GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Topic started by: Neo Badness on 04 November 2009, 00:12
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Been talking about converting my '91 16v to ABF for ages and reckon I have the majority of the parts/ complete donor car, a lack of time and space has meant that it's been on the back burner.
However I've diagnosed a knackered water pump on the KR/ heater matrix/ slipping clutch and can't be arsed spending any more on it if it's not the engine I want to run. Also means I'll get my ass in gear.
Been reading various threads as homework.
My question so far is aside from an engine hoist are there any tools that I should defo need? special VW tools or anything?
Got a decent socket/ spanner set/ torque wrenchs/ breaker bars, pliers maul grips etc but anything that anyone can think of would be greatly appreciated.
I've never attempted anthing this major before and am a complete wiring/ electrophobe but I'm pretty sure I can work it out....
Sorry for blether but just been swimming round my head for last day or two.
Best regards
NB
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XYZ (triple square) 8mm for the driveshafts.
Decent soldering iron, some heatshrink tubing, good wire strippers
Multimeter
17mm hex for gearbox (if changing oil).
Nothing else really springs to mind.... look here:
http://www.golfgtiforum.co.uk/index.php?topic=49436.msg576761#msg576761
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Cheers Ben, I'll have a good look at your thread when I get home from work as can't view pictures here.
Also thinking of using the mk3 gearbox that is cable change, found this on TSR website
Hydraulic to Cable Clutch Conversion
When a VR6 or 1.8T conversion is fitted to a Golf 1 or Golf 2 it us usually necessary to convert the pedal box to suit the master cylinder of the 02A cable change gearbox.
This kit converts the clutch to cable operation so the original pedal box can be retained. £89.99
Worth it or should I just use the one from the mk3?
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I didn't think it was possible to use the hyd. clutch from the ABF box ?
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I didn't think it was possible to use the hyd. clutch from the ABF box ?
With some modifcation it can be. You need a couple of parts from the dealer to get it done...
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Ok, maybe I'm being dippy but as I understand it, the mk2 has a rod change box and the mk3 has a cable change(?)
To convert mk2 to mk3 G/box you need to change the pedal box(?)
Cable change is stronger and if using the ABF engine you will be at the limit of what the mk2 (2Y) G/box can take?
So I might as well convert it to mk3 engine G.box? Don't really want to go wide track but don't think you can use mk3 g/box without using the shafts off the mk3 and thus the hubs...?
This is what I've gathered so far but happy to be corrected on any of the above.
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i asked about the driveshafts before i decided to use all ibiza gubbins but if i remember right you can use the mk2 n/s shaft but the o/s shaft isnt long enough
where the cable change box selector bolts to the tunnel it isnt as wide as the mk2 so doesnt bolt straight up but i got round this by grinding a few mm off the outer edges where the bolts go then got some big washers and used these to hold it in place
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You can have cable change - but the problem is the hyd. clutch - it means changing the pedal box (nightmare).
They did a ABF box that is cable change and cable clutch.
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Ok, maybe I'm being dippy but as I understand it, the mk2 has a rod change box and the mk3 has a cable change(?)
To convert mk2 to mk3 G/box you need to change the pedal box(?)
No, you add a SEAT Toledo 16V clutch actuator, clutch outer stop to fit to the gearbox and a Toledo 16V clutch cable.
You'll also need a super early Passat 2.0 speedo cable to link straight up from the 02A to the G2 speedo.
So I might as well convert it to mk3 engine G.box? Don't really want to go wide track but don't think you can use mk3 g/box without using the shafts off the mk3 and thus the hubs...?
No, you can re-use your n/s driveshaft. I'm not 100% about the o/s as the cable-change conversions I've done have been Syncro units, but it is likely the cable-changer has a wider diff, like the Syncro cable-changer, so the rod-change o/s shaft would be too long. The 02A box uses the same 100mm bolt pitch CVs as the 020 boxes.
If you need the shorter o/s driveshaft you can find 'narrow track' cable-change shafts on Cordoba 16Vs and Corrado 16V and G60 cars.
where the cable change box selector bolts to the tunnel it isnt as wide as the mk2 so doesnt bolt straight up
I understand the same, from what I've read. I DO know the Syncro tunnel is higher and the cable-changer mechanism does bolt right up there.
You shouldn't need to do any soldering - just get the loom from a Golf3 16V - it plugs into your 90-spec fusebox. If it's early enough you'll have no immobiliser to flap about with.
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abf's are like dog. and cars a bit like dog baskets.
step 1 ) perswaded dog to leave manky old basket
step 2 ) dispose of mankey old basket
step 3 ) point dog at new basket ( engine / dog should quite happily nest in new basket )
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Cheers for the replies guys, this is helping me straighten out my plan of attack.
I'm hoping to get all the bits I need before I begin hence why I've been making a shopping list (the fun kind) So I don't end up reducing two once servicable vehicles to a pile of parts...
So to add to the list is a SEAT Toledo 16V clutch actuator and a Toledo 16v clutch cable.
I'm using my 94 golf as a donor, this doesn't make any difference I'd still use the parts mentioned already?
I know SEAT was part of VW by this time etc.
Clutch outer stop? Will this become obvious when I'm looking at the gearbox? I can still use my mk3 g/box just convert it from a hyd. clutch?
Super early speedo cable from a passat was already on the list as I'm hoping to retain the mk2 clocks.
Again apologies if I'm being a bit thick with any of this...
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The stop won't be obvious. There is a bracket on the Golf3 02A gearbox, which goes from the front of the gearbox, to the back. This isn't fitted to the Toledo. Instead, there's asmall bracket that bolts to the front of the gearbox. This is the part that stops the outer, so the arm has something to pull against.
The early 90's Passats also have this, but it's a slightly larger version, as part of the front-to-back bracketry, as on the G3 bracket, with the stop welded to it.
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just use you 020 mk2 box. ratios sre perfect, the fly is lighter, and its cheaper :grin:
im having no probs using mine, and dont think i will. until the head gets flowed. even then im lucky to get an extra 15hp
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just use you 020 mk2 box. ratios sre perfect, the fly is lighter, and its cheaper :grin:
im having no probs using mine, and dont think i will. until the head gets flowed. even then im lucky to get an extra 15hp
Hmmmn, main reason I was thinking of using my 02a was that my 020 is little bit notchy/ clutch is slipping/ reckon the linkages could do with being changed. But changing to the mk3 g/box is starting look like more hassle than I have knowledge to do. Plus I need to get the car back on the road as I'm without wheels at the mo and taking a ripping over ownin two broken golfs...