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Go Back   TDIClub Forums > VW TDI Discussion Areas > Upgrades (non TDI Engine related)

Upgrades (non TDI Engine related) The place of handling, lighting and other upgrades that do not relate to the performance or economy of the TDI engine. In other words upgrades to your TDI that don't fit into TDI Fuel Economy & TDI Engine Enhancements.Please note the Performance Disclaimer

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Old September 25th, 2008, 22:11   #796
Losha
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[quote=alphaseinor]there is no flywheel on an AT
quote]

Hmm, so what you call that thing that starter turns over to start engine? I always thought and remember in repair manuals it always called flywheel for AT & MT. The MT flywheel is a lot thicker and has milled out surface against which clutch grinds. On AT flywheels is thin and nothing grinds against other then torque converter bolts on to. just my .02
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Old September 25th, 2008, 23:49   #797
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the AT is the torque converter, not a flywheel... and the thin metal thingie is called a flex plate.
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Old October 2nd, 2008, 10:49   #798
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Default mongo brake pedal

Several times my foot hit the edge of the brake pedal when going for the clutch; unsettling to say the least. So I have been think about just taking a metal cutoff disk to the excess brake pedal. I'm thinking if I do it right, the rubber cover from a 5 speed brake pedal will fit just right. Of course I'll need to debur the sharp edges so the the cover does not get cut.

From this comparison picture below, it looks like the pedals all come down from the same location, and my plan will make just like OEM 5 speed (which must have the smaller pedal for this very reason).

[IMG]%5Bimg%5Dhttp://pics.tdiclub.com/data/500/medium/Pedal_comparison.jpg%5B/img%5D[/IMG] <<< VISTA GARBAGE



Side note: My foot has never sliped off the clutch, so why do I need such a mongo brake pedal? Maybe they are marketing to former US cars with even bigger brake pedals.
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Last edited by GdB; October 2nd, 2008 at 10:52.
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Old October 3rd, 2008, 18:57   #799
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Found a great deal on an engine support bar... $50 at Harbor Freight
http://www.harborfreight.com/cpi/cta...emnumber=96524
not sure if this is a sale or not, price is good at least for this weekend.
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Old October 18th, 2008, 22:01   #800
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Default Auto to Manual Brake Pedal Conversion

I did the Auto to Manual Brake Pedal Conversion today. Thanks to thebigarniedog for sending the OEM cover.

1st I measured the inside of the new smaller cover and the bigger auto brake pedal to see how much to cut off:

H W
Auto 2.6" 3.8"
Manual 2.3" 1.9" (estimated)

The old and new covers:



Mark off how much to cut, including the grease pencil line:
Trim 0.3 to 0.35 off the bottom, the left half, and lower left angle...


Looking at the back side I see some welds, but they look like no problem. If they are cut, no biggie, since you push straight down (no side torque load), so they wont be needed as much.


Getting ready to make a lot of dust with a metal cuting wheel.


My rotozip with a elbow and 4" wheel makes this job go fast.


After cutting and some filing rough edges and sanding to polish:


Some cold galvanizing spray paint:


Push hard on the cover with my foot, after triming some of the inference rubber on the right side.
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Last edited by GdB; October 18th, 2008 at 22:04.
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Old October 18th, 2008, 22:52   #801
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GdB, you did nice job on brake pedal modification! Just curious, why did you decided to cut a pedal instead of going to junkyard and get a pedal from 5speed VW?
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Old October 19th, 2008, 00:10   #802
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Nice going...I can see why, that clutch pedal was pretty close to the brake.

I'm planning a 5 speed swap very soon and I'm dealing with a guy on vwvortex and just planning on getting the brake pedal from him too.

I have a semi-related question though. I am well-versed with driving manuals and dont have any concerns there, however I have never driven a VW manual. I did sit in a 5 spd NB TDI last week but didnt drive it, the stupid detailers had armor-alled the clutch pedal and it was very slick so I didnt bother driving it. I doubt they would not have liked my foot slipping off the clutch and then plowing into a line of brand new Passats.

Anyway, apart from the slippy pedal...I found the position a bit far right for my tastes, and it had longer travel than I anticipated. How much of that travel is actually used in driving? What I would like is to be able to have my left foot on the dead pedal, and then be able to rotate on my heel to control the clutch without too much issue. I'm a big guy and I like my legroom and being able to spread out.

I'm thinking if there was some way I could modify the clutch pedal to be the size of the A/T brake pedal...that I could be pretty happy. Any of you think this would be possible?

Losha I'd like to talk to you sometime about maybe getting some help from you on the swap. If not on person, then at least keep you on retainer for online/phone help? I'm loosely planning on sometime in december or january. My temp. job placement will be done then. Hopefully I'll have another job by then, but if I have a few weeks to myself...it'll be swap time for sure.
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Last edited by TDICADDGUY; October 19th, 2008 at 00:14.
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Old October 19th, 2008, 12:07   #803
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Quote:
Originally Posted by TDICADDGUY
Losha I'd like to talk to you sometime about maybe getting some help from you on the swap. If not on person, then at least keep you on retainer for online/phone help? I'm loosely planning on sometime in december or january. My temp. job placement will be done then. Hopefully I'll have another job by then, but if I have a few weeks to myself...it'll be swap time for sure.
Feel free to contact me via email or PM. I will be doing another manual swap sometime in november on friends jetta. So if you have sometime you could come and take a look whats involves in doing manual swap. Also I'm planning on going to MN next weekend or on november 8th, so we could get together and you can see how I do swaps and test drive my TDI. I will let you know when I will be in your neighborhood next time.
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Old October 19th, 2008, 14:44   #804
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Default Time

I am extremely busy, so time was a big deal. Also, I am very handy with fabricating. The time it took to do this way was about 1 hour. It helped that I happen to have a very complete set of tools to do metal cuting and filing, sanding. My shop vac and and other stuff was all close at hand.

Do you think an OEM brake pedal could be installed in 1 hour?

Quote:
Originally Posted by Losha
GdB, you did nice job on brake pedal modification! Just curious, why did you decided to cut a pedal instead of going to junkyard and get a pedal from 5speed VW?
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http://pics.tdiclub.com/data/500/GdB...D_VERSION2.doc
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Old October 20th, 2008, 11:43   #805
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Probably not since to replace the glove box on my Jetta I have to remove the center console.
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Old October 20th, 2008, 14:37   #806
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Quote:
Originally Posted by midntdi
Probably not since to replace the glove box on my Jetta I have to remove the center console.
Hmm, when I replaced glove box on my golf and another GTI never had to remove center console. All you do is loose 3 on top screws and 3 on bottom then pop off right side cover and you just pull glove box out, that simple. Don't know why you had to take half interior out to remove the glove box.
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Old October 20th, 2008, 14:39   #807
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Quote:
Originally Posted by GdB
Do you think an OEM brake pedal could be installed in 1 hour?
Don't know I haven't really looked into that, what it involves in removing brake pedal. I don't notice any issues with clutch pedal been too close to brake pedal yet.
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Old October 22nd, 2008, 11:07   #808
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Default A3 020 tranny into A4 for 5 speed tranny swap?

Just wondering if a 020 tranny from a A3 TDI would work in an A4 TDI?

It looks tricky, and probably not worth it.

QUESTION: Are the 020 tranny Speedometer cable threads and interface the same as the 02j?
QUESTION: Are the 020 tranny mounts different?

Some research results:

http://en.wikipedia.org/wiki/Volkswagen_Golf
Golf Mk3 (A3/Typ 1H, 1992-1998)

http://forums.vwvortex.com/zerothrea...rint&id=642018
“CORRECT ME IF I'm WRONG:
020 - Mk1, Mk2, Mk3, Scirocco, B4 passat 4cyl gasoline engines,
02A - Corrado, B3 Passat, B4 passat TDI & VR6, Mk3 VR6 & TDI
02J - Mk4, B5
02M - 6 speeds from Mk4's”


http://forums.tdiclub.com/showpost.php?p=389785&postcount=2

A3 Cars (~1996-1999.5 in NA)
-------
1.9L TDI (engine code AHU)
5-spd manual tranny (code 020 or 021)
4-spd auto tranny (code 096 or 01M)

A4 Cars (~1998-present in NA)
-------
1.9L TDI (engine code ALH)
5-spd manual tranny (code 02J)
4-spd auto tranny (code 01M)

02m swap into a mk4 http://mistralvr6.topcities.com/02MSwap.html#1
“02j and 02a transmission are interchangeable. some of them require replacing the flanges. but is very easy to do with a sledges hammer and a chisel.”

“020 Trans Speedometer cable gears:
020 3.9= 171 957 821 A (WHITE)
020 3.6= 171 957 821 B (RED)
020 4.2= 171 957 821 C (Green)”

in case it was driving anyone else bonkers as well- the bolt for the 020 speedo gear plate (that holds the cable into the tranny) is M7X1.25- a thread pitch that is incredibly difficult to find in places other than the dealer. thanks vw! the bolts that hold the lower inspection plate to the bellhousing are M7X1.0, some hardware stores will carry these.”

“ok, 020 gears and 02a/02j gears WILL NOT INTERCHANGE. now alot of stuff between 02a and 02j will interchange, but I don't know all the technicalities here. I think al the 02a/j gears will interchange, and also 02B, 02C, and 02D tranny internals for the most part”

“The case of the O2A/J is actually shorter then the 020's. The O2A/J's are pretty similar on the outside, but not exact, as we found out. The casting around the diff case has a bit more meat on it, as well as the casting for that we use for the sidemount.”

020 Transmission Specifications
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Last edited by GdB; October 22nd, 2008 at 11:11.
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Old October 22nd, 2008, 14:50   #809
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I've had a lot of requests to put in a 02j into a mk3 where an 02a was... it looks like it should work just fine... the shift linkage box on a mk3 only has three mounting points, where the mk4 has four...

That's the extent of what I know for sure...
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Old October 24th, 2008, 19:08   #810
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I got the metal coolant flange installed to fix a leak. I also used the grey coolant specific RTV sealant to be double sure of no future leakage.

For reference, the hose that is unique to the manual metal coolant flange is

VW PN: 1J0 122 157 BF

That way if you want a new hose when you install it you can get it on worldimpex for $20 or maybe at Napa?
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