Planning to upgrade the transmission for way more torque.

 

Going for 02R gearbox (light from magnesium? titanium? case, compact, 200Nm capable, same bolt pattern as 02J, LSD possible) with an adaptor plate to 084/085 Polo style.  

 

This is 228mm 6 paddle clutch friction disc and Sachs cover plate for 1.8T or 1.9TDI reconditioned with a lick of paint. 

 

Any one know if Corrado G60 or Golf mk6 1.4TSI flywheels are same bolt pattern as Polo Mk2 crank?

 

 

some good info in that. 

02T gearbox design is described in VW Self Study Program 237

 

This confirms it is magnesium.

https://www.yumpu.com/en/document/view/36379322/ssp-237-02t-manual-b

 

I think 02R has 100mm drive flanges and 02T and 02J have 108mm.

But 085 has only 90mm, so looking like custom drive shafts may be needed... but the Polo mk2 ones are quite puny.

108mm flanges will fit apparently.

Nice article about custom driveshafts supplied by Satchell Engineering.

https://pinderwagen.com/build-topics/custom-driveshafts/

can the uprated transmission be fit  in the AFH POLO 6N engine bay

so it's 02R gearbox with an adaptor plate?

Probably... mounting might be simpler than on a narrow mk2, which will need some inner wing cutting (like the cutout for 085 5-speed on mk2f) and reinforce welding.

 

But do count on custom mounts, custom drive shafts. Might even need to tilt the engine back so inner CV joints sit a little lower as the adaptor plate holes set the rotation block to gearbox.

If it needs more than 5° of tilt that might affect my carb float height.

 

If you do have to tilt it, the bottom dogbone mount on AFH won't be long enough and a replacement can't be straight but will need the same angle as the tilt. So that's the thing that'll stop you doing this.

 

Needs to change to hydraulic clutch too. I reckon mk1 Golf and mk2 Polo pedal box are similar so this from Retrofication might work...

(Never looked at 6N pedals, so dunno about that suitability)

 https://www.ebay.co.uk/itm/124763295903

 

I do like the precise feel of hydraulic clutch pedal. 

Edited 29 March, 20242 yr by dvderlm

My Polo mk2 is LHD so this Golf mk1 hydraulic clutch conversion better suited

https://www.ebay.co.uk/itm/124774715447

You know on a turbo 1.6 AFH setup, are the AVY rods but in H-beam setup the correct size?

Do you just change the pistons? Can you get away with cast if using k04 (240BHP)

https://www.bar-tek.com/polo-1-6l-16v-gti-high-performance-pistons-kit-wiseco

The AG Bell book on forced induction wants lower compression than standard cast pistons' shape gives, and warns against milling the crown to achieve lower compression if the engine is to last.

 

So forged seems sensible investment to me.

 

If staying with cast pistons, maybe a bigger intercooler to keep the charged air cooler?

 

Standard rods are surely strong enough.

 

I usually look up on MS Motorservice catalogue the exact measurements including pin diameter and piston height.

 

Using shorter rods to reduce compression with same height of piston means they move faster from TDC, and so must be stronger, but I suspect going that way assumes a custom crank shaft too, or you lose swept volume... but it could rev higher.

Wiseco have good reputation. Block rebore  needed or is it that big (77.5)?

 

Did not see the dropdown menu. They do 76.5mm diameter for 8.8:1 CR too.

Edited 30 March, 20242 yr by dvderlm

Have you still got the Rosten AVY H-beam rods?

 

Use those if right length and pin...

 

 

Yeah I have the AVY 1.6 16V H beams and the AVY crankshaft. But wanted to get another set as did not want to mess with my current setup. Rosten out of business now. Just didn't know which pistons to get but obviously Bar-tek link looks most likely.

20mm wide conrods with 17mm bronze bushing. 

I did look into forged Honda D16 pistons with custom rods as bigger choice and lower prices

eg

https://www.ebay.co.uk/itm/195740277633

 

but did not reach any conclusive result.

read about drilling out rivets on 085 box and replacing them with bolts. can put a LSD in there while at it if going turbo.

Thats probably best bet. GTI box fits too. They should be more readly available.

For the 02R I think the LSD choices are

• Quaife's QDF26R 
• WaveTrac 10.309.181WK
• Peloquin 02jB diff 
  • https://www.peloquins.com/products/product-02j-b
• Blackline HLF062 (maybe?)
  • https://mattlewisracing.co.uk/products/blackline-audi-a3-a4-tt-02j-5-speed-helical-gear-lsd
• Kaaz clutch plate diff 02A/early 02J (maybe?)
  •  https://www.usrallyteam.com/index.php?main_page=product_info&cPath=0&products_id=200

 

and if 02A/O2R are compatible (might depend on ring and pinion gear diameter) then might be able to use this cheap solution

• https://racingdiffs.com/products/vw-02a-gearbox-lsd-conversion-set

Edited 1 April, 20242 yr by dvderlm

Racingdiffs conversion won't fit an 02R, but they might have a similar item for 02R by end of 2024.