My Rallye, with video updates

[h4den1]

hi guys, I have owned my car for about 3 months now, the car in question is a 1990 rallye in graphite metallic, I have had nothing but bother with my car(mostly due to the fact that it has only done 4k in the last 6 years), but still puts a smile on my face every time I drive it,

the engine is standard just now I dont have any major plans apart from a pulley etc,

I bought the car with a set of oz wheels that I have swapped out for a set of 9″ borbet A’s to fill the arches a bit more,

the car will be coming off the road at the end of feb for a strip down and paint and just a genral tidy up,

I am running standard suspension the now but soon to be coilovers

I am having a bit of bother at the moment with my transfer box, but i am new to the syncro setup so i am still trying to get my head round it.
anyhow here are some pics.

[Chris S]

Quote, I am having a bit of bother at the moment with my transfer box.

Ouch, any idea what your gearbox code is?

[h4den1]

not sure can and will find out (maybe where will it b ?)

[Chris S]

Your gearbox code is here,

http://www2.plus8.net/jpegstore/uk/vwsyncro_chriss/p_preview.asp?fileName=d833%5F1%2Ejpg&archive=Technical+info

The semi circle at the top left is where the starter motor sits & the bolthead at the bottom of the picture is the gearchange tower, you are looking at the gearbox from over the left wing, your code will probably start with ASU.

[h4den1]

kl i found it easy enough with ur directions, it reads 1 ASU07099

cheers john

[VR6SyncroMark2]

Nice car, wheels look good. I think the term is PHAT.

[Chris S]

You have a late type Rallye gearbox with oilways which means you can fit a 35i G60 Passat transfer box,
and as VW no longer stock any of the internals for the ASU transfer box this is realistically your only option other than changing the complete box for a Passat type one.

Even if VW did still have the parts needed to repair your transfer box they would cost over 600 pounds which with labour & vat added on would not give much change from 1000 pounds in total.

I wouldnt drive to far with your box in this condition as you are very likely to have shed some of the gear teeth from the bevel drive in the transfer box,
and as these teeth or more likely pieces of teeth are made of hardened steel it wont take them long to totally destroy you gearbox completely & utterly.

What you are looking at is either a complete teardown & reconditioning of your existing gearbox mainly to remove all loose metal particles and then rebuilding using a 2nd hand Passat type transfer box, while this is a more expensive option but at least you know that all the internals are good.
or getting a 2nd hand box and fitting it.

[h4den1]

thanks for pointing me in the ryt direction, where can i look to get a gear box etc ?, also i have been offered, a tt gearbox with all running gear etc etc, again im new to this but can it bolt on to my g60 lump or will is it only god for a 20vt etc conversion

cheers john h

[Chris S]

Lets move all future transfer box related posts from this thread over to here please
http://www.vwsyncro.co.uk/data/forums/topic.asp?TOPIC_ID=1969

[h4den1]

kl no bother soz

[h4den1]

Update, i sold the car roughly 18 months ago as a bare shell to fund a new business venture, i regretted it straight away, …..

anyway now the business is paying its way i found myself in the position to buy another one …. i spoke with the person whom i sold the car to . he explained he was tight on cash so a deal was done there and then. []

last seen like this :ninja:

this is when i brought it back to the workshop

wheels have been sold

when i first looked at the car i thought it was 90% complete but after some digging its more like 40% complete … s a resto will continue , the paint work is fresh so wont touch that , im more looking to freshin up all the running gear etc so started on calipers now the engine is going to come out ……

[h4den1]

2 days ago I dropped the rear subframe off and started stripping it down, with help from Chris and Pascal via the internet ….

I,m glad i have dropped it off as all of the bushes have seriousley perished, everything else looks in good condition [] just time to fire the shot blaster up []

[h4den1]

I stripped the rear subframe off and started to strip it down,

here is my experience of the ordeal,

this is in no way a how to, more of a how not to do? will let you decide :pray:

I will update more pictures as only half the pictures have downloaded :uhm:

everything came off very easly no exess force etc needed here :ninja:

first off alll i stripped the rear beam from the car

first job was to remove the unwanted brake pipes,

then i lubed all bolts to be taken out

went for a cuppa while i let it soak
after this i cleaned the bolt heads on the driveshaft bolts ready to loosen them off ,

i also removed the large nut on the other end of the drive shaft

i then removed the anti roll bar mount from the wishbones


after they were off i set about removing the wishbones




sorted ,
after both were removed i started removing the rear diff, 4 bolts and it was off :thumbs:


i then removed the rear brake bias valve and bracket

after that all that was left was the antiroll bar its self , 2 miniutes later and it was off

cup of tea time :rthumb:

the brakes still need removed and all the bushes etc

[g60syncro]

Looks like a proper job going on here!!

[h4den1]

also video updates

engine out ready for clean up

a sample of the finish on engineware, although this is a bracket for the rear diff and wont be seen again for another 20 years

engine out , need a clean up

http://i163.photobucket.com/albums/t291/h4den1/th_MOV00179.jpg

http://s163.photobucket.com/albums/t291/h4den1/?action=view¤t=MOV00178.flv%5D

http://i163.photobucket.com/albums/t291/h4den1/th_MOV00178.jpg

and what all the bits are getting treated to ..

[Author]

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