homemade mk1 golf caddy (4motion 4wd /holset hx40 ,,turbo resto,56k warning

[adaptorman]

more quality work by your good self, respect!!

cheers jase , as said its just a bit of fun really , only a case of cut , shape fit and weld ,,,but it works , as i couldnt find anyone in the u,k thats done one runing ,,

[adaptorman]

well i thought might as check the gearbox as i was hearing a horrible free play noise and excess play between gears (like a engine mount had gone , so here we are the insides of a 6speed 02m gearbox lol

looks nice and clean ,
diff looks beefy

beefy gears , so thought rip the lot out , and check all the bearings


everything looks realy nice and all bearings look in decent shape too with no rough or pittered bearings ,or damaged teeth


 i only found some very slight wear on the input shaft

so im happy to the problem is the dam horried dual mass flywheel , as i grabbed it and there must be 3inch of side to side play  and 4mm of bearing movemenet , so
waiting on new single mass flywheel, so decided to re build the gearbox ,, miht as well reuse it ...

[Baylez8v]

the thought of taking a gearbox apart makes my balls jump into my mouth, u r one crazy mofo

[adaptorman]

the thought of taking a gearbox apart makes my balls jump into my mouth, u r one crazy mofo

lol lol not bad to mess with
this after more gearbox ratios and dif changeing as iwant taller gears
first to 2 6speed 02m gearboxs  one is the 4motion 4wd the other 2wd
notice the differce in bellhouseings
then riped both gearboxs apart and removed the difs from both gearboxs
and removed the studs (nice little job lol)

which then looks like this

and split the ring gear of the 4motion dif

then split the other gearbox

remove diff ull see the lengh differnce as one has a spline for the transfor box

had to drill these as i dint want to damage the ring gear
30mins later

little tip when tapping these pins out , drill a piolet hole and insurt a punch , as if u try to hammer these out they cruch and go really tight in the holes

rivots removed (orderd new bolts to refit )
youll see the size differnce

then re fit and bolt it back together ,, done done lol

[nige_s]

dead easy 

[adaptorman]

dead easy 

it is ,,,, nothing hard about this bit , just a few wacks with the old hammer , and no bark missing from my hands either lmao

[adaptorman]

few pics of diff , fitted and therd locked




job sorted

[Asbo Sovfinger]

I've had a number plate holder that needs to be changed over for the last week and I can't get the motivation to do that, let alone rebuild a gearbox 'cos I've got a few minutes spare 

Can't say anything more than fair play, fella.  This has got be one of the most interesting threads on here and I look forward to each and every update.

Keep up the good work mate.

[adaptorman]

lol top man fella , will basicly im awaiting a flywheel then i can re fit the lot ,,

[adaptorman]

well still no dam flywheel yet , so i thought id kill a bit of free time and split this r32 engine see how bad it is ,has a mint dual mass flywheel

removed head and my first thought was right , meaning basicly the engines crank is shot , as u can se were the piston has been tapping at the head,

removed pistonds and rod and tbh they dont look that bad , considering some ive seen in the past and the bores look good in the block


then found the problem (ive never seen mains this bad )


so tested the clyinder head and removed the 4 valves and lucky they fine , so i have my r32 head i wanted ,,,which ill build another moter up when ive more time , regards the rest of the r32 i dont think ill be bothering with it