Mk2 tdi syncro golf project

[Simonm]

Hi all ive just got my hands on a mk2 golf syncro less an engine so have a b4 tdi passat donor so really just wondering can any one tell me what gearbox/ transfer box would be recommended and where would I find one I have the 020 box but don’t think it’s the strongest set up any info much apricieated thanks

[Chris S]

You really need an 02C box fitted with a high ratio final drive diff, otherwise you will be screaming the b-lls off the diesel motor on the m-way

[Simonm]

Thanks, that’s what I had thought, is that the box that came in the passat syncro?
also what other models may have had it might make the search easier have a couple of standard tdi boxes that can swap internals from

[Chris S]

If your Passat donor car was 4wd? then just swap everything in.

[Simonm]

Unfortunately my tdi is only front drive so only internals will be good from that I have a 020 box but want to build this thing once and be done so must be right first time round thanks for info

[Chris S]

Do you know the gearbox code on the Passat? cos if its an 02A box? then as minimum you only need an 02a/02C flywheel, an 02C Syncro bellhousing & transfer box,
(all of which I have here (inc a skimmed lighter flywheel)+ a brand new 02A/02C clutch assembly consisting of the release bearing, friction & pressure plates) then you can swap the internals over.

the 020 box is not really strong enough to handle the torque from the diesel for very long, also the internals are not compatable with the 02a/02c type gearbox

[Simonm]

I think it has an 02a box in it can you tell me if I can still use my transfer box or will I need the 02c on aswell thanks

[Simonm]

I think my clutch and flywheel should be ok as it’s the bigger ahu one and I’ll also be converting to hyd clutch with the pedal cluster from the b4 for the dbw also how much would the bell housing and transfer box be and could you do postage thanks

[Chris S]

You will need an 02C transfer box

Complete gearboxes here on ebay

http://www.ebay.de/itm/Passat-35i-Golf-Syncro-G60-Getriebe-AWR-Schaltgetriebe-/110544269023

http://www.ebay.de/itm/VW-Passat-35i-2-0l-Syncro-Getriebe-/160667315806

http://www.ebay.de/itm/G60-2-0-Getriebe-AYR-SYNCRO-VW-Passat-Golf-120Tkm-/350108174432

[Simonm]

Excelent thanks Chris I had seen them but was unsure if they would suit or not so will look in to shipping costs on them again thank you

[Simonm]

If I change my gearbox to 02c will my current 020 prop shaft match up hopefully have a box this week end and just wondering will I need a prop also thanks

[Chris S]

yes the propshaft is compatable, depending on the year of your car only the front donut may be different & need changing

you will need to swap the front driveshafts as well

[Simonm]

Just one question will a 1.8 Audi tt 2001 quatro gear box and transfer box mount up I’m my mk2 as I can get one for a good price

[Housey]

you need a new mount for the gearbox. and haldex rear diff along with somekind of haldex controller

[Simonm]

Ok so there is no way it can work with my current diff and the prop I have what are the differences with the haldex system

[Author]

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