Can I keep my manual steering rack on an abf subframe in the mk2

[Dogbot]

Basically have got a 90 spec mk2 8v on digi (ce2 fusebox) that I will be putting my mk3 abf engine into,
Now I have done plenty of research but there are 2 questions that remain unanswered so far,

1. I would like to keep my manual steering rack, as it feels very nice an much more responsive than my mk3 item which always feels heavy an creaks occasionally, will the mk2 rack bolt up to my freshly refurbished mk3 subframe, ( not fussed on using the mk3 subframe but definatley want to use my recently over hauled wishbones & hubs and tie rod ends) and if it will what belt should I run as it will need to be a lot shorter when not going around the ps pump... 

2. I really want to keep my hydro clutch and O2A gearbox from the abf as its just had a fresh VR clutch and flywheel lightened, now I have read that the corrado pedal box and master cylinder will allow me to do this when coupled with the abf's slave cylinder, can anyone confirm this? Or can I use my mk3 servo master cylinder and slave cylinder, with a corrado pedal box as I read the mk3 pedal box will not fit?

3. I read I need a mk2 1.3 gearbox cable for the speedo drive will this be the right calibration?

Many thanks in advance!! I've read so many threads & how too's I think I'm starting to confuse myself!! Lol

[Diamond Hell]

You've said there are two questions, yet you've asked three.

1. I would like to keep my manual steering rack, as it feels very nice an much more responsive than my mk3 item which always feels heavy an creaks occasionally, will the mk2 rack bolt up to my freshly refurbished mk3 subframe, ( not fussed on using the mk3 subframe but definatley want to use my recently over hauled wishbones & hubs and tie rod ends) and if it will what belt should I run as it will need to be a lot shorter when not going around the ps pump... 

Your non-PAS rack is more turns lock to lock.  Your decision to keep manual steering is a poor one.  The G3 subframe should fit the G2 and the non-PAS rack should fit the G3 subframe.  I'm not sure about the rack ends and balljoint combinations to get the right overall width with your set up.  I would keep the G2 subframe until the new motor is in and bedding down.

The PAS runs on a separate belt, so running no PAS doesn't make much odds.

2. I really want to keep my hydro clutch and O2A gearbox from the abf as its just had a fresh VR clutch and flywheel lightened, now I have read that the corrado pedal box and master cylinder will allow me to do this when coupled with the abf's slave cylinder, can anyone confirm this? Or can I use my mk3 servo master cylinder and slave cylinder, with a corrado pedal box as I read the mk3 pedal box will not fit?

hydro clutch will be ball-ache to sort.  I suspect the Corrado pedal box will fit, but I hope you're not precious about cutting away your firewall, as you're going to need to.  I'm not aware of any difference between master and slave cylinders between the cars - they're all using 02A gearboxes, so I don't think there will be any difference.

3. I read I need a mk2 1.3 gearbox cable for the speedo drive will this be the right calibration?

The speedo cable will probably work (I used an early Passat one).  The question is, what is the donor car?  If it's a 1.3 the speedo will be the wrong ratio.  You need a GTI speedo head with the 02A gearbox.

I think there's 3/2 of your questions answered.  The question you haven't asked is 'what driveshafts will I need to use?'.  With an 02A gearbox you need to use the long shaft from a Golf3, Eyebeefa 16V or a Corrado 8 or 16V - you're proposing narrow-track with an 02A gearbox so the wide-track Golf3 shafts will be too long.  The short shaft can come off anything that uses 100mm inner CV on a narrow track set up.

[Dogbot]

thankyou for your reply DH,
Im sorry, the third question popped up as i was finishing up my post & i forgot to change the first bit, pmsl... see I told you i'd confused myself 

The Donor Car Is my mk3 golf 16v,

Your non-PAS rack is more turns lock to lock.  Your decision to keep manual steering is a poor one.  The G3 subframe should fit the G2 and the non-PAS rack should fit the G3 subframe.  I'm not sure about the rack ends and balljoint combinations to get the right overall width with your set up.  I would keep the G2 subframe until the new motor is in and bedding down.

The PAS runs on a separate belt, so running no PAS doesn't make much odds.

hydro clutch will be ball-ache to sort.  I suspect the Corrado pedal box will fit, but I hope you're not precious about cutting away your firewall, as you're going to need to.  I'm not aware of any difference between master and slave cylinders between the cars - they're all using 02A gearboxes, so I don't think there will be any difference.

The speedo cable will probably work (I used an early Passat one).  The question is, what is the donor car?  If it's a 1.3 the speedo will be the wrong ratio.  You need a GTI speedo head with the 02A gearbox.

I think there's 3/2 of your questions answered.  The question you haven't asked is 'what driveshafts will I need to use?'.  With an 02A gearbox you need to use the long shaft from a Golf3, Eyebeefa 16V or a Corrado 8 or 16V - you're proposing narrow-track with an 02A gearbox so the wide-track Golf3 shafts will be too long.  The short shaft can come off anything that uses 100mm inner CV on a narrow track set up.

As it is a poor decision I will take over my PAS rack, thankyou for your advice, of course it runs on a seperate belt.... i replaced it not long ago.... blonde moment.... i do apologise :embarassed:

Thanks for confirming my thinkings that the cylinders should be the same as all on o2a boxes, although i didnt realise there would be bulkhead cutting involed was aware of some flattening with a hammer and drilling 3 holes but no cuttin..... i will look further into this.....

I will also look into the wide track as i've obviously mis understood something!!

[mk2bal]

Do the hydro clutch, don't do half a job. Its easy to do, especially with engine out, its just fiddly and laborious, but certainly not hard. Getting the corrado box into position with fuseboard and wiring etc in situ can be fiddly.. If there is a difference from flange to flange distance on gearboxes then shafts may need changing, if not just use the mk3 setup. As said earlier, I'd use the pas off the mk3, then you neednt change anything, just offer the whole subframe, including engine,gbox etc still attached up to the car and bolt it. You will need to change steering uj to pas model one, mk3 one should fit to your mk2 column (so I'm told, I changed my whole column)

[Dogbot]

Do the hydro clutch, don't do half a job. Its easy to do, especially with engine out, its just fiddly and laborious, but certainly not hard. Getting the corrado box into position with fuseboard and wiring etc in situ can be fiddly.. If there is a difference from flange to flange distance on gearboxes then shafts may need changing, if not just use the mk3 setup. As said earlier, I'd use the pas off the mk3, then you neednt change anything, just offer the whole subframe, including engine,gbox etc still attached up to the car and bolt it. You will need to change steering uj to pas model one, mk3 one should fit to your mk2 column (so I'm told, I changed my whole column)

Thanks for the reply
I think i know whereim goin with this now, you've all been verry helpful!!

[lemski]

I'm using mk4 golf track rod ends on a mk2 golf rack. Don't know if mk3s can be used, guy I bought it off put mk4 ones on as there longer (apparently)
Puttin the hydo clutch in is easy. R holes and she in. Will need to adapt where the throttle cable goes in. Cut and weld the corrado box. Ull see when its in the.

Also usin the mk3 shift ull need to cut the lungs off the mk2 shifter to bolt it up to the shell. Ull see it when ur undernieth though

[Diamond Hell]

In English?

[lemski]

Dh, half my text is missing.
Hydro clutch is easy. 3 holes and its in.
On the mk3 shifter, to make it fit the mk2 u need to make some new lugs up to be welded on to line it up to the mk2 mounting holes.

Corrado pedal box needs the throttle pedal modding on a differant angle to allow for the throttle to open fully.

I hope this makes more sense

[Dogbot]

Lol sort of makes sense, I'm aware of the mk3 shifter scenario and have a corrado shifter to drop in as that bolts up the same..

[danny_p]

mk4 shifter  and selector tower  idealy. mk3 one is a bit floppy