What is it in the gearbox that tends to fail, is there a common fault?

Adaptor plate to fit 02x series 'box was available from Sorg Motorsport back in the day for something like €900. Plus you've then got to chop the chassis up to fit an 02a or similar in there and get custom driveshafts made. By the time you've done that, you may as well have saved your AEE forged build funds and the €900 and just put a 20v lump in there anyway! More power, more reliability, less cost and the same chassis choppage.

were the AAE fitted to later golfs with with the big block gear box? if so using one of them would be a way to knock €900 off the build for the cost of an adaptor plate, if your handy with a grinder/welder then the chassis leg will cost nothing but time and materials, then its just the custom shafts to buy which can cost about £3-400?

it would take a brave man to chop their chassis leg to that extent, but if you have the balls it shouldn't really be expensive to switch to the 02 boxes

I've made an 020 box fit my afh easy enough just made an adapter plate and machined the bell housing

Shouldn't need custom driveshafts either as from what I measured the drive flanges are same distance apart as an 085 box

It would just need a new mount for the gbox at the front as the mount sits directly under the chassis rail so could mount directly to that and some of the sheet metal cut away for the box to poke through into wheel well a little

For the rear mount you would need to adapt the polo item and could probably sort of mix and match with the standard golf item to make a good strong mount

I haven't looked into the rear one yet but mine will be custom anyway

Just to add if you do need custom shafts I found someone who will shorten and sleeve driveshafts for £30 each one he does it for a lot of the mini lads who drop vtecs in and has a good reputation

I'd imagine you probably would need custom shafts, the small block golfs use different length drive shafts to the big block ones so maybe the positioning of that part of the box is different?

Adaptor plate to fit 02x series 'box was available from Sorg Motorsport back in the day for something like €900. Plus you've then got to chop the chassis up to fit an 02a or similar in there and get custom driveshafts made. By the time you've done that, you may as well have saved your AEE forged build funds and the €900 and just put a 20v lump in there anyway! More power, more reliability, less cost and the same chassis choppage.

were the AAE fitted to later golfs with with the big block gear box? if so using one of them would be a way to knock €900 off the build for the cost of an adaptor plate, if your handy with a grinder/welder then the chassis leg will cost nothing but time and materials, then its just the custom shafts to buy which can cost about £3-400?

it would take a brave man to chop their chassis leg to that extent, but if you have the balls it shouldn't really be expensive to switch to the 02 boxes

True, but even just looking at the chassis choppage - I reckon by the time you're doing that you may as well go 20v. Custom shafts are a good idea either way (I'm assuming decent power here, so sleeved stock items aren't suitable - ask the 20v 6N guys!!), and you've got to chop the chassis either way.

That leaves you with AEE lump (£50), fancy cylinderhead (£650), pistons and rods (£1200), turbo manifold (£150) and lots of other odds n sods to get maybe 220-250bhp versus £800 20v donor car, £500 bigger turbo and £300 remap for an easy and reliable 280bhp. Obviously there's fuelling and ignition to think of, and loom etc. etc, but I think it illustrates the point.

If anyone can suss out a way of getting a big block 'box on a small block engine into an 86C chassis'd Polo without major front-end surgery for cheap then fair play, otherwise I reckon we should encourage them to do that bit more fabrication and get a 20v in there.

There's a German guy on CG40 with an 02A on his G60'd AFH race car though, but the front-end is semi-spaceframed, and he's tilted the motor 20° apparently to get it to fit. Bellhousing was mounted using a 20mm adaptor plate, but even after all that he's had to move the alternator to the back of the block, knock up new mounts all round and build a custom oil system and sump. Guess it makes sense for him where there are strict engine capacity rules for each race series/class, but without that restriction surely a 20v is a similar amount of fabbing?

for custom adapter plate you can mail this person,,,

http://www.polotreff.de/profil/27528 this guy can make everything and it,s good stuf, ore you can build it yourself :) but his price is not to bad i think..

wen i was mailing him the price was,, 290 euro,s

Hallo,

Eine Platte für das 02A Getriebe kann ich Dir fräßen. Die Kostet 290.-€ + Versand nach Holland! Die passt 100%ig !

Dominic

he also has a tread on g-laderseite,

http://www.g-laderseite.de/forum/viewtopic.php?t=11609

Profile

http://www.g-laderseite.de/forum/profile.p...file&u=2240

You can also take the golf aee engine and then you can bold the gearbox to it because it,s a bog block conversion in the golf3 :)

but i dont know if the are in england (GB}

Gr Richard

The later type 02* as fitted to so many post 90s VW's, including my mrs '02 Golf TDi, looks really short compared to the previous design with the rod clutch release mechanism. It was used in the 6-speed Lupo and they're not the widest car in the world, and a well known couple of 6n2's didn't need chassis legs chopped afaik.

There's an assumption that the chassis will need chopping up, but does anyone actually know it does..? (wife's out so i can't measure it atm)

You'd need the right cylinder block, being the iron Golf/Bora/Lupo 1.6 16v block if going for that deck height, or as Guy says the MK3 Golf 1.6 AEE block if going for AEE for the tall deck (yes it's an AEE, yes it takes the 02 box).

How much taller is the AEE block to a normal polo short block Mikey do you know

Edited 21 October, 201213 yr by StinkyPete

About 10mm I think! It's about 5mm off the bonnet when it's closed anyway haha

Adaptor plate to fit 02x series 'box was available from Sorg Motorsport back in the day for something like €900. Plus you've then got to chop the chassis up to fit an 02a or similar in there and get custom driveshafts made. By the time you've done that, you may as well have saved your AEE forged build funds and the €900 and just put a 20v lump in there anyway! More power, more reliability, less cost and the same chassis choppage.

were the AAE fitted to later golfs with with the big block gear box? if so using one of them would be a way to knock €900 off the build for the cost of an adaptor plate, if your handy with a grinder/welder then the chassis leg will cost nothing but time and materials, then its just the custom shafts to buy which can cost about £3-400?

it would take a brave man to chop their chassis leg to that extent, but if you have the balls it shouldn't really be expensive to switch to the 02 boxes

True, but even just looking at the chassis choppage - I reckon by the time you're doing that you may as well go 20v. Custom shafts are a good idea either way (I'm assuming decent power here, so sleeved stock items aren't suitable - ask the 20v 6N guys!!), and you've got to chop the chassis either way.

That leaves you with AEE lump (£50), fancy cylinderhead (£650), pistons and rods (£1200), turbo manifold (£150) and lots of other odds n sods to get maybe 220-250bhp versus £800 20v donor car, £500 bigger turbo and £300 remap for an easy and reliable 280bhp. Obviously there's fuelling and ignition to think of, and loom etc. etc, but I think it illustrates the point.

If anyone can suss out a way of getting a big block 'box on a small block engine into an 86C chassis'd Polo without major front-end surgery for cheap then fair play, otherwise I reckon we should encourage them to do that bit more fabrication and get a 20v in there.

There's a German guy on CG40 with an 02A on his G60'd AFH race car though, but the front-end is semi-spaceframed, and he's tilted the motor 20° apparently to get it to fit. Bellhousing was mounted using a 20mm adaptor plate, but even after all that he's had to move the alternator to the back of the block, knock up new mounts all round and build a custom oil system and sump. Guess it makes sense for him where there are strict engine capacity rules for each race series/class, but without that restriction surely a 20v is a similar amount of fabbing?

If 250bhp can be had from a turbo'd G40 engine then surely you can get more than that out of a charged AEE or AVY

Sticking a 20vt in is all well and good but it also comes with its own issues that you wouldn't come across with a small block lump, ground and bonnet clearance are two, also master cylinder clearance, plus the extra weight of the 20v lump. And then there's the issue of useable space in the bay and wiring one into a polo

Tbh I'd just like to see more big power polo's, whether it be 20vt or boosted small blocked I don't really care. Both have their good and bad points and I don't think you could knock anyone for doing either, its personal preference at the end of the day and just two different ways of reaching the same goal

About 10mm I think! It's about 5mm off the bonnet when it's closed anyway haha

Think I read on here that the deck height is 9mm taller on AEE

I've made an 020 box fit my afh easy enough just made an adapter plate and machined the bell housing

Shouldn't need custom driveshafts either as from what I measured the drive flanges are same distance apart as an 085 box

It would just need a new mount for the gbox at the front as the mount sits directly under the chassis rail so could mount directly to that and some of the sheet metal cut away for the box to poke through into wheel well a little

For the rear mount you would need to adapt the polo item and could probably sort of mix and match with the standard golf item to make a good strong mount

I haven't looked into the rear one yet but mine will be custom anyway

The later type 02* as fitted to so many post 90s VW's, including my mrs '02 Golf TDi, looks really short compared to the previous design with the rod clutch release mechanism. It was used in the 6-speed Lupo and they're not the widest car in the world, and a well known couple of 6n2's didn't need chassis legs chopped afaik.

There's an assumption that the chassis will need chopping up, but does anyone actually know it does..? (wife's out so i can't measure it atm)

You'd need the right cylinder block, being the iron Golf/Bora/Lupo 1.6 16v block if going for that deck height, or as Guy says the MK3 Golf 1.6 AEE block if going for AEE for the tall deck (yes it's an AEE, yes it takes the 02 box).

Chop chop:

http://www.polog40.co.uk/forum/index.php?topic=3343.0

That's a 6-speed from a Lupo, which are still shit...

Considerations for small block to big block gearbox swap:

Driveshafts (need to be golf inner splines, Polo outer splines)

Gearlinkage/shifter mech

Speedo Drive to clocks

Starter & ring gear (I think Sorg conversion retains 085 setup)

Clutch release bearing actuation - hydro/cable

PTO splines

Lots to consider, and lots of cost- it's £8k for elite racing tranmissions to make you a gucci box capable of 550Nm (6-spd Seq) that's worth chopping stuff about for!

Interesting thread:

http://www.clubgti.com/showthread.php?2464...ck-bolt-pattern

Worth e-mailing Sorg to see the true costs...

Guy- If I knew what I now know, I'd go 20v from the off, dry sump solves ground clearance, and bonnet scoops have been cool since MadMax Granted there's lots more engineering to be thought about, but I'm getting bored of replacing 085 boxes.

Will see what tinkering can be done over winter.

http://www.clubgti.com/showthread.php?1155...os-FAQ-VW-range

For info

i forgot about the gear linkage etc which would be a pain for most other people and tbh yeah it is alot of modification to just fit an 020 box so not really too much of a possibility

Gear linkage should be easy enough as its cable change, just use the whole golf cable change shit?

Would the vr6 box fit onto a lupo gti block? Surely one of those could take what a boosted avy could chuck at it? Pretty sure these can still use the mechanical speedo drive and they can be converted to cable clutch with off the shelf parts, all the clutch and starter bits should be useable off the lupo gti or vr surely?

Yoof, proper pimps run golf cv joints anyway

Regarding chassis leg cutting, I think you can gt away with it, but dependant on shifter required need bulkhead mods, and also custom subframe.

Guy- you're too cool for school Presume Golf stuff is a little hardr than Polo stuff!

The golf cv's are chunkier than the polo ones so I can only assume they are a bit harder wearing. whether they are needed tho is questionable, after all I don't think I've ever seen mention of you killing any polo cv's?

I'm only running golf ones due to the golf hubs i'm running with my coilies rather than as an upgrade

Depends how you launch:

Hayesey has the heaviest lead feet I know.

Oh right, might be a worthwhile upgrade after all then

I'm putting a rod change linkage in as that's what my box takes and converting the cable clutch to run hydraulic

But I didn't think about the cable change boxes that would make that side a lot easier other than te bulkhead chopping like Yoof says

And isn't the vr6 box just an 020 box as its the same as the corrado G60 box isn't it and could they also be used as they must take some abuse too

When researching the vr6 swap I was doing in a mates mk2 I happened upon this

Just to pick up on what cerips said. It is a cable change box that is fitted to the VR6. But it needs to be a VR specific cable change box, this is because the bellhousings are different compared to the cable change boxes fitted to the 4 cylinder engines such as ABF or 9A. Make sure you check any box you are thinking of buying first to see it will work.

I never bothered looking any further into why they are different because he already had the correct gearbox and it was info on the clutch/gear linkage I was looking for, but apparently there is a difference between the vr and other big block boxes which is why I wasn't sure if it would fit the avy

Would you need to chop out the bulkhead for a cable change on one of those? I know you do with the 085 cable change but the Selection mech is on top of the golf box rather than at the back

I've got a german guide to doing the 02a swap, for the same effort and cutting- you can put a big block engine in! but you will have issues with the steering rack - exhaust and brake servo/master cylinder - block.

you will need to make a hydro clutch pedal (i will have done my hydro clutch pedal boxes and be selling them by the end of the year)

all issues to overcome but if you want serious power then the small block engines have limits- Yoof has shown this with the amount of stuff he has destroyed, a 225bam engine remapped to 280 is about £1000. fabrication work and custom parts a further £1500.

£2500 for a monster? and for that tuning parts are a lot cheaper to get further power.

Right so even if I forge it. I can up the boost til things break, either upgrade them then, or back the boost off - would still be an AEE stronger than the stock pistons and rods, 300hp would be pointless anyway so even if I capped it to say 200 odd it would still be good fun and not just another g40 with a turbo on it :)

depends what you mean by break things, if you forge it and it screws up you will have to buy to replace the bits damaged when it breaks like yoof had to when his rod went.