[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

[Chris S]

What you have at the moment will cope (or not cope) Just as well as the “Rallye diff”, the same for the VC,

but at 250 bhp you are approaching the limit of reliability for the Syncro rear diff,

if you search through my photos

http://www.vwsyncro.co.uk/?arc=&page=1&size=3&tpxbasketid=&search=&sortby=filename&sortbydir=asc&cols=3&cmd=do_search&i=0&big=0&gotourl=&p=6.Photos_ChrisS%2F_&basket_params=&basket_params_index=&noflash=&video_or_image=

you will see the difference between the Road Rallye & the Rallye Rallye running gear – believe me thats another world

Rallye Rallye rear diff below, notice the lack of VC unit (not recomended for road use)

Please dont ask, as none of that very tasty VWMS stuff belongs to me, (I wish) & is at a secret location here in Holland, thats secret in that the owner does not want his whereabouts published on line, or in any other way.

Its enough to say, that there were a few members from on here that were allowed to tour the premises and just see the extent of the early 90s VWMS Rallye program,

Also the fact that of the 9 Golf Rallye cars on site, 3 of them were ex VWMS Rallys & had actually done the biz

There were things like carbon fibre propshafts, wheel hubs & drive shafts with 120mm diameter CV Joints (instead of 90 & 100mm items)

To give you some idea of what I mean just look at the size of the transfer box gears & then compare them to your own!

We were very privileged to be allowed into his storage facility & must respect his wishes over privacy, again before you ask, no nothing there is for sale, please dont even think about it! []

[Chris S]

All the Golf 2 & Passat 4 cylinder rear diffs are exactly the same, at the rear its only the VC unit & donut which differs.

[Chris S]

The differential will fit the Rallye, but with your differential code of AOK 21-02-9
the VC unit will not fit the Rallye propshaft,
you must either change the VC unit from a 22mm one to a 25mm one, or change the rear donut to a 22mm one

btw, over the lifespan of the Golf 2 Syncro there were 3 different VC units fitted

18mm from 1986 to 1989 – Diff code 9v
22mm from 1989 to 28-10-90 Diff code AOK
25mm from 29-10-90 onward Diff code CBX, AAR, ARR, AOK

[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

[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

[Chris S]

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

[Chris S]

Sorry but thats not a part number, have a look here,
the arrow 1 shows where the part number is stamped into the casing.

[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

[Chris S]

That is a casting number & not a part number, the actual part number is stamped onto a machined flat area & is made up from either 9V, AOK, ARR or CBX followed by 6 numbers, its not cast in as the other numbers are.

If you can give us the part number then we can say what its from.

[Chris S]

That will be a better ride.

[Chris S]

& sorted out!

[Chris S]

What year country? as there are small but very important differences in the rear drive flange?

please can you email me the vin number

[Chris S]

Prijs: 50 euros + postage

[Chris S]

With regard to bearing wear being fixable with the engine in the car, the answer is that it depends on how bad the wear is,

you may get away just with fitting new standard size shells, this is doable with the engine in the car,

If you can just fit new shells (after checking the big ends for ovality) I would check the oil pump while you have the bottom end open as I have seen Golfs with over 200,000 miles on them & no appreciable wear on the crankshaft, it all depends on the oil pump pressure

However if the crankshaft needs re grinding to take undersize shells then the complete engine must come out.

Does it knock on overrun? I.E. when the gearbox is in neutral & the engine is slowing down with no load? this can be a sign that the big ends are on the way out

[Author]

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