[Chris S]

I think the fault is that the earth connection on the corner of the cam cover (flywheel end) is not making a proper connection,
this will cause all sorts of problems and can at worst can even fry your ECU,
so please check/clean ALL earth connections/cables as I am 99.9% certain that this is the problem. []

[Chris S]

Yes, Turkey it was.

[Chris S]

I can’t wait for you to get it running, will you make a video?

[Chris S]

btw part nr 2 the 3 ball reservoir sits under the right front wing.

[Chris S]

Yes, the manifold & downpipe are different.

[Chris S]

As he is from the UK I think he wants the right hand drive type?

[Chris S]

ETKA says that the bonnet & tailgate are the same, but doors are different.

[Chris S]

If you cant find any housey (Dan) in Norway has a full set of Passat ones which will fit with a bit of fiddling.

[Chris S]

And what does it feel like when you turn the drivers side flange? and the rear flange? Is the box in gear at all?
have you tried turning the clutch shaft?

If it is not in gear then it sounds like you could possibly have a gearbox fault of some description,

btw he lives in Hemel Hempstead, does anyone live close enough & have the time to help him out?

[Chris S]

Do you mean the downpipe? as LD50 may have one of those lying about.

[Chris S]

I hope you fitted the muff?
thats the internally splined sleeve that transfers the drive from the diff to the rear output shaft in the transfer box.

[Chris S]

Its when you are using the Passat Syncro ABS/EDL master cylinder & wiring loom, or you could extend all the cables and fit the computer in its original place in the back panel.

[Chris S]

How cold is it by you?

[Chris S]

The sills are the same as is the rear valance.

[Chris S]

Its more likely to be a vacuum pipe that has become disconected (the ones that you thought were brake pipes), the clicking you can hear is the freewheel (like a pedal bicycle freewheel)

The reverse 4wd is switched by the reversing light switch (mounted on the gearbox) so yes it could be either that or the solenoid or or vacuum pipes / actuator that is not working.

As in your original post you say that it goes away after a few hundered meters I would first look at the non return valve in the vacuum line, It is a set in a green plastic pipe coming off the inlet manifold and heading off along the bulkhead towards the left front wing.

A 6 potter is a 6 cylinder motor, the transfer box/ rear diff have different ratios to the 4 cylinder motor and are not compatable with each other.

[Author]

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