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Apart from the fact that I fitted a brand new rad in July I would agree with that diagnosis! [
]http://www.vwsyncro.co.uk/data/forums/topic.asp?TOPIC_ID=459
Here is the uprated cooling.
The old & new fans.
The old and new radiators.
How it looks when fitted.
The counterflow exhaust manifold will bolt straight up on the crossflow head, They even use the same exhaust gasket, the 2 liter ports are slightly larger but could be opened still further and remain within the confines of the gasket.
The ASU code box has a cast iron transfer case instead of the normal aluminium one,
Just as you say Les the ratios are different, strangely enough the Rallye has a lowered 5th gear!
As for availability, I have 2 second hand ASU code Rallye gearboxes for sale here at the moment. I can get one delivered to you in the early hours of the 1st of november if you like? as Mark (slateford) will be getting off the the Dunkirk/Dover ferry in his Rallye at about midnight on the 31st Oct on his way home to Edinburgh after a visit over here.OK, The Rallye rear diff & transfer are obviously compatable as both have a 20/21 ratio,
unfortunately the Rallye transfer box internals, Gears, Shafts, Bearings, etc are a different diameter and are not compatable with the later (oilway) casing, personally I think your best plan might be to find a transfer box with the oilways, as this is will only need bolting in.The transfer box internals wont swap as the bearings, shafts etc are different diameters, the ratios are also different between the Rallye transfer box & the VR6 rear diff, the Rallye being 20/21 and the VR6 16/21 so thats a non runner as well!
Unfortunately I dont know, possibly? probably? who knows? unless you find a motorsport one and again who knows what size bearings are in that.
Unfortunately for the Jetta Syncro the only off the shelf option is the original VW part, or you may be able to cut off and extend the inlet pipe (after the bend over the axle but before the silencer box) of the Golf Syncro part, in which case you can fit the relatively cheap Bosal Golf Syncro back box,
the Bosal part number is 278-467(a) Golf Syncro Rear Silencerquote:
Originally posted by skattrdI’m not rich enough atm to get a custom exhaust made for the Jetta so which exhaust system is the closest fit …. and will need these modifying?
I was thinking that a standard mk2 8v exhaust shouldn’t be too difficult to get to fit, or am I miles off?Thx
Sorry to rain on your parade, but yes you are miles off, not even the 2wd back box will fit without modification, and as for the rest of the system it just wont go, I an afraid I cant help either as all my manifold/downpipes are left hand drive, from the downpipe back though both left & right hand drive are exactly the same.
What parts is it you need exactly?
You have definitely stripped 4th gear, I can do you an exchange reconditioned box if you like please e-mail me for details
Its an O2C, thats the 4wd version of the O2A box, the ASU code was only fitted to the Rallye & there are 2 versions of this box, The later one has oilways between the main box & the transfer box, do you know the full gearbox code including the numbers?
As for having no 4th gear, you have stripped either the teeth of one of the cogs or done the selector mechanism in, however if as you say it feels like it is going into gear then it is very likely that you have stripped the teeth from one of the cogwheels, try draining the oil and see if any of the gear teeth come out with it?
Please dont drive it any further as the loose teeth will eventually get caught up and wreck the other gears or can even be pushed through the casings and destroy them.
btw Whereabouts in the UK are you based? I may be interested in your box if there any good internals left intact.
