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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old June 8th, 2018, 18:26   #61
3L3M3NT
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Looking for some help to resolve why my car won't go into reverse, but will go into all the other gears just fine.
For those not familiar the transmission is a 6 speed FEL 4 Motion out of a MKIV Golf/Bora TDI(diesel) over in Europe.
So if there's anything you can think of feel free to post it up. TIA
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Old June 10th, 2018, 20:32   #62
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Guessing that if it can find all the other gears just fine there's probably nothing wrong with the transmission itself, but there maybe something amiss in the shifter box?

An easy way to check if it's the transmission or shifter box would be to pull the shifter cables off the top of the transmission and see if you can select reverse "manually" without the shifter connected.

The reverse "lockout" mechanism is in the shifter box by your knee. Unfortunately, it requires removing the exhaust and driveshaft to do anymore than a visual check inside the shifter box.

Dieselgeek has any/all parts that you might need inside this box.
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Old June 10th, 2018, 21:07   #63
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Quote:
Originally Posted by Fix_Until_Broke View Post
Guessing that if it can find all the other gears just fine there's probably nothing wrong with the transmission itself, but there maybe something amiss in the shifter box?

An easy way to check if it's the transmission or shifter box would be to pull the shifter cables off the top of the transmission and see if you can select reverse "manually" without the shifter connected.

The reverse "lockout" mechanism is in the shifter box by your knee. Unfortunately, it requires removing the exhaust and driveshaft to do anymore than a visual check inside the shifter box.

Dieselgeek has any/all parts that you might need inside this box.
What's weird is the car was shifting into reverse just fine last fall, so hopefully it's just the shifter bushings that you're referring to.

I'll mention to the shop to try disconnecting the cables and then try getting the car into reverse using the weight on top of the transmission, since I'm really hoping it isn't anything internal.

Fingers crossed that it's just the bushings, even if the exhaust and driveshaft need to be removed, it's better than having to drop the transmission.
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Old June 16th, 2018, 18:36   #64
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I figure I'd update the thread on what is going on with the car. The guys at Trudell Performance were able to figure out what was causing the car not to go into reverse and that would be some melted shifter cables. We came to the conclusion that with the turbo manifold loosening up, it was spewing hot exhaust gases right on to the shift cables, causing the protective plastic coating to melt making the shifter cables stiff and not letting the cables inside move as freely as they should.

With the help of Chris at Korwerks LLC he was able to get me a new to me set of shifter cables for an amazing price, so hit him up and see if he can help you out with your TDI needs. https://www.facebook.com/AWDTDI/?ref=br_tf He's also selling the back half of MK4 AWD cars, so if you're looking for a way to turn your FWD car into an AWD car he's your man.

I decided that with the shifter box and cables out of the car it would be a good opportunity to upgrade to the Sigma 6 Six Speed Short Shift Kit and eliminate any slop in the shifter with Dieselgeek's Deluxe MK4 Shifter Bushing Kit
Talk about having some precise shifts.

I should have some pictures to post coming up in the next few weeks as things finally wrap up and we can get the car on the road and on the track real soon.
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Old June 26th, 2018, 18:27   #65
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Well, things are starting to come together for the car. With the battery that came no longer willing to take a charge, I went with a lightweight Lithium Ion battery from Antigravity Batteries and got their RS-30 that only weighs 11.5 lbs and with their RS-30 Battery Tray weighs a total of 13.5 lbs




With me being in a wheelchair, I need a way to bring it with to the events, so last year I purchased a 5x9 all aluminum enclosed trailer from http://www.blizzardmfg.com/ this way I can load it up with my chair, tools, extra set of wheels, jack, cooler, spare parts, etc and not have to worry about it getting wet or stolen.
For whatever reason I haven't taken a picture of my trailer, but it's like the trailer below, but in a dark blue that matches my Galactic Blue Jetta.




My plan was to have a friend drive my Jetta towing the trailer and me and my friend that were signed up would be in the RTDI. I soon realized that I might not always be able to find someone to drive the Jetta, so I needed to come up with a way to tow the trailer with RTDI. I thought that I was going to have to have something custom fabricated, since I thought what are the odds that a company out there makes a hitch for an AWD MKIV Golf... low and behold Westfalia in the UK makes a towbar as they call it for my car!
After doing some searching around for places that would ship one to the US, I was able to work with the guys at Darkside Developments on getting it shipped over here.
Here's how it looks installed without the bumper cover in place.

Add the swan neck to the hitch, hook up the trailer lights, and you're all set to tow


Link to the hitch/towbar for those that might be interested in getting one for their car.
https://www.westfalia-automotive.com...277600001-438/

Then last but not least, after discovering that the shift cables needed to be replaced, I figured it would be a good time to upgrade to the Dieselgeek Sigma 6 short shift kit. It sure is a shame that these magnificent looking parts are hidden under the hood of the car, so I took some pictures of them before they got installed.




With any luck the car should be ready to go in the next couple of weeks.
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Old July 6th, 2018, 14:06   #66
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With the LiPo battery, what are you doing with charging rate?

I’ve wanted to get one, but I figure I’d wait until the bugs are worked out, and the prices come down a bit.

-Todd
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Old July 6th, 2018, 19:53   #67
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Quote:
Originally Posted by ToddA1 View Post
With the LiPo battery, what are you doing with charging rate?

Ive wanted to get one, but I figure Id wait until the bugs are worked out, and the prices come down a bit.

-Todd
There shouldn't be any issues with the charging rate from what I've read over on Rennlist when I was doing my Li Ion battery research. The newer ones all have Battery Management Systems build in to safeguard the battery.

Depending on what you're planning on doing with the car, you can get away with running a smaller battery than I am in my car. When I was emailing different Li Ion battery manufacturers they all said I could run a smaller size battery than I was inquiring about. When I was looking at them to start with, I was also keeping Ah in mind and they mentioned that if it was a daily driver it wouldn't be problem, but leave it sit for a week or 2 like I do and you better think of putting a battery charger on it or buy the next size up. The great think about the Antigravity battery is you can turn it off if want.

Here's the battery that Antigravity said would start my TDI no problem.
https://shop.antigravitybatteries.co...tive/atx30-rs/

Here's the Rennlist thread about Antigravity batteries. Start on page 2.
https://rennlist.com/forums/991-gt3-...for-2-gt3.html

Continuing with my build...
The shift cables are getting the finishing touches and they're protected by Heat Sheath - Aluminized Sleeving from DEI to prevent any future problems with the shift cables getting to hot. You can't really see it in the following picture, but it does capture the new Dieselgeek Sigma 6 short shift kit.


On other news, I couldn't help myself since they were on sale and still are until the 8th of July, but I purchased a set of Epic Euro Tuning Ultra Adjustable Control Arms. I was going to hold off until this next winter, but I saw how amazing the price was and had to purchase a set, since I didn't know if I was going to see them this low when I was ready to order them this fall.
Here's what I ordered: MK4 Ultra Adjustable Control Arms
They also have a more basic option as well: MK4 Control Arms

Depending on when I get them, I may go ahead and install them this summer still, otherwise it'll be a winter project. If they do get installed, I'll report back with how they perform.
Some teaser shots of the control arms(All credit of the pictures goes to Epic Euro Tuning)








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Old July 25th, 2018, 21:25   #68
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Nothing to crazy to post up, but I figure I might as add some more pictures to this thread.

Relocation of the battery is complete with the wires ran to the back of the car.


And last, but not least the rear bumper is back on the car and to fit the swan neck a little bit of trimming had to be done.


The goal now is to have the car finished for an August 27th track day at Road America.
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Old August 1st, 2018, 12:39   #69
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What routing did you choose for the power cable?
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Old August 5th, 2018, 18:58   #70
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Quote:
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What routing did you choose for the power cable?
The power cable got routed through the firewall and the was run under the driver's sill plate all the way to the wheel arc, then to the battery.

Here's a video I found on Youtube that explains it better, plus you can visually see what I'm trying to type out. lol
https://www.youtube.com/watch?v=5m7tJzn2WmA

Hope that helps.
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Old August 11th, 2018, 14:11   #71
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Well good news bad news situation. I might as well start with the bad news...As I had been posting my car has been at Trudell Performance in Green Bay, WI and earlier this week I made to decision to move my car to VL Performance in Appleton. I had finally had enough of the guys at Trudell not getting enough done with the car to make my August 27th track day.

The shop manager at Trudell kept on making promises that certain things would get done and then he told me that he got offered the opportunity to own a different shop in 1.5-2 years, so he left Trudell only giving them 4 days notice. He told me that he would be moving my car to the new shop that started at and he would finish it there. That was in the middle of July, so when I went down there at the end of July for a doctor's appointment and stopped by his new shop. When I got out of my van, I started looking for my car, only to find out it hadn't been moved so I went back to Trudell's' to see what, if any progress had been made. The only real progress that had been made is they re-installed the bumper cover after they installed the hitch. If that's the only thing they could get done in 2 weeks, I knew I needed to rescue my car and take it elsewhere.

With my dad's help he was able to pick it up from Trudell with all the parts and interior loaded in the car he headed to Appleton to drop the car at VL Performance. Right away he meet the shop manager there who helped bring everything in and inventory what was there. Since I couldn't make it down there, the shop manager gave me a call to discuss what needed to be done still and I also told him about all the stuff Trudell had done, so they could double check their work. Overall just from our phone conversation I got a much better feeling about moving my car to VL Performance, so a big thank you to Kevinski4 for recommending them as a shop.

The tubular control arms I ordered from Euro Epic Tuning showed up and they look amazing. I'm probably going to hold off on installing them till this winter, since I don't wanna play with my current settings at the end of the season.

Here's how they look in black powdercoat.


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Old August 19th, 2018, 20:51   #72
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I'll start off by saying the guys at VL Performance (VLP) have been phenomenal to work with so far and gone beyond my expectations. After realizing the poor quality of welds used on the roll cage and mounting plates, they completely removed the cage and mounting plates. VLP sent me pictures with how $#!tty of a job Trudell did when prepping the sheet metal in the car for the plates to be welded to them. Apparently rather than use a wire wheel or something of that nature, Trudell used a grinder to prep the metal, causing the sheet metal to be so thin in spots you could see the light from a flashlight pass through.

Like so








So the guys at VLP went and made custom mounting points for the cage to attach to.








As you can see there's a huge difference the quality of work.
Which makes me very happy that I changed shops and I'm still kicking myself for not moving the car to VLP way back in the middle May when Trudell missed my track day deadline. Lesson learned and now I know where I'll be going in the future for any custom work.

Especially, since here are the "high quality" welds that Trudell layed down.


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Old August 26th, 2018, 18:43   #73
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Well with the RTDI out of commission right now, I decided we might as well take my decently modified Jetta to the track instead. So we hooked onto the trailer I had Blizzard make for me so I could take tools, tires, jack, spare parts, and most importantly my wheelchair to different events in the area.

So if you're in the market for a quality aluminum trailer and you live in the eastern part of the US or Canada look no further than http://www.blizzardmfg.com/









And of course my dog thought he should be the center of attention.
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