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You will need half Rallye shafts jointed to TT shafts
Rallye outer – TT inner
prop shaft on front is TT shortened with TT cv cup fitted on middle of prop front end.
with TT front doughnut.front section is 475mm long.
middle is Rallye with the above cv cup fitted.
on the rear I used Dutchbuild conversion flange to do away with rear doughnut.
look on their website
cable-x is the solution for 02m swap on mk1 and mk2 so that the stock speedometer will work!!!!!
Hi,just a little technical support to all of you guys that put 02m gearbox and want to keep the stock instrument cluster(speedometer) on mk1 and mk2 golf.
since the 02m gearbox comes with hall effect speed sensor(digital)
and the speedometer on the instrument cluster drive by cable(mechanical)(on most mk2 and for sure on mk1),I tried to find a solution to this problem,since I wanted to keep the stock instrument cluster.
I did alot of research here and couldn’t find any good info until “CrewCabCaddy” a guy over here told me about cable-x
so first thanks to you
read post on it:http://forums.vwvortex.com/zerothread?id=3626789
I bought this product from http://www.atrol.com/and I must say they have awesome technical support(thanks jerry).
don’t think that it was easy to install but after you understand how it works,it is very simple.
you have to do modifacation to the cable-x
you need to put a ressistor 10kohm 1/4 watt between the red wire and the white wire that comes on the cable-xso this is how it works:
there are 3 wires that goes out from the 02m speed sensor
black/white:+
blue/white:signal
brown:groundon cable-x:3 wires
red:+
white:signal
black:groundyou have to connect it like this:
1.you need to put a ressistor 10kohm 1/4 watt between the red wire and the white wire that comes on the cable-x as I wrote above
2.connect brown wire from sensor to black wire from cable-x and together to battery ground
3.connect blue/white from sensor to white from cable-x
4.connect black/white from sensor to +(after switch)
5.connect red from cable-x to +(after switch)
this is it
you must to do modifacation to the speedo cable in order to fitt it to the instrument cluster and the cable-x,but it is easy since the cable-x comes with it
this is the product:today got the hubs refitted with new tack rod ends and bottom ball joints. also managed to get the shifter fitted for the 02m box. i used the polo shifter housing and it bolt straight in. just had to cut the bottom plate a little because i fitted a b&m short shift lever and its longer so the cable touches the bottom plate.
also did sum measuring for the driveshafts.
was looking at the measurements on syncro site and i measured slightly
longer, but because the inner cv can move in and out a inch each way i
think there is quite alot of room for error.i measured 320mm drivers side( mines lhd)
passenger side 416mm
i measured flange to flange.
so for total length its 320mm + 36mm (splined bit for inner cv) + 48mm (splined bit for outer cv) total = 404mm
so for total length its 416mm + 36mm (splined bit for inner cv) + 48mm (splined bit for outer cv) total = 500mm
ive also made an error as i was going to use vr6 front cv;s but these dont fit on the tt shafts so going to use the tt inner and outer cv joints.
i had new vr6 front wheel bearings and vr6 front hubs fitted to my rallye hub carriers.
also had my 305mm discs redrilled to 5×100 and had the disc retaining screw tapped back in.
this lot cost £46 to have done. i have a bearing press but couldnt be bothered to do it myself 😆the rallye abs rings need to be fitted to the vr6 hubs as the vr6 abs rings are a different offset.
when fitting the rallye abs rings to vr6 hubs sum machining is needed to abs ring to make space for the wheel bolts.just got to fit my new stone guards to the hubs now and job done.
currently have my new wheels welded and redrilled by voodoo motorsport.
well ive made a start…..
had a right job getting hub nut undone. 15mins with alot heat finally did it after i broker a big breaker bar 😆
took me about an hour to do, never had this problem before. forgot the socket was hot and picked it up. now have ring burned in my hand 😆
removing rear mount from subframe to allow cv clearance
new clutch fitted with new oem flywheel bolts
had to remove balance weight from subframe as gearbox rests on it and remove my lower strutbrace.
engine back in with the 02m 6sp box fittedjust need to weld mount back on subframe when i check clearance of cv with rear mount and power steering pipes
worth noting you need to have a bracket made to fit the vw front mount to stop it twisting. i’ll put pic up off one i had made.
picked up clutch today after waiting 6weeks.
clutchmasters cm725 twin disc.
shud be good for full throttle 2nd gear launches 😆
right, lost 2nd and reverse so the haldex conversion is now on.
this meant getting the rallye converted axle of my shed. already bought one about year ago but hadnt bothered to start it yet.
me and a friend got the rear arms stripped of bushes and bearings ready for painting.
now the fun begins, i bought 4xvr6 cv’s joints, 2x rallye 68mm bearings, drilled rallye rear discs, 4x vr6 front hubs and 2x new abs rings.
bought sum rallye driveshafts but they turned out to be syncro ones, but luck has the rears are same as rallye and thats what i needed.right the machining. friends neighbour is an engineer and works from home so this little lot cost me £45.
what im using:-
tt inner rear cv’s
syncro/rallye rear driveshafts……………..mk3 vr6 front cv’scv’s need bit machining down to fit abs ring
rear shafts need 2.5mm off both ends on both shafts.
rallye rear shafts are :404mm long, 390mm circlip to circlip and 544mm long, 530mm circlip to circlipafter 2.5 off either end they should be 399mm and 539mm in total length
shud now be 31mm for tt cv(same as tt cv)
inner cv needs 5mm machined to allow tt inner to slide further on with washer.
as for rear hubs i have used mk3 vr6 front hubs which require slight modifying.
2mm on overall size of hub as rallye discs didnt fit.
also on the back is sum steps. one step needs machining down.
i already had bought sum drilled/grooved rear rallye discs but there 4 stud and i want 5 stud. so they’re been redrilled.
worth mentioning this a 5stud setup!!…….
this should be the rear setup done.
email from cable x firm.
You would need the Cable-X-30HC-S. The “S” model requires you to send your speedometer cable/housing in to be modified to fit the Cable-X. The standard length is 36″ but since you will be sending yours in for modification, you can specify the length required to fit your application, depending on where you will be mounting the Cable-X.
Thanks!
Jerry Monk
Abbott Enterprises
info@atrol.comhttp://www.atrol.com/order.htm
