The "What did you do to your B4 today" thread...

BamaB4S

Veteran Member
Joined
Oct 28, 2011
Location
AL
TDI
1996 Passat
A pressure plate spring broke on my original clutch at about 235,000 miles
 

alext91

Veteran Member
Joined
Mar 26, 2015
Location
Northwood, New Hampshire
TDI
1996 Passat TDI, 2013 Jetta Sportwagen TDI 6MT Pano (Sold), 2015 Golf S 4DR 6MT (Sold), 1999.5 Jetta TDI Tornado Red (Sold)
Competed in my first TSD rally with a friend in my B4. Had fun, learned a lot and didn't come in last 👍


 

JordanTr

Well-known member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V, 2006 Dmax
Very cool on the rally!!

Today I glued on a mk4 passenger mirror glass on to replace the original (and already re-glued once) glass that fell off. I used windshield urethane so hopefully it’ll work better. Now both sides have mk4 glass. Drivers side was done by the PO.
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
Picked up a 95 or 96 Passat GLS for parts. Now I finally have everything I needed to make my interior all black - carpet included.

20230902_184830.jpg

Gauge cluster doesn't look original. From a 2.0 car, maybe? I was thinking about doing the MFA conversion but apparently this isn't the one.

20230902_174642.jpg
 

Steve Addy

Top Post Dawg
Joined
Aug 7, 2002
Location
Iowa
TDI
97 Mk3
Picked up a 95 or 96 Passat GLS for parts. Now I finally have everything I needed to make my interior all black - carpet included.

View attachment 132989

Gauge cluster doesn't look original. From a 2.0 car, maybe? I was thinking about doing the MFA conversion but apparently this isn't the one.

View attachment 132990
Yeah, that cluster is not MFA, unfortunately. Must have been from a 2.0 ABA powered car because all the VR cars got MFA.

Steve
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
After a full day of work I finished the black interior swap. I pressure washed the carpet for a good half hour and was shocked at how much coffee-looking water came out. It looked brand new after it dried though, MUCH better than the old tan carpet which was absolutely filthy. The worst part was having to remove the center console and all the trim pieces under the dash. I cut it in a couple of spots to make the installation easier considering those areas get covered up anyway. Now I'm just waiting for my new black floor mats to arrive and it'll be done.

20230904_101002.jpg

20230904_101047.jpg

Sadly I found a couple of rather large rust holes under the passenger seat area where the rubber plugs were. Going to see how possible it is to attach a piece of sheet metal from the bottom with self-tapping screws and windshield urethane. If anybody has tips for a decent fix other than an expensive body shop repair, feel free to comment.

I also swapped on the hood and front trim piece from my donor car due to how clean they were, plus the color matches each other. Much easier on the eyes than white on black.

20230903_181006.jpg

In the next couple of days I'll be doing an oil change and looking over the front end for what's causing the loud "pop" every time I hit a bump. It still rides and drives perfectly though.
 

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
Sadly I found a couple of rather large rust holes under the passenger seat area where the rubber plugs were.
Sadly, I expect that…. those plugs are notorious for that.

I’d weld the patches in, but I’ve also done what you intend to do, on Rotbox. It got me a few years, but if you’re actually planning on keeping that car, I’d weld them.

-Todd
 

starrd

Veteran Member
Joined
Nov 24, 2003
Location
Merritt, BC
TDI
1996 Passat
Finally installed my MkIV rear calipers and stainless steel rear brake lines. I got them from ECS tuning years ago. One of the brake line connections (banjo bolt) on the stainless steel rear brake lines would not seal. On closer inspection, the surface next to the copper sealing washer on the brake line was nicked. I had to file that out, sand and aneal the copper washers and was able to get it to seal. These brake lines have circular machined grooves to help the copper washer seal, but they don't work if there is a radial nick which is what this had. I'm not sure how I could have done that because I installed the copper washers and banjo bolt all at once. Machining on these brake lines is poor.

Picture of brake line banjo bolt area here:

One other trick I did was to swap the hand brake cable bracket from the old calipers to the new ones. The old ones are slightly different and present the hand brake cable at a better entry angle to the hand brake lever on the caliper. Of course the allen bolt that mounts this bracket is not at the same radial distance from the lever pivot point. I just drilled out the bolt hole slightly larger to fix this.
 
Last edited:

JordanTr

Well-known member
Joined
Mar 28, 2022
Location
Kimberley, BC
TDI
1996 B4V, 2006 Dmax
I collected the other half of the 02J shifter upgrade today! $40 for the whole shebang! There were lots to pick from so I was able to find shift cables without split boots.
 

thechoochlyman

Vendor , w/Business number
Joined
May 7, 2015
Location
Campbellsville, Kentucky
TDI
1997 B4 Sedan
Oil change last night. Inspected my front driveline for loose or defective parts but it all looks good, so I'm a little stumped on what's making that popping sound. Maybe it has something to do with all the space between the front struts and the strut tower?

My transmission gets to where it doesn't shift as easily after about 20k miles. I wanted to at least check the fluid level, and I had to use an air chisel on the plug to get it out. I've always filled through the shift tower in the past so I never had a reason to remove the plug. I have a spare O2A sitting in the corner, so I salvaged a good plug from it. I ended up draining the fluid and filling it up with Royal Purple 75w-90 I had leftover from a previous project. First time using anything in it other than G070 in a while, but it's shifting nice again.

Drain Plug.jpg
 

alanack

Well-known member
Joined
May 10, 2022
Location
Rhode Island
TDI
1998 Jetta
@alanack, it’s like they grow on trees down south! As my dad says… Never hurts to have a spare…
Its actually from NY garaged its whole life.
Was a VR swapped to a TDI. 70k on shell 330 on motor.

Ran away on me at least twice already. Should probably look into that.

The 2 quarts of oil that came out of the intercooler might have something to do with that.
🧐
 

TDIDaveNH

Left Lane Coal Roller at Large
Joined
Feb 17, 2009
Location
North Conway, NH
TDI
'97 Passat x2
More progress on I-red to report: New SBC Stage 2 daily clutch installed, new steering rack boots, new oil pan gasket, both front wheel bearings replaced and both tone rings media blasted & painted since they were getting a bit crusty after almost 5 years off the road. Lastly in this repair session I put on new Zimmerman front rotors & pads, changed the engine oil and filled the transaxle with Redline MTL. The car is now back together and driving, as of tonight I have 650 miles on it...feels good to daily a B4 TDI after 4 years of hauling the mail with various Scooby cars. Instruments long dormant once again register life in the machine....and a piece of my soul has returned. I have a pretty good list going with everything else it needs to be "West coast ready" which I'll be getting to very shortly, not the least of which is figuring out where all the brake fluid is going. I have about 5-6 more repair sessions planned out but the clutch was the biggest most involved one.

 
Last edited:

alext91

Veteran Member
Joined
Mar 26, 2015
Location
Northwood, New Hampshire
TDI
1996 Passat TDI, 2013 Jetta Sportwagen TDI 6MT Pano (Sold), 2015 Golf S 4DR 6MT (Sold), 1999.5 Jetta TDI Tornado Red (Sold)
More progress on I-red to report: New SBC Stage 2 daily clutch installed, new steering rack boots, new oil pan gasket, both front wheel bearings replaced and both tone rings media blasted & painted since they were getting a bit crusty after almost 5 years off the road. Lastly in this repair session I put on new Zimmerman front rotors & pads, changed the engine oil and filled the transaxle with Redline MTL. The car is now back together and driving, as of tonight I have 650 miles on it...feels good to daily a B4 TDI after 4 years of hauling the mail with various Scooby cars. Instruments long dormant once again register life in the machine....and a piece of my soul has returned. I have a pretty good list going with everything else it needs to be "West coast ready" which I'll be getting to very shortly, not the least of which is figuring out where all the brake fluid is going. I have about 5-6 more repair sessions planned out but the clutch was the biggest most involved one.

This is awesome! Nice to know there are others in NH driving these cars, I've only seen a couple around. Mine is currently down due to a power steering leak that I have yet to investigate. Might get time to dig into it this weekend, but I need to replace sticky rear caliper(s) on my mk6 first.
 

Mcgink

Veteran Member
Joined
Oct 15, 2004
Location
South of Boston MA
TDI
I-Red,"The Passat formerly known as Harlequin" 97 B4, a non VW GTDI too
More progress on I-red to report: New SBC Stage 2 daily clutch installed, new steering rack boots, new oil pan gasket, both front wheel bearings replaced and both tone rings media blasted & painted since they were getting a bit crusty after almost 5 years off the road. Lastly in this repair session I put on new Zimmerman front rotors & pads, changed the engine oil and filled the transaxle with Redline MTL. The car is now back together and driving, as of tonight I have 650 miles on it...feels good to daily a B4 TDI after 4 years of hauling the mail with various Scooby cars. Instruments long dormant once again register life in the machine....and a piece of my soul has returned. I have a pretty good list going with everything else it needs to be "West coast ready" which I'll be getting to very shortly, not the least of which is figuring out where all the brake fluid is going. I have about 5-6 more repair sessions planned out but the clutch was the biggest most involved one
Nice work Dave, it's great to hear that I-Red is back on the road. West coast will hopefully get it out of the rust belt.
 

TDIDaveNH

Left Lane Coal Roller at Large
Joined
Feb 17, 2009
Location
North Conway, NH
TDI
'97 Passat x2
Nice work Dave, it's great to hear that I-Red is back on the road. West coast will hopefully get it out of the rust belt.
Thanks, I've got lots more to address on I-Red. My daily scooby mobile was giving me extremely low power drivability problems so I had to get the clutch done fast and could not wait on axles to show up or upgrade the turbo drain line like I wanted since I had to get I-Red rolling. It's burning through a 1/2 liter of brake fluid a day, there is a leak below the master and it's leaking all over the new steering boot on that side. It'll all be fixed soon. I'm not moving..."west coast ready" is a state of mechanical confidence. I-Red will be off the road for the winter in a couple months.
 

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
both tone rings media blasted & painted
Ah…. I have/had a set of hubs with those tone ring screw holes, and never knew what they were for. I never owned a B4 with ABS, so I was a bit stumped. Mystery solved….

-Todd
 

Abacus

That helpful B4 guy
Joined
Nov 10, 2007
Location
Relocated from Maine to Dewey, AZ
TDI
Only the B4V left
I have a pretty good list going with everything else it needs to be "West coast ready" which I'll be getting to very shortly
Let me know what you need, I have some stuff here. While there aren't any B4's in the local yards, there are other avenues.

I'm also West Coast if you want to make a test trip, we always have room and you can stay as long as you'd like. You can even borrow the wagon to fetch parts so long as the 6 speed is still in it when you're done. :LOL:
 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
All due respect, Mark, you're in the Southwest. You're some 400 miles from the coast. Which may be a good thing. ;)
 

Abacus

That helpful B4 guy
Joined
Nov 10, 2007
Location
Relocated from Maine to Dewey, AZ
TDI
Only the B4V left
All due respect, Mark, you're in the Southwest. You're some 400 miles from the coast. Which may be a good thing. ;)
That won’t even register on the wagons fuel gauge, so I consider it a rounding error. Admittedly the seafood here is pretty horrible but I bought some beachfront property, along with a bridge somewhere, from a ‘trustworthy’ source a few years ago.
 
Top