TDI transmission on IDI

[jaed_43725]

I done searched and searched and could find nothing. Is it possible to hook up a TDI transmission to a 1.6IDI in a 85 Jetta? If it is, what is needed? I came across a list of parts that would seem relevant when I searched for putting a VR6 into a MK2. I could find it again and post it if necessary.

[CRSMP5]

vr6 02a different then tdi 02a.. bell housing bolts different...

parts

pedals from b3/b4passat or corrado.. hydro clutch..

clutch master/slave and line..

some type of fluid bottle/master bottle from non abs hydro clutch b3/b4/roddo

shifter and cables

starter

flywheel/clutch/pplate

tranny

bolts

roddo speedo cable...

100mm axles from mk2

[jaed_43725]

So which transmission do I need? And is it worth it?

[mzak88]

Pretty sure there is a cable clutch kit out there for 02a, heard of them.

[burn_your_money]

They are spendy though.

If your 1.6 is NA you don't need a 02A unless you are driving 75+ regularly, and even then a good 020 would do fine. I don't think a 1.6 will make good use of the low gearing on a TDI. An AAZ might, but again, you'd have to drive fast for it to be worthwhile. I do 60-70 and I didn't appreciate the CTN (mk3 TDI) tranny behind a modified AAZ. I felt it was verging on lugging. IDIs like revs. You might be able to find a nice 16v tranny or something though, but for the hassle I'd say it's not worth the effort.

[R.O.R-2.0]

02A is an EXPENSIVE swap unless you have ALL the parts sitting in front of you..

an ACN, or something like that (020 trans, direct bolt-in for a mk2) would be more than enough for the power most people have, and nicely geared..

go figure, the best 020 diesel transmissions were installed in gasser cars!

[rodpaslow]

I've just changed my MK3 over to an 02A, much easier to work on than an 020, as far a taking it apart and changing anything internal, in my opinion.  However it is a lot of work to change everything in the car over to a cable shift.  As listed above all need changing, I kept mine a cable clutch, as I found that much easier to do than pull the pedal assembly.  I'm just finishing mine, it's with a 1.6, however its a passat 02a with a final drive of 3.944 so I think it will match well for city and I changed the fifth to a .681 so highway driving should not be terrible either.  As per one website (forget which) my revs in fifth will be lower than the 020 with 3.667 final and a .75 fifth.  I do a lot of driving that is 75 mph or better tho, which is why I went for the  02A setup.

[vwnut84]

Having just installed a CTN 02A in my mk2 AAZ I can attest to the fact that its expensive and labor intensive, but for my needs (taller gears for mostly highway driving) the 02A swap made sense. If you're just going to be doing mostly under 70mph driving, then sticking with the 020 is probably the better choice. My swap cost me about $900 and about 20 hours of my time all said and done. An 020 will be a quarter of that.

Burn_your_money, what turbo/mods do you have?  My AAZ is pretty much stock with a k03 and I feel that it loves the 1500-2500 rpm range with this transmission.

[vanbcguy]

I've just changed my MK3 over to an 02A, much easier to work on than an 020, as far a taking it apart and changing anything internal, in my opinion.  However it is a lot of work to change everything in the car over to a cable shift.  As listed above all need changing, I kept mine a cable clutch, as I found that much easier to do than pull the pedal assembly.  I'm just finishing mine, it's with a 1.6, however its a passat 02a with a final drive of 3.944 so I think it will match well for city and I changed the fifth to a .681 so highway driving should not be terrible either.  As per one website (forget which) my revs in fifth will be lower than the 020 with 3.667 final and a .75 fifth.  I do a lot of driving that is 75 mph or better tho, which is why I went for the  02A setup.

Would be very interested in hearing more about your swap - where'd you find the cable clutch parts?  I've got an 02A sitting on my shop floor at the moment...

[burn_your_money]

Burn_your_money, what turbo/mods do you have?  My AAZ is pretty much stock with a k03 and I feel that it loves the 1500-2500 rpm range with this transmission.

It was Giles's car. B3 Passat, performance pump, TDI intercooler, 20 psi, I forget if it had the K14 or T3 on it at that point. I forget if the head was ported or not. He also had an exhaust, but again, I forget if that was installed at the time.

I like higher RPMs on IDIs though. The way many people drive I consider near lugging, if not lugging.

[mzak88]

If you are working on a mk3 you do not need to pull pedal assembly. Just get new master, it will come with plastic bushing. Remove stock o2o cable, install bushing on master cyl pushrod, insert through firewall into recess in clutch pedal, shove hard & bobs yer uncle. You then just need to cut end of nipple on brake fluid res install lint to clutch master. I've done this on mine. I'm running aaz with a ctn 3.165 r&p with .658 5th, this gets me a 100km/h cruise at2000 ish. I also adjusted smoke screw, 1.6 boost pin, 15 psi, tdi IC.

[rodpaslow]

I know at the time I was considering doing like mzak88 suggested, used parts on MK3 cars are still pretty scarce here so I opted for the cable.   I used the CRX Honda cable, just had to replace the inner cable as I needed slightly longer cable for the MK3, but still able to use the outer part of the CRX cable to run it.  Works good and I can easily adjust tension/slack if needed.  Just another option if not installing 020.

[rodpaslow]

One other note, with the 020 I had steel ball fittings(not the oe plastic connections) and the shifter was nice, solid shifts and precise shifter feel.  I decided to go with a dieselgeek (or other would work) short shifter and MK4 ball type cable shifter(newer M4 shifter).  Feels just as precise and I would recommend using this if going to the 02A.  Just $.02

[mzak88]

One other note, with the 020 I had steel ball fittings(not the oe plastic connections) and the shifter was nice, solid shifts and precise shifter feel.  I decided to go with a dieselgeek (or other would work) short shifter and MK4 ball type cable shifter(newer M4 shifter).  Feels just as precise and I would recommend using this if going to the 02A.  Just $.02

What's it like to install mk4 shift box into the 3?

[rodpaslow]

Vortex has a lot of different suggestions.  All I did, you have to slot the holes at the back end of the box - the slots are slotted forward and to the outside of the box.   Remove the bottom plate on the box and remove the two front bolts.  Drill a hole in the center of these two bolts so you can tap it to M8.  I used a old vw bolt and threaded it all the way (you need about 80 mm or about 3.25" long bolt) and screw the bolt in.   You'll need a spacer to take up the difference from the MK3 to Mk4 box on this front bolt.  I estimated using the old MK3 box and put them side, by side to see what spacer I needed.  Bolt it in!