After being without the car for nearly three weeks I finally had the nod from the Mechanic to take the car in to see what was bent thanks to the pot hole prior to Christmas and got 500yards up the road and the box ate itself!! Got the car recovered to the garage and even though it was out of gear it locked up when rolling off the flatbed (they originally sent a van with a dolly ) took them a few attempts of pushing and pulling to get it to free up to be able to roll it into the garage so looks like something is loose in the final drive and getting in the cogs.

SO what boxes are a suitable replacement on the 4x4? can a 2wd box be use if the transfer box is swapped onto it or does it need to be a 4x4 (S3,A3Q,VR6?TDi4x4) part numbers appreciated if you have them.

Bad luck :(

On the positive side, its a perfect excuse reason to get an O2M 6 speed 4x4 box

Lower revs in top gear = more MPG on the motorway.

S3/TT main source.

Clutch would probably need changing (? - got my engine and gearbox together so don't know I'm afraid) ...

You could fit a diesel O2M box (as found on the Octavia 1U 1.9TDI 4x4's), but not sure what other bits might need changing ...

gears are different ratios - was a thread on here the other day where this was mentioned ...

Edited 7 January, 201115 yr by snow_muncher

It was the diesel 02M that I was thinking of as the ratios would be super economical would also NEED to go big turbo then as well

Here's the Thread: 6 speed conversion

You don't really need the big turbo - but if you want to use it as an excuse - then yes, clearly stands to reason a turbo is required

Following that logic, you wil need to fit a Peloquin too ... of course that requires a blue haldex controller ... which clearly won't work without rocket boost system ...

are you selling yours ? I could just get the LPG swapped over then :D :D

Need a lot more than just the 02M box and clutch though from memory?

Hanging onto old engine and gearbox for a while I'm afraid ...

Partly in case somethings goes wrong with my new setup, and partly because it might be going into a Mk.1 or Mk.2 Golf ....

I was talking about the WHOLE CAR!!!! :D

What is the gearbox code for the 4x4? mine is now in the garage and having recently rebuilt my PC I haven't got round to sorting ETKA out yet. Why do so many parts need changing? is it the change from 5 to 6 gears? as I thought the 4x4 was basically the same setup as the S3?

I was talking about the WHOLE CAR!!!! :D

Don't think you'd like the MPG ...

... Why do so many parts need changing? ...

Flywheel/Clutch - Think this is due to power, not fitment (?) - Recon the G60 route would be OK - a worthwhile mod anyway.

Starter motor - Yep - its different fitment - hopefully would come attached to gearbox, but worst case £100-ish recond.

Drive shafts - I thought this was due to power rating, not fitment (?)

bell housing bolts - hopefully would still be attached to gearbox ...

Mounting and bolts - ? not sure about, from what I've been told, all universal - my uprated mounts are identical to the old, just better poly inside ...

Clutch line - I've got my old clutch line fitted, no problems fitting. Gear selection all seems fine.

Even the 5 speed paddle fits and operates (I've got a Forge unit waiting to go on though...).

based on the cost of getting the box recon'd, a low mileage 02M conversion would be about the same but if the 02M is that much stronger than the 02C? then 2nd user should be OK unless its from a heavily modded car. I spoke to my mechanic and I was going to get the Clutch changed anyway seeing as it is all out for changing the box.

So does anyone have a complete list of what needs to be changed and from what vehicle? I saw a box from an A3 1.8T Quattro that was listed as a 5 speed 02M but I thought that model was identical to the octavia?

Can you confirm the box Code on your old one Graham? As the one I found is a DXW?

Can you confirm the box Code on your old one Graham? As the one I found is a DXW?

I'm in Switzerland at the mo, and won't be in Devon till somewhere between the 17th to 20th Jan - I can go look after then, but guess its too long to wait

I'm afraid I turned off my ETKA computer too, so can't remotely access it :(

edit: sorry, brain not working - 5 speed O2M ?? - must be wrong - guess would really be an O2C ?

Edited 8 January, 201115 yr by snow_muncher

no problem Graham I will dig out etka and get it back on

Sorry can't be more helpful. Keep posting as to your progress

OK. got the chance of a gearbox and bits from a 2003 S3 for a good price but can someone confirm that this is a complete list of what is required:

Gearbox (02M but any particular codes to avoid or hope for? How many variations are there of this box?)

Flywheel (no plans to go big turbo yet so as long as its OK stick to the S3 one then G60 in the future)

Clutch (depending on condition may replace when fitting if the 2nd hand one is no good)

Starter motor

Drive shafts (is it just the front ones or is the front half of the propshaft required as well?)

bell housing bolts (how many are there?)

Mounting and bolts (I assume this is the mount that is under the airbox?)

Clutch line and damper (is this a different size as Snow_Muncher reused his original?)

I am asuming that a 2nd user 02M box should a good option compared to getting my 02C repaired as they are stronger than the standard one (obiously not if its come off a highly modified one)?

hope to talk to the mechanic tomorrow and get his input as well as I am way too busy to attempt on the drive at the moment.

If there is anything else that I may need or should consider while its in bits please feel free to let me know.

I did think about breaking it if the costs were too high but the 02m upgrade is looking like the cheapest option

Already got a set of hel hoses ready to go on as well as the pikey modded dogbone mount, car will also be getting engine oil/filter change as well as Haldex oil and filter.

Fitting the 02M diesel box will be a waste of time if you aren't pushing big bhp!!!! Even a remapped ko4 hybrid would struggle!!!

G60 clutch and flywheel are for 5 speeders only.

Get a good TT/S3 02M and fit that, they have very similar ratios to the 4x4 box with the addition of an extra (6th) gear.

Bits you'll need:

Driveshafts (2)

Starter motor

Clutch kit (Sachs ate good!!)

Flywheel

Clutch slave cylinder

Gear selector guide (mounted on gearbox)

Modified hydraulic clutch line

Gearbox mount (locating on chassis)

I'd personally fit it, test it and if it works pull it out, and then get the box stripped and rebuilt with a peloquin limited slip!

Before thinking if going big turbo, what gave you done to the handling & brakes??

Steve

... front half of the propshaft required as well? ...

99.5% sure not required.

... I'd personally fit it, test it and if it works pull it out, and then get the box stripped and rebuilt with a peloquin limited slip! ...

I know that's what I did, and its make sense to do at same time (fitting costs etc), but, it is an extra £1500+ on the pricetag ...

TBH not sure what the effect/effectiveness of front Peloquin + normal haldex would be either ... maybe less slippage at the front, and therefore less engagement of the eLSD ? ...

I suspect most people who've fitted them have done it after blue or orange haldex (like me)

Maybe phone Jabbasport and ask them if anyone has experience of doing this (they're the UK Peloquin importer), or go direct to source and give Garry Peloquin a ring himself.

ps

Not trying to put you off - just pretending to be sensible (not something I've got much experience though )

Edited 11 January, 201115 yr by snow_muncher

Cheers for the input guys. I was going to just get it fixed, but when a 2nd hand box is £500(unknown condition), a recon with 12 month guarantee is £900 or sending mine for a rebuild/repair is going to cost £595+vat plus £70+vat shipping then the upgrade option starts to make more sense

Hoping to get the box and bits sent direct to the garage so hopefully be up and running by next week (fingers crossed)

Handling is fairly standard at the moment, just 17" spiders and pikey dogbone going on. Brakes are 312's with redstuff pads and got a set of Hel hoses going on while its in for the box. I have one 4 pot brembo and a set of carriers but not sure when I will get round to that - maybe in the summer

on the list of bits

Clutch slave cylinder - (where abouts does this bit live) not got my ETKA reinstalled yet

Gear selector guide (mounted on gearbox) - are these different? as Graham has reused the 5 speed one?

Modified hydraulic clutch line - what needs to be modified? is it not just a swap?

I think I need to repair about another 10 Imacs to pay for it all now though

Bits ordered. Now the waiting begins

...

Gear selector guide (mounted on gearbox) - are these different? as Graham has reused the 5 speed one?

Modified hydraulic clutch line - what needs to be modified? is it not just a swap?

...

Gear selector guide = Yes, new one needed

Modified hydraulic clutch line - ... swap ? - Mines wasn't changed - all seems to work fine

Hope it all goes to plan

Cheap fix depending on the damage. VRS cluster fits straight into the 4x4 box & will give taller ratios so if the casings not ferucked your OK. remember to take the rivets out of the diff & replace with bolts, if your not going big power then the G60 clutch is a good cheap upgrade

The VRS cluster is is only OK to about 350 bhp, I shredded 3rd gear with 356 bhp, a tasty bang at just over 100

If you are taking the car to that sort of power you will need to rebuild the internals as well to guarantee reliability

I had a TT 6 speed box put in mine but that was a few years ago, your list looks OK but you only need one drive shaft but cant remember which side, its due to a different length.

I cant see prop shaft mentioned, The prop shaft front to rear on mine needed to be bespoke as the 4x4 one wouldnt mate with the TT box, on mine they modded a TT one

Dont forget the gear knob with a 6 on as well

Edited 13 January, 201115 yr by Stuart_J