Have hit a snag on the home run getting this done.

The box is in and the car drives (if you select a gear with a spanner) the problem now is the original wiring to the battery box. it is supposed to be bracketed to the top of the starter but in that position it fouls the selector weight?

So to anyone who has already done this conversion, how did you get around this issue?????

Karl

UPDATE:

forget the wiring that was us being thrown off course by the shape of the bracket, the problem appears to be the pivot bracket that comes up from the selector spline. The box I have is a DQB but all the images I can find for 6spd selector are like this.

which is what it should look like. I have the selector off an R32 which is the same pattern as the S3 but a shorter throw due to the pin location.

However, the one on the box I have looks like this.

which means the selector is out of position by about an inch like this

Edited 13 February, 201115 yr by karlbar2k

Left hand drive vs right hand drive units ? ...

I'm out the country again, so can't go look @ mine ...

I did wonder that but the part number on that peice starts 0a8 which is Polo I believe? 0A8301232 is the full number

When I did mine I had no issue, but then nine is only fwd, so I guess the cases might be different.......

Saying that....... I do remember having to grind part of the gearbox casing to make space for something.... Can't remember what now.

Sorry I can't help more!

Steve

Oh, I forgot I had to fabricate the gear selector bracket/bush assembly as it was miles out synch with the gear selector arm (forge short shift).

Steve

Pretty sure everything just fitted in when I did Bengies.

I think it is definately the wrong bracket as all the pictures of people fitting the forge short shifter etc show the bracket like in the first pic. I have compared the shifter that I have been sent and it is of an R32 so is identical to the S3 shifter apart from the throw lenght. I just cant seem to find why an S3 would have a different selector mech? the box came out of a 2001 S3 and from what I have read they all should look the same? I have not even found any mention of S3 owners modding to use a diiferent mech other than the usual forge etc short shifters which retain the standard bracket.

Update:

spoke to PSI Tuning again and god bless them, Andy sounded as confused as I was when I first figured it out. But they have a replacement bracket with the proper 02M 301 232 part number and it is being shipped tonight. Fingers crossed that if it turns up tomorrow I can get it to the garage on Thursday, I might actually get my car back for the weekend

PSI have been really helpful resolving any issues that have arisen with a minimum amount of fuss. They have also been reasonable with their pricing for any extras that I have had to get hold of.

Fingers crossed for you!!!

finally got the car back yesterday :D The box is in and it works :D

I can honestly say that I did not realise how much I missed BOOST

Not sure how much of a difference having the R32 shifter makes as I could hardly remember what colour the car was it has been that long But it does feel good.

now I just need to:

change the top mounts

change the oil and filters

change the Haldex oil and filter

change the brake lines and fluid

then:

fit the twintercoolers

fit the brembos either with the 312's or some nice new 330's

get the downpipe and decat done

get the rest of the exhaust done

(need a new job for all that though - might just get the IC's fitted when the weather improves)

Glad to hear you gearbox issues fixed

The input bearing on my box has decided to pack up on Jabba's rolling road

Keep up the good work!

Glad to hear you gearbox issues fixed

The input bearing on my box has decided to pack up on Jabba's rolling road

Bummer! What stage did you get to? was it pre mapping, during or on a power run?

Final dyno run

Ouch! Partial Graph? LOL

you getting it sorted Graham? or you back off to the land of the Switzers?

no graphs, just more delays

Folks who installed the diff into the box, claim the bearing was fine and not their fault, etc, etc.

Got the speak to Jabba tom. and see what they quote to fix ...

... jabba says gearbox kaput, gears shredded

:'( Ouch :'( so you looking for a new 02M then? The guys at PSI Tuning seem to be breaking S3's like fun. They may have one? Ask to talk to Andy (I think someone said he used to work at Awesome?) Just tell him the really annoying guy that bought the S3 box for the Octavia, Karl put you onto him LOL

Yes new box is needed

Tar for lead on replacement box

Jabba have offered me a spare they've got in, and have all the bits needed to swap the diff over

Hoping the diff is ok :S

I paid £400 for Box, clutch, flywheel, driveshafts, starter, clutch cylinder and loads of nuts and bolts so if you need just the box try and talk them down. HTH

Thanks for the info. I'll try to haggle them down a bit.

Going to speak to the garage that fitted and arranged fitment of the diff about why such a thing should happen, and so quickly, and why so little oil was found in the box ...

How's your box, enjoying the extra gear ?

not 100% yet as there are still a few jobs that need sorting. Because we had so many stupid avoidable setbacks it delayed all the other jobs he had in so I picked it up with the box fitted wile he plays catchup. It needs to go back in for service, brake lines, top mounts, haldex service etc. On top of this SWMBO's passat needs some work before the 7th for the MOT so I seem to be taking up a lot of his time

It does seem to be a little bit taller in 6th as 70mph equates to 2700ish where previously I recall it was just over 3000. Hope this will make up for some of the lost mpg due tot he 225 tyres the gear change is great though, very direct

really looking forward to some warmer weather so I can get on with some of the jobs myself. Need to fix and sell a good deal more IMacs before I can afford to sort the twin IC piping, the downpipe and decat

if you are using the 02m box what prop shaft are you using then? i was told that it had to be half tt and half octavia to fit in properly?

front half off the S3 or a TT as the Flange size is different. The "Donut" (black rubber transfer damper) on a 5spd is smaller than the 6spd one so it has to be changed as the original one won't mate up to the transfer box. Then because the Donut is changed you have to change the front half of the Propshaft as well. I think you have the choice to change the whole of the propshaft if you want as the rear end connector is standard to the Haldex but it just depends what your access is like. If you have the exhaust OFF the vehicle change all of it, if you just drop the Exhaust from the front then just change the front half.

We did as much homework as possible at the start but still ended up needing bits along the way. Add to that some "male chicken ups" and some supply blips and it seemed to take forever. But in the end I have spent less than the cost of a reconditioned 4x4 box without the fitting so I am happy, modding is always nice when it works out cheaper than replacing like for like.

I will be posting full details soon (no pics though as mechanic wanted my blood, my car spent that much time in the air I thought I was going to need a pilots license ) as there seems to be lots of conflicting info when it comes to doing this job, even when you talk to "the experts" they forget the little mods that are needed