Rich's '91 80Q M-TDI

[oil_me]

death 4kqt wrote:[/quote]you should come to the carlisle show in may. I am hope to be able to make it this year with mine.[/quote]
I will go this year if the tranny's in. No BS.

[oil_me]

death 4kqt wrote:

you should come to the carlisle show in may. I am hope to be able to make it this year with mine.[/quote]
I will go this year if the tranny's in. No BS.[/quote]
My first long trip though will be to the middle of VT; so you're on notice. :-)

[oil_me]

The trans is here but I missed delivery. They'll be back Monday. I'm looking for a way to change drive flanges or adapt tripod joints used with this trans. http://www.motorgeek.com/viewtopic.php? ... 28#p689028
UPDATE: Transmission was delivered today; they came back. Best birthday present ever. It's a DGW as ordered.

[scubagli]

Not 100 percent on this but you should be able to swap flanges, you can on the o1e...those tripod joints suck...

[oil_me]

While working out which the axles for the new trans. I decided I'm keeping the tripod flanges. It's been revealed I need a pair of front axles from an Audi 90 V6 FWD manual trans. I need to swap the outer CVs for B3 80q stock joints. Hybrid axles; like the rest of the car. I'd prefer to find someone to assemble me a pair of axles from their good used parts. Piecemeal would be the second choice.
The mileage last tank was 43.5 mpg. That's up from a dismal 39 mpg I got during the coldest weather & a lot of testing and idling. I have the intercooler disconnected temporarily until I can roll beads on all the boost pipes. Losing boost while passing uphill doesn't suck; it blows.

[oil_me]

I reinstalled my intercooler after making a bead crimper & putting beads on all of the IC pipes. I found a How-To tool mod on youtube.
https://www.youtube.com/watch?v=JVDUM2Z ... YkWUYUkbyQ



Bought a pair of crimper cutters & cut the tip off with an angle grinder. I cleaned up the crimp form with a Dremel to fit the round contour of the pipe. It is so simple and it works great. I made it in 20 minutes. I would leave a bit more tip on the next set of crimpers I make and soften the sharp edges more. I put the bottom edge of the pipe on the top edge of the ziptie and squeeze. Move 1/8" and squeeze again. Go all the way around 1x and it's done. Boost comes up quick & holds steady. I'm using a Dawes device next to raise the boost to 15. We'll see how it holds. I originally had joints blowing off at full throttle. The mileage this last tank is back up to 44 mpg; 717 miles on 16.2 gal. I expect the mpg's to rise further next tank with the addition of the IC.

[PRY4SNO]

Love simple DIY innovations.

[DE80q]

Nice little tool there, I think Im going to have to make one for myself.

[oil_me]

The car is back up to 46 mpg, the beaded pipes are holding boost great. I have to change the timing belt in the Jetta this week; this car goes up on stands to get its new trans. right after.

[oil_me]

The V6 tranny's out; TDI going in.


The clutch looks good after 20k, cleaned the splines. The trans. is now bolted up. I'm replacing all suspension bolts with 316 stainless while everything's apart. The swap has been going smoothly.

[scubagli]

Excited.


Old and grumpy.

[death 4kqt]

awesome rich! Your car is clean underneath!

[oil_me]

death 4kqt wrote:[/quote]awesome rich! Your car is clean underneath![/quote]
It lived previously on the left coast in the shadow of Disneyland. When it arrived here on top of the car carrier I was able to walk under it. I had never seen such a rust-free car in my life.

[oil_me]

The car is back together. I'm waiting for a pair of axles I ordered for a B4 V6 FWD manual. I need to swap my 33 spline outer CVs onto them to make this gearbox work. Fingers crossed, silent prayers, incantations uttered.

[scubagli]

Good luck. I hope they work for you!


Old Audi's rule all.

[oil_me]

I am at an impasse with my front axle choice for the TDI trans. The new trans is in and ready to run except for that. I have a set of new V6 axles made by Empi. I planned to swap 33 spline CV's on them but they seem too short over all. The 38 spline joint is obviously larger in diameter and longer as well. I had no success removing the smaller 33 spline joint from the original shaft. I broke the factory removal tool on the first use; I used assorted brass drifts and punches and it didn't budge. No hidden inner spring clip; just wouldn't come off. They're Empi as well, I'm not surprised with their quality issues. I don't really know what spline size or count is under the new joint if I were to try to take them off, so I haven't yet. Here's where it stands;

1. I have no hint from anyone of any other flange that will fit into this trans. to replace the troublesome 130mm Tripod joint.
2. I've decided to ask one of our members who created my custom rear axles to repeat his great effort on the front. He's usually extremely busy and I hesitate to ask but he seems to be the only person I can find ANYWHERE that does this.
3. The other option, mentioned in another thread is to change the hub carrier to a B4 and be done with it. That requires new brakes, loss of 14" wheels, alignment, maybe balljoints and so on. My current alignment setup is dead on, and it's hard to justify messing with it.
Is it possible to use Coupe hub carriers with a B4 38 spline hub or are there important differences between them?

[oil_me]

I've looked further into my options and answered my own questions. I finally got around to calling my friend; a local VW/Audi dismantler who's business was decimated by hurricane Irene in 2011. He's crushed 1000 cars in the last 10 months. There were 20-30 each B3's and B4's, dozens of 44's 43's C4's etc. I was saddened to see all those cars gone forever. B3 genocide. I happened to show as they were stripping an early build Coupe; all they took was the bag of snakes and the 7A cams. They trashed a good head, bumper, hatch and tail lights. I halted them before the tossed the car in a huge dumpster with a clamshell front loader. The Coupe and an '89 90 fwd(mermaid) 5spd were the last two small bodied cars left and would've been gone if I showed up 1 hour later. I took the entire suspension off the Coupe and bought the '89 for scrap value. It has 71k original miles and sat inside for 10 years. It's not wrecked at all and has perfect body panels, perfectly unworn leather interior. All that was taken was the headlights. I describe all this to highlight my ineptitude. The Coupe hubs I saved in desperation from destruction; I ultimately discovered have the correct splines to fit my axles. I now have a bolt-on solution for my dilemna. This was mentioned earlier in my thread but I forgot or overlooked the fact that Coupes have 38 spline CV's. This solution was not my first choice, as it involves changing calipers, rotors, master cylinder, and most disturbing is no more 14" wheels. I test fit the Coupe hubs with the BN B4 V6 axles and they fit perfectly. I have a set of used Speedlines I'll dig out and put tires on them. Can anyone tell me if I absolutely need a Coupe master cylinder or can I get away without it? This is an unexplored territory for me, is there anything I haven't thought of? Suggestions and input welcome. I've heard nothing from my other axle queries so I'm moving ahead.

[scubagli]

Rich you probably don't need to change the master, but I would. I had one in my mkii, with the g60's and it made a big difference in stopping power.

[oil_me]

I installed the CQ hubs which fit the V6 axles perfectly. Everything is bolted in place. I put in the G60's and bought new pads & rotors.The stock 80q caliper line from the bracket was too short so I cut and made bracket extensions. I found the Speedlines and ordered new tires for them. An alignment will be in order.

[ur20v]

Didn't Mark Swanson change all his 4kq suspension bolts over to stainless in the early 2000's with terrible (and expensive) results?

[oil_me]

The car is finished; runs and drives, ready for alignment.

[ralleyquattro]

Woohoo!!

[scubagli]

Good to hear!

[oil_me]

Thanks for the support. This has been a stressful stretch to get through. It looks badass with the Speedlines I must admit.

[scubagli]

Pics?