Big Hairy Bear

Removing intake manifold isn't too tricky, recently did the job myself. Trust me well worth the effort as mine was really gummed up. Once you have the EGR valve off its only 6x6mm allen bolts for the manifold and a couple of nuts to remove heat shield. A good tool kit is a must with a couple of universal socket connectors and you will be fine, allow around 90 mins to remove and the same to refit. Re blanking off the EGR I recently discovered a post on a Golf forum, just disconnect the vac hose that attaches to the mushroom valve on top of the EGR and pop a bolt in the hose to seal it. This stops the EGR from opening. I've done this and it works fine and no warning light on the dash. Seems to accelerate smoother now.

Hi, Can anyone recommend a good 'tuning' company in Sussex who do good remaps for the TDi? Cheers

Hi all, Can someone tell me if a Mk 4 Golf TDi gearbox is a straight swap for mine? The box I am looking at is the 02A style with black end cap. I'm guessing the ratios may be slightly different though across the range?? Trying to find a suitable box is a mare!!!

Thats what I have experienced in the past, the bell housing should just lift away. There is something inside the box catching and stopping the bell housing lifting away more than about an inch. Damn those german engineers:rolleyes:

It is a high miler so just needs some new bearings, it's not hugely difficult rebuilding boxes (this is my 3rd) I just can't seem to get the casing opened.

Hi all, This is my first posting so hello to all. I currently have the manual gearbox out of my Octy TDi which I want to rebuild. The Haynes manual is utter tribe with help relating to the gearbox. Has anyone ever done this before? I am having trouble removing the bell housing from the case and a search on the net has failed to turn up any useful info. I have removed all the bolts around the bell housing and the diff and have removed the two drive shaft flanges as well. When I try to lift the housing away it seems to be still attached inside and I can't see anyway to free it. Any tips gratefully recd???:confused: