Jetta Syncro Engine Conversion

[SamSam]

LD40 that’s what I was hoping however it would seem I’m missing a few things;

* Rear caliper carriers (I could fab these but OEM would be nicer)
* Rallye/passat syncro rear engine mount ( p/n 357 199 354F) – the G60 euro drive shaft doesn’t have a rubber vibration damper so do I “need” the rallye mount?
* 02C Transfer box carrier bracket p/n 02C 409 905 – are these not the same as on my current syncro box?
* 02C Transfer box support bracket p/n 02C 409 907 – are these not the same as on my current syncro box?
* 02C reverse switch
* Rallye donught? https://www.volkswagen-classic-parts.de/en/gelenkscheibe-133e22.html

On the Corrado I swapped the gearbox out and fitted a modified 02J cable shifter, will this fit the 02C seeing as they’re both cable?

I think that’s everything.

CHRIS S I totally missed that you might have some items (skim reading tsk tsk), I tried to PM you but have no idea how. Do you still have these parts and are you willing to sell them?

I can do full engine & loom swap in a weekend and was hoping to get the Jetta back on the road in a couple of weeks but seems I didn’t factor in obtaining the number of obsolete parts required..,(slaps forehead) DOH!

• This reply was modified 6 years, 3 months ago by SamSam.

[Chris S]

I have these parts here

Rallye/passat syncro rear engine mount ( p/n 357 199 354F)
– the G60 euro drive shaft doesn’t have a rubber vibration damper so do I “need” the rallye mount?
yes cos the inner cv boot rubs on the bracket

* 02C Transfer box carrier bracket p/n 02C 409 905 – are these not the same as on my current syncro box?
no its different

* 02C Transfer box support bracket p/n 02C 409 907
also different

you cam e-mail me at syncrogolf2 (at) zonnet.nl replace the at with @ or phone on 0031 527 750 606

[Chris S]

your conversion would run smoother & with less strain/Vibration on the propshaft rear diff if you fit one of these

1H0521307 in place of the one you have now without the balance weight, I have one here as well & can also supply the longer VW bolts (new)

[Chris S]

Mounting brackets for 02C transfer box if you compare them to your 020 brackets you will see how different they are

also in photo the rear donut with the vibration damper; I will post the Rallye rear mount when I find it, prob later today

btw you will also need a G60 Syncro exhaust manifold, as the 2wd G60 one sends the downpipe right through the middle of the transfer box

• This reply was modified 6 years, 3 months ago by Chris S.

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[Chris S]

I found the Rally rear engine mount, as you can see its different to the G60 mount

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[SamSam]

Oh my word Chris, awesome.
I shall email you shortly.

I did notice this morning how close the boot is to the bracket ?

My synchro is right-hand drive so my intention was to cut up the existing four branch g60 manifold and modify it to fit around the steering boot and prop – I’ll wrap it protect the surrounding area from heat.

Rear brake caliper carriers I sourced last night from eBay Poland.

There seems to be some debate as to whether I can modify existing handbrake cables or will need Rallye runs to run discs on the rear.

When removing the syncro pedal box yesterday evening I noticed that the clutch pedal has a switch on it – any ideas as to it’s purpose?

This engine swap is a little more involved than first anticipated ? thank goodness for the syncro forum ??

[Chris S]

Hi Sam,

While you can use the the drum handbrake cables it is a pain to modify them to take to the calipers + they are not new any more so it does make sense if you can get new cables to fit the calipers.

You may have to cut the bulkhead & re weld to get clearance for the double downpipe! its a bit busy under there with the transfer box, front donut, gearchange cables etc.

I cant remember what the clutch pedal switch is for, but not all G2 & J2 syncro models have them
I will look it up for you over week end if I get the chance

[SamSam]

Hello Chris.

Email sent 🙂

It IS going to be super tight for the exhaust, to be honest I’d rather not mess with the body at this stage – perhaps a 4-1? I’ve removed the subframe/engine/struts in one piece to try and keep the routing true, I’ll fiddle with it over the next couple of days.

Did the US model have the switch..I have a vague memory of this (?) I could be wrong..either way I’ve not seen one on a mk2 before.

Good point on the handbrake cables, rallye items are sourced and will be ordered tomorrow.

Your knowledge is much appreciated.

[conor]

Just seeing this thread for the first time now. That is a very nice looking Jetta. You are going a similar route to what I did with mine. I converted my 89 Jetta Syncro to g60 a few years back. I also upgraded the rear brakes to discs. However I retained the the 020 gearbox (Just replacing the diff rivets) and I also retained the GU manifold and downpipe. I had intended to go back and upgrade these in the future but ended up melting a piston in the engine!

I look forward to seeing your progress.

[SamSam]

Hi Conor!
No idea how many rhd jetta syncros there are but can’t be many (and yours is a looker).
I did actually read through your posts some time ago to see how you’d gone about the conversion. Luckily at the same time as getting my Jetta a passat g60 transfer and gearbox popped up for sale (although I’m still awaiting delivery). Do you know what kind of power you were running, or even what mods?

It’s been a busy couple of weeks to be honest but should get progress posted over the weekend.

[Chris S]

If I remember correctly,
Between 1986 & 1991 there were only just over 600 RHD Golf 2 Syncro imported, + this was only available in the 4 door version,
& only 112 of the Jetta Syncro in RHD (Presumably also with 4 doors?) were UK registered during this time

its little wonder that VW did not bother to convert the Golf 3 Syncro to RHD

https://www.howmanyleft.co.uk/vehicle/volkswagen_jetta_syncro

[Chris S]

btw the Corrado /G60 2wd Gearbox has better (higher) ratios than the Rallye box,

I actually have a Corrado G60 2wd gearbox here that I bought for the conversion but never got round to swapping out.

[conor]

Thanks! My G60 was standard apart from a smaller charger pulley so was running more boost than standard, but it hadn’t been chipped and was running the standard GU downpipe and a 2″ exhaust which was probably holding it back some.
It now has a 1.8T AUM engine with 150bhp.

[SamSam]

Hi Chris – I’m pretty sure the 2dr Jettas were only LHD, I’ve been trying to find out how RHD syncro Jettas are left but so far no joy.

I have a corrado G60 box so good to know (another job on the list of this to do…)

Conor are you running the AUM on your modified 020 box and if so how’s it holding up?

[conor]

Including mine there are three RHD Jetta Syncros that I know of in Ireland.

The 020 is holding up fine, I have a stage 2 black diamond clutch and fitted the diff bolt kit.
Since I am aware of the 020 box limitations I just don’t launch hard from a standing start. I’m not hard on gearboxes and I doubt I’ll ever try and run big power through it!

For the past few weeks I have been running it without the propshaft and its amazing how many times the front wheels will spin when taking off, and thats not driving like a hooligan either, need to get that propshaft back together!

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