mattneck - mk2 ryder

[mattneck(Beavis)]

Progression! Has been made.. 

So, circlip was off and needed replacing..



As you can see the width it reached stretched, jsut through removal was significantly losoer and larger than it's new counterpart. A nice pair of circlip pleirs side on soon opened the enw one enough to slip it on and drift it down with a suitable socket. Job done 

Thus gear was refitted fully, 5th bolt still to fit (box needs to be locked in both 5th and reverse to be able to torque the bolt up to the req'd 150Nm!) but the selector fork was fitted with tis 5mm of protrusion and the lockpalte had to be reused - oddly these are now obsolete from VW 



Next was to refurb and check over the 5th housing. So, remvoed was; green cap, release bearing, clip, pushrod finger, spring, clutch arm and finally the seal. Everything was cleaned up and check, the figner was found to be perfectly fine to reuse so was then refitted, along with a new clutch arm seal 

Bits & pieces..



Housing sat in place..



I have also released the clutch arm retainer clip so as can be seen ehre the release bearing finger can be lifted, the 5th bolt torqued and the release bearing fitted, along with pushrod and green end cap. Pushrod bush, seal and input shaft seal require attention and the selector shaft seal will also be replace, then box bolted up to block! 

Also picked up a second airbox bottom as mine came with no hot air feed and vacuum flap - later to find the one I had was a diesel one and the vacuum hot/cold one was a proper digifant model. The diesel one seems less restrictive, not only with the removal of the cold air trumpet but the missing vaccum system and sealed over rear meaning all air coming in has only one route to follow.. Wether this will be an advantage or not I'm unsure! Maybe fitting the digibox with no trumpet could be the way.. at elast it'll help it warm up nicer! 

Inside digi box..



In and out on the diesel..





Much more to do.. but getting there slowly! next key item on the lsit is recieving my tappets, fitting the cam with the new oil seal and bolting that down, along with fitting cambelt, covers and outer pulleys at long last.. Always more to be done! 

[mattneck(Beavis)]

Green end cap on and release bearing, that means 5th swap is complete! 

Almsot gave me dad a hernia trying to do this earlier.. 150Nm of torque is A LOT!

We ahd to stick the box down on the floor, upright, with a piece of box section jsut underneath the 5th end of the casing to hold it off the floor.. My dad holding the gearbox mount bracket bolted to the diff housing and also holding the starter apature left me free to line up the torque wrench, stick a foot on the box, stand on wrench and support ymself on him.. about 1 full 260 turn eventually got it to click after a bit of effort upright before that, but it got there, and clicked bloody loudly! no arguing with it there 

So this leaves me with the hybrid box of 2..

          #1    #2   #3   #4   #5   FD
AUG - 3.45 1.94 1.44 1.13 0.89 3.67
CHE - 3.45 1.94 1.28 0.97 0.80 3.67

Now reads as..
          #1    #2   #3   #4   #5   FD
AUG - 3.45 1.94 1.44 1.13 0.80 3.67

Thus giving me my better cruising 5th 

All this was further spurred on also by a PM recieved from Mk2Kezza earleir this week:

Hi Mattneck,

Just to let you know that i've got a 0.75 5th gear cog (out of a 4T box) in my AUG box. Motorway cruising is immense as it ticks over about 2750 rpm at 70 mph. This of course means I get a return of around 42 mpg @ 70 mph - much better than the 0.89 cog that is standard in the AUG, as that gave me around 34 mpg @ 70 mph.

I did the conversion as I was travelling 450 miles a week and I didn't want to get a diesel!

What I would say though is that if I did the conversion again I would probably go for the 0.80 cog out of the CHE as this would give the best compromise between economy and acceleration. Surprisingly, she still pulls well with the 0.75 particulary when your up to about 4000 rpm, of course at this point your doing about 90pmh!

Anyway, good luck with the rest of the modding and i'll be watching with interest.

Keri.

P.s Mines a 1.8 EZ i think (out of a sirocco) digifant golf II.

P.p.s My record is 430 miles from one tank, this was averaging 70 mph - at 60 mph I may even get up to about 450?

some useful advice, and also defiantely swayed me from looking at 0.75 or 0.71 gearsets! 

[mattneck(Beavis)]

Gearbox nearing completion.. last few bits are now on order and will be arriving in a combination of genuine and bits from my works..

Pushrod Bush
Pushrod Seal
Input Shaft Seal
Selector Shaft Seal
Starter Bush (in GB)

Once these are all fitted and the box given a damn good clean and degrease as the bellhousing is full of cack, It will be promptly offered up, and bolted up to the block this week 

Next on the agenda drive shaft refurb! 

[mattneck(Beavis)]

Box seals complete!



Pushrod Bush
Pushrod Seal
Input Shaft Seal
Selector Shaft Seal
 
all done now.. Starter bushing needs to be looked at still.. tapping into that is required.. 

280s have become and addition to the collection



along with a £1 stealth shelf, what is gonig to happen with that is of course, anyones guess 





Now have an extensiv elsit of small things I need to source and attach and parts from germany are on their way somewhere, until then I'm stuck for any more doing! Doh.

[mattneck(Beavis)]

Driveshafts stripped and cleaned, gear stick housing and rods and that, stripped and cleaned, parts from germany arrived.. Things ar elooking ready to be put togetherish once again 

Did have an issue finding TDC the other night. the green plug had been loctited into the box, it required hammer screwdriver and some brutish behavious to get it out but it came free.. 





but the other one refitted fine even with the thread chaffed.

Starter and front mount bracket fitted up nicely and confirmed box was aligned perfect and bolted up no trouble. jsut requries lower clutch cover palte and rear little one by the flange to be fitted now 



Also managed to get a pair of marks on the pulleys for use when timing up the cambelt when the tappets finally get slotted in..



So not far off ahving it all bolted together and pushed out to one side to fester, while eveything else that needs done gets built! 

Current ponders: Powerflex, Eibach Springs and stick with Boge Turbo's..

[mattneck(Beavis)]

Well, powerflex thought amounted in me buying rally design polysport all round instead.. read up many reviews pointing to these and saying no increase in noise, or reduction in comfort, just optimal steering and handling

So here they all are:
ARB Eylet, ARB Bolt, ARB Inner, Wishbone Rear, Wishbone Front, Rear Beam 



And of course these got fitted up into the new bits ready to assemble the subframe..









So as stated, should see more positive and truer steering, and a more predictable solid ride and handling. Still in 2 minds regarding the rear beam bushes but have heard so much positive for them, it would almost now be rude not to try them at least!

Also read up on the Boge's I currently have fitted and they are applicable for most Mk2 applications.. 1.0, 1.3 and 16v carry the same, so with Eibach springs I'm sure will suit me just fine both in ride and handling

Also now thinking of mating the fronts with Mk3 VR6 (PR code 2E1) top mount setup combined with Mk4 sports type bump stops, though I hear this raises the front a little, the comfort and solidity of it is a gaining factor - oh and they are much easier to change than the evil slotted nut etc of a mk2! - Though thats one that still requires thought currently.

The engine will finally be sealed up soon also.. new tappets are here!



And the brake calipers will get a rebuild also, including the sliders etc upfront and the entire rear assembly's..



Have also picked up the front hub assembly's, which will be receiving new bearings as the old were dry even when turned by hand, and onto these the 280's will be fitted up.. Plus the PAS setup has arrived for which I have new boots, clips and tie rod ends, and am now pondering getting this professionally reconditioned by a local firm who my work use for all steering related stuff.. this includes a full seal/bush etc swap internal and externally in/on the rack..

Though it's freezing at the moment so I ain't doing hardly anything on it