2 questions.

[jaed_43725]

1. How do I get rid of the safety mechanism for charging where the engine has to go to 2K rpm before it will start to charge?

2. What options for a manual tranny are there out there? Can a TDI engine work easy enough? Are there gears available, especially 5th. I am not a fan of how close the gears are, it is very annoying. Thank you.

[burn_your_money]

1) It's probably bad connections. Do a voltage drop test on the system to pinpoint the problem.

2) Any 020 will install with relative ease. www.scirocco.org/gears will help you decide what code you want. Pay attention to axle size (90mm vs 100mm) and also splines on the input shaft. If it's different you'll have to change clutches and possible the PP/flywheel.

[bajacalal]

1. I don't think this is a safety mechanism, just the way these Bosch alternators work. It's less obvious on a gas engine because they tend to have a post start-up surge. I've noticed the issue on other cars with the same alternator design which includes many European cars. A poor connection from the alternator to battery seems to make the problem worse though, specifically if it alternator is not well grounded, consider running heavy gage wire to the alternator case, from the battery negative. Make sure the alternator connection to the battery positive side is good and make sure the exciter wire (usually a small blue wire connected to the alternator) which comes through your dash is getting power. It should have 12 volts DC when the key is on, engine off and no volts with the key off.

2. The 020 series of transmissions was used for many years and they're pretty much interchangeable with most differences being minor things that can be sorted out. They came with many different ratios and if you have a gas transmission connected to a diesel engine it will seem like the gears are too close, especially the lower gears.
This page has all sorts of information: http://www.brokevw.com/

[jaed_43725]

Its not bad connections. Its even in the usual manual you have to rev to 2K before it starts to charge. I wish to eliminate that.

I wont gain much moving to a .71 5th as I already have .75. I was hoping someone knew how to swap in a TDI tranny or of aftermarket gears to help me out.

[745 turbogreasel]

I've had  a few not charge till reved, and new or newer brushes has always fixed it.

[burn_your_money]

You likely have a 3.94 final. If you swap in a tranny with a 3.67 you'll have wider gears.

[R.O.R-2.0]

You likely have a 3.94 final. If you swap in a tranny with a 3.67 you'll have wider gears.

^^ THIS ^^

[bbob203]

Its not bad connections. Its even in the usual manual you have to rev to 2K before it starts to charge. I wish to eliminate that.

I wont gain much moving to a .71 5th as I already have .75. I was hoping someone knew how to swap in a TDI tranny or of aftermarket gears to help me out.

to put a tdi tranny into an mk2 td you'll need new pp fw gearbox shifter box with cables pedal cluster master cylinder and bracket that attaches to the brake booster and a few other bits and bobs and a tiny bit of modification to the firewall i have all that stuff minus the gearbox, pp and fw. let me know if your interested in it.

[R.O.R-2.0]

Its not bad connections. Its even in the usual manual you have to rev to 2K before it starts to charge. I wish to eliminate that.

I wont gain much moving to a .71 5th as I already have .75. I was hoping someone knew how to swap in a TDI tranny or of aftermarket gears to help me out.

to put a tdi tranny into an mk2 td you'll need new pp fw gearbox shifter box with cables pedal cluster master cylinder and bracket that attaches to the brake booster and a few other bits and bobs and a tiny bit of modification to the firewall i have all that stuff minus the gearbox, pp and fw. let me know if your interested in it.

O2A swap in a mk2 is not easy..

i NEED an 02A trans in my car tho.

unless you are WAY modified, and over the stock power levels by like 2x, then you are fine with the 020 w/ 3.67 & .75

[jaed_43725]

I will have to check into the 3.67 ratio tranny thing. I am not a fan of the 5th gear though in any of those. I would like something like .67. Still if anyone knows about after market gears let me know.

I guess I will opt out of the TDI tranny then. To much work with not enough pay off.  When mine finally goes I will get me a 3.67 tranny.

Also I believe my alternator is new. But I will get it checked out and see if something can be done. Thanks.

[JamesT]

Do some quick math. A 3.67 with a .71 5th is taller than a 3.94 with a .67. I wouldn't want anything that tall because of the jump from 4th to 5th, making for a lot of downshifting and sluggish highway driving.

[mystery3]

I have the late FF and the fifth is like an overdrive, it's a big jump between fourth and fifth, I wish they were tighter.

[libbydiesel]

Just wondering why you care that it doesn't charge until you blip the pedal?

[bbob203]

3.67 with a. 71 fifth is great for these engines. A taller. 94 fourth from your ags into an acn or asf with. 71 swapped in is even better on paper at least.  The acn is a very common if not most common gearbox of the 020 series.

[Zaro]

AUG trannyis what you want. came off of certain aaz powered cars