box and tbox in the end[]

[Chris S]

quote:

---

Originally posted by blue95

Cheers fellas.[8D]

I was under the car last night, I have big block of metal attached to the subframe (just in from of where the diff will go) that will needs to be removed. Think its some kind of balance or vibration damper. Looked on VAGCAT and the Rallye does not seem to have one.

Can also confirm the 16v 9a lump has the mounting lugs for the tbox bracket, as I attached the bracket last night []

---

That is a balance weight & counterbalances some of the weight of the transfer box

[blue95]

Appears to be a harmonic balancer/damper. Used for changing the frequency of vibrations and certain speeds/road conditions.

Seems to appear on some models and not on others, not sure why.

Some peeps have removed it and had no adverse effects, will see what happens

[Chris S]

The Rallye should have one fitted, p/n 191 199 322C balance weight for motorcodes 1H & PG

[Author]

Posts