Cheers Nige, that's really useful! :)

I'm not sure if I've mentioned it but I had by ATV (G40) rebuilt and fitted with an LSD. But ever since I had it its been 'falling' out of 5th when the box hasn't been under load. So not popping out of gear when under load just when its not under load. Now people have said that I needed to adjust 5th but I was thinking that meant adjusting the gear linkage but that's not the case. Thanks to Vic for the guidance of what I needed to do. Unless the box has been apart for some reason I can't imagine why you would need to adjust it but if you do I hope this helps a bit.

Do to this I put the car up on axle stands and removed the passengers front wheel.

First of all if you have fluid in the box you need to drain it. This can be done by undoing the bottom 17mm plug. It might be worth making sure you can undo the fill plug first as you want to make sure you can fill it up again.




When its empty put the plug back in and then its time to remove the gearbox end plate which houses 5th. Before I did this I cleaned off all loose dirt and grime as I didn't want it dropping off into the gearbox.

Remove the 3 9mm bolts and the end plate should just come off.

This is a video of mine before adjustment.

As you can see there is a huge amount of moment when you engage 5th and it really shouldn't be anything like that.



Below is pretty much word for word what Vic told me: :)
So to adjust you need to tighten this bolt on the selector fork.Behind it is a 13mm nut which locks the bolt in place. Loosen this off and then slowly tighten the allen key bolt. reselect fifth a few times. What you want is a smallest amount of play between the selector fork and the engagement ring when in fifth gear. About 0.5mm is all you need. What you don't want is pressure from those two forks when its in fifth against the engagement ring, just gently touching all the time is fine but not pressing hard.

So with this ringing in my ears,this is it after the 1st bit of adjustment.

Much better but still a bit too much play.

And after a slight further adjustment.

Bingo!

Make sure the Lock nut behind the allen key is tight. Clean up the mounting face of the gearbox and the rubber seals and then refit making sure not to oven tighten the 3 nuts.

Refit the wheel and lower the car to the ground. You now need to fill the gearbox back up.

Remove the top 17mm allen key plug and fill the gearbox until its level with the top hole. I'm using standard VW oil (G060726A2) as that's what is recommended by Quaife due to me having an LSD fitted. The box takes 3.1 liters. so you might be able to get away with just 3 1 liter bottles but for the small additional cost I would by the 4.

Refit the top plug and you are done. Take it for a short easy test drive checking all the gears. If all is good bring the car back and check the gearbox level and top up if required.

That should be that.. :)

Thanks to Vic for his guidance! :)

Spend the day looking at my Vauxhall 256mm brake set up.

Had it for a while but not really done anything with it.

I wanted to see which wheels would fit over them

So I got them build up

And then went through my wheels.

First up standard 13inch VW Hockenheims

Not even close. the diameter of the wheel gets less closer to the wheel face. With some epic spacers it would fit :)

Next up my 13 inch BBS Mahles these are 13x5.5 and ET18

These actually just about clear with 15mm spacers on

You can just about see the markings on the inside of the wheel

and finally my 14 inch Compomotive TH's

Plenty of clearance :)

Next is to get the calipers rebuilt and the struts refurbished to house the H&R kit :)

Exchange Vauxhall calipers are normally pass cheap, like similar price to a rebuild kit.

Good stuff mark!

Can we have a track day this year? Don't think I'll be running, but be good to see everyone blasting around!

Cheers Max,

We certainly are just getting the final details but Saturday 25th July 2015 @ Blyton Park

Legend!

There may be hope for them dates then!

You know when you did the GT swap, what size was the new fuel line to replace the std one?

You know when you did the GT swap, what size was the new fuel line to replace the std one?

That I don't really know. All I have was that picture in this thread :)

Any more updates with this? :) Also where did you get the 16v front grille badge from

Really want to see that splitter fitted

No updates really apart from an outing at the Clubs Rolling Road day.

Made 143 bhp and 123 ft/lbs. There is much more in the engine too as its really is still running in :)

HuyiRR2015.pdf

Will be heading out to Polo Treffen in Holland in a few weeks will be continuing on to Wolfsburg and to Techno Classica Essen. so will be giving her a good check over making sure everything is ok! :)

That's the dream. When you go to Wolfsburg make sure you visit the smaller vw museum too in the town. It's where all the good dubs are

That's the dream. When you go to Wolfsburg make sure you visit the smaller vw museum too in the town. It's where all the good dubs are

Yep that's in the book to do [emoji3]

Once I'm back I'm going to overhaul the cooling system which I think will consist of new radiator maybe using a twin fan setup and a oil cooler.

Will then hopefully get the brakes and suspension on for The Polo Social and trackday.

This should mean than everything is bedded in nicely for the Retro Car magazine European roadtrip [emoji594]

Some really healthy numbers there Mark. In a car that weighs f*** all, it must go quite well!

Cheers Simon. I does go well and the more miles I put on the engine the quicker it seems to get :)

Not really done much apart from completing the 2000 mile european road trip. Hit Polo Treffen in Holland, Autostadt - Wolfsburg, Stiftung - Wolfsburg and finally Techno Classica - Essen. The trip was brilliant and Huyi took everything in her stride! :)

Some pics

Totally great trip and driving in Europe is soooo nice..

Anyway.. back on with the project.

Still need to to the brakes, suspension, change the thermostat for the lower temp one, change the alternator, buy and fit an oil cooler. :)

I want one of them Polo Bunny badges. Did you buy that or just spot it?

I want the sausages/chips n mayo !!! never mind any badges !

Looks like the three of you had great time over there loved the video on IG through the tunnel

I want one of them Polo Bunny badges. Did you buy that or just spot it?

The badge came home with us :)

I want the sausages/chips n mayo !!! never mind any badges !

Looks like the three of you had great time over there loved the video on IG through the tunnel

Volkswagen sausage or currywurst :)

Oh I need to post that video up also got another one that I need to upload

Tunnel run! :)

epic waggon, need you manifold though

epic waggon, need you manifold though

You can't have it! :)

What is a Polo Bunny?

Its an Austrian special edition :)

Cool. What was special about them?

Its just like a Fox or something..

http://www.vwpolo-info.de/Sondermodelle-Polo-86c/Bunny

But the badges are cool :)