Thezorn's AAZ rebuild.

[Thezorn]

Finally got around to testing the exciter wire (B+) ?? if thats the right one..? and it has a good 12V power supply once the key is on. So the alt. is getting excited.. any ideas?

[BillyWillicker]

Well, Big red wire has batt. voltage, little blue wire has batt. voltage: No charge?  maybe brush/regulator pack??  Or give it a smack w/hammer?

[Powered by Spearco]

Yeah, give it a wack with a hammer. If that doesn't fix it, it must be electrical.

Pull off the brush pack and see if they have any life left of them.

Start the car, check again if the little blue wire has 12V at the Alt.  If it does, check with DVM (digital volt meter)to see if the Alt. is putting out voltage at the big red lead at the connection. It could be the connection at the Alt. too. The blue wire is from the cluster to send 12V to the Alt. to start charging.
Big red wire is always going to be Batt. voltage when engine is off.

[Thezorn]

Well, Big red wire has batt. voltage, little blue wire has batt. voltage: No charge?  maybe brush/regulator pack??  Or give it a smack w/hammer?

Yea Ill give it a good smack with a hammer today and see if that knocks some sence into it
If not ill pull it apart and see what I can find.

[Thezorn]

Well, Big red wire has batt. voltage, little blue wire has batt. voltage: No charge?  maybe brush/regulator pack??  Or give it a smack w/hammer?

Yea Ill give it a good smack with a hammer today and see if that knocks some sence into it
If not ill pull it apart and see what I can find.

Turns out some idiot hooked up the red wire from the alt to the wrong bolt when he was building the engine.. anyways its all good now, tach works, oil pressure light went out, and the battery is getting charged.
On a bad note there seems to be something wrong with my clutch/transmission...
When the engine is running and I push the clutch in it seems to start almost grinding something, release the clutch and its all good.
I can also put it in gear with the engine running and not depressing the clutch and it doesnt grind. Pretty sure something is not working how its supposed too..
any ideas?

[Powered by Spearco]

Awsome about the charging issue. The tach wire/ black with red wire is also what is needed for the dynamic oil control in the cluster. Cool, glad you got it figured out.

Now the clutch. When you put the trans to the engine, did you replace the clutch. Forgive me if you did in earlier posts. It kind of sounds like the clutch fork is slightly broken/worn and is getting worse. Just a thought.

[Thezorn]

Awsome about the charging issue. The tach wire/ black with red wire is also what is needed for the dynamic oil control in the cluster. Cool, glad you got it figured out.

Now the clutch. When you put the trans to the engine, did you replace the clutch. Forgive me if you did in earlier posts. It kind of sounds like the clutch fork is slightly broken/worn and is getting worse. Just a thought.

Hahaha yea that was a HUGE facepalm moment when I realised that, thanks for youre help spearco!
 
After alot of searching I found this http://forums.subdriven.com/showthread.php?3399144-Broke-need-your-assitance..-020-noise
This is the exact same problem Im having with the ACT clutch/pressure plate. I never measured or test fitted the disk on the actually input splines on the tranny, so by the looks of it I was sent a 24mm one but I need a 22mm one. So when I push the pedal down it was (disengaging) spelling?
the disk from the PP and trying to put it on the tranny splines, but since hole in the disk was alot bigger it was just slipping and grinding on the splines on the tranny. Time to go clutch shopping.
I think for now I might just get a stock disk since I can have one in 2 days, but I will see how much it is tomorrow.

What do you guys suggest for the clutch disk? something a bit better to moderatley better then stock?

[Thezorn]

Cant get a good stock disk locally so im going to have to do some shopping. Where is the best place going to be for me to get a stage 1 or 2 disk for my car.
On a side note I found out my car doesnt actually have the OG transmision in it...its has a 1.8l gasser tranny.
Or at least thats what I was told by the dealer today when I was talking to the guy there that had worked on it before I got it.

Is this gunna change what I am going to be looking for when It comes to the clutch disk. I believe the code of this tranny is AUG? Compaired to the ATH it should have with it....lame.

[theman53]

I did clutchnet.

[Thezorn]

I did clutchnet.

There is SOOOOOOOO many choicess AHHHH
What did you get? haha

[R.O.R-2.0]

YOU HAVE AN AUG TRANS?!?!

you will hate it, better start shopping for trannies too. cause the AUG trannies SUCK behind a diesel..

boy, you can rip thru the gears, but they scream pretty good at highway speed..

[Thezorn]

YOU HAVE AN AUG TRANS?!?!

you will hate it, better start shopping for trannies too. cause the AUG trannies SUCK behind a diesel..

boy, you can rip thru the gears, but they scream pretty good at highway speed..

Hahaha yea I know, just actually found this out yesterday when I was talking to the dealer. The PO didnt want to have the reverse fixed in the original ATH trans so they got this crappy AUG to replaace it...The bottom of the tranny where the markings are is super scraped off so I couldnt figure out the code before.
Always wondered why it reved SO HIGH at highway speeds (or seemed to, since I didnt have a tach to tell)
With this tranny (AUG) at 100KPH ill be reving at 3008rpms, but the ATH it should have I would be at about 2550....this alot explains the crappy fuel milage when highway driving.

Does anyone know If the MK4 (02J or 02A)?? trannys from a TDI have the same bell housing bolt pattern as our mk3 trannys?

[RadoTD]

Does anyone know If the MK4 (02J or 02A)?? trannys from a TDI have the same bell housing bolt pattern as our mk3 trannys?

Yes, they do. All of VW's 4 cylinder motors bolt to the same bellhousing.

02A or 02J are basically the same transmission; internals are nearly identical, except 6sp 02J's exist. The myth that 02J's hold more power is false. With all necessary pieces (off the top of my head; trans, clutch, pedal box, brake fluid reservoir, clutch master and clutch slave, shifter box & cables), it all bolts in.
02M is stronger, but you need custom mounts and custom axles to fit it.

[Thezorn]

Does anyone know If the MK4 (02J or 02A)?? trannys from a TDI have the same bell housing bolt pattern as our mk3 trannys?

Yes, they do. All of VW's 4 cylinder motors bolt to the same bellhousing.

02A or 02J are basically the same transmission; internals are nearly identical, except 6sp 02J's exist. The myth that 02J's hold more power is false. With all necessary pieces (off the top of my head; trans, clutch, pedal box, brake fluid reservoir, clutch master and clutch slave, shifter box & cables), it all bolts in.
02M is stronger, but you need custom mounts and custom axles to fit it.

Awsome, thats what It looked like to me. I can only imagine how nice a 6 speed 02J would be in my car haha. Maybe in the future though.I think Ill try and track down an ATH for now.

Still trying to find a good clutch disk though. I cant even seem to find a stock disk anywhere locally. Does anyone know if the clutch disk are different for the 1.8L gasser and the 1.9TD? I do know they are both 210mm but the only part im having a hard time figuring out is if they have the same spline diameter

[Thezorn]

Got the right clutch disk in it now and took it for the first test drive today, Drives nice, and man do the turbos scream!
Could the fact that my timing may be to far advanced cause it to not build boost very quickly?
I was getting about 15psi at 3-3.5k rpms, which is waaay off what it shoud be.