so after so thought I’ve decided to not put the 9a into my mk2 as I want to be rid of the underbody pump assembly. I’m buying a 2003 mk4 Jetta gli with a 24v vr6 and 6 speed gear box. Besides the motor, gear box, ecu and wiring harness, what else do I need to pull out of the mk4 before scraping it?
gearstick and cables, throttle pedal + bracket if DBW, clutch and brake switches, loom from all of the able, diagnostics port and as much wire as you can cut, find 14 pin plug on main bay where the sensor loom connects and take that with lots of length too, rear calipers gearbox will be 02m which is a bit of a pain to fit in a mk2 so may want to leave that and go for much easier vr6 or v5 02a/j 5 speed
I planed on fabricating engine mounts for the chassis so I can use the mk4 engine/gearbox mounts. Plus adding a dog bone mount to the subframe. I’m going to be using mk3 vr6 control arms, hubs and brakes as well. Will I’m still need custom drive shafts if I use the vr6 control arms and hubs?
are you sure you need to mess about like that though, with 5 speed box you can use all standard v6 mounts etc IIRC with a certain wishbone combo there is 1 shaft you can get off the shelf, possibly skoda platform. the other side still needs custom, though you may be able to find a place that sells it all off the shelf. just have to ask yourself is that extra gear really worth it, after researchign the ratios available in the 5 speed vr6 boxes etc
I’ve got to say that you make a very good argument and make excellent points sooooo, I’m going with a 5 speed box. Can I use the shifter box and cables from the 02m?
shifter is the same yes, cables are the same design but slightly different lengths to the 5 speed 02j. give them a go may find they're close enough to work fine anyway, obviously try all the gears out before you refit the exhaust if you get a mk3 or early mk4 box then you just need later 5 speed 02j mk4 type shift tower to match the 02m stick and cables
As far a I'm aware, the speedo will drop into a mk3 box but not sure about mk4. You unscrew the electronic drive and screw in a 1.3 mk2 speedo cable. Worked for me. On my mk2 Tdi I used a tacho converter for the revs but not sure you'll need it as you're staying petrol.
as above for the 5 speed vr6 type box with speedo you need a mk2 1.3, corrado or passat cable, vw heritage can send you one if you cant gwet any rhd ones local. another advantage vs 02m, as they are purely digital so you need an adaptor or electronic speedo for them rev counter one of these: http://ashlocktech.com/Home.php
If you don't want much fuss with the hydro clutch, you can flatten bulk head, drill holes for master cylinder and weld a pin onto the pedal to accept the rod. Really simple but I chose to fit a hydro pedal box
You mean a brake booster? I've never run manual brakes so wouldn't have a clue buddy. On the clutch front though, I've run cable and now hydro and I'd go hydro every time now!
Yeah, the brake booster. I was thinking of just getting a floor mounted pedal box if I can’t find a corrado pedal box. I don’t really want to run a cable clutch anymore, parts are very scarce here in the states.
Someone will know how they feel but personally I have not run that setup before. I think along with corrado there is also a Passat item that you could use. I have a spare pedal box but unfortunately it's not hydro