Parts list for 020 to 02C Gearbox conversion,
btw this may not be a full list as you may need other parts.
02C Gearbox +transfer box
G60 type front engine mounting bracket, p/n 357 199 273 (just the top bracket that bolts onto the motor & not the hydraulic/rubber mount itself as they are compatable)
Rallye or Passat Syncro Rear engine mounting bracket p/n 357 199 354F
(as the rubber boot on the 100mm driveshaft joint rubs and lasts about 5 miles)
02C Transfer box carrier bracket p/n 02C 409 905
02C Transfer box support bracket p/n 02C 409 907
Rallye or Corrado 2WD right hand front drive shaft p/n 191 407 271K
or any left or right hand front G60 hollow shaft cut to the correct length. (Passat 2wd etc)
The bare shaft lengths you need (without any cv joints etc) are Left Hand 454mm & Right Hand 525mm, I must check these lengths out to make sure that they are correct!
100mm inner joint for left hand driveshaft, original is 90mm to vin nr1G-K-990-000. from 1G-L-000 001 you already have the 100mm joints fitted
Modified front donut or Rallye propshaft front section (again a Passat front section can be cut to the correct length and welded up) (donut mod is easy)
Cable change gear lever mechanism & cables (2wd Passat will fit)
228mm flywheel & full 228mm clutch assembly (original is 210mm) T4 2.5 litre van among others has same clutch
Clutch operating mechanism,
LHD, Lucky you, you have a choice between hydraulic or cable, cable is easiest as you already have the cable. You need p/n 02A 141 708B Bearing bracket for mechanical clutch operation , 02A 141 728 rubber boot for bearing bracket & p/n 357 199 356 transmission support.
RHD, Cable only I am afraid, but again it is not a great problem as the cable is already fitted. You just need the same parts as above thats p/n 02A 141 708B Bearing bracket for mechanical clutch operation , 02A 141 728 rubber boot for bearing bracket & p/n 357 199 356 transmission support
Reversing light wiring must be replugged to fit the 02C gearbox reverse switch, which btw has been dropped without replacement from VW so please make sure you get one with your gearbox, the p/n was 02A 919 823B,
Les in Canada was looking at a workaround for this, Hopefully he will post his findings.
Good FAQ, Chris.
good list Chris!
In retrospect I’m glad I didn’t try and go for cable shift just yet. I counted at least 3 things I hadn’t accounted for and I don’t think the piggy-bank would have withstood that too.
This is very nice to know if someone is considering the upgrade to the cable shift gearbox.
How much should one be looking at to do all these aside the labor??
Bloody hell that’s a lot of work, I think ill bight the bullet now and get a full car that’s got haldex and convert the lot, take the cr off the road and do it properly, cheers again Chris I appreciate the help