81 Rabbit LS AAZ (2023: now tdi-m) - page 11 - User's ride Wall - VWDiesel.net The IDI, TDI, and mTDI source.

• #150 by RabbitJockey on 27 Apr, 2025 18:11
• Time for a Spring update. It sat all winter, then this spring I timed the engine again and adjusted the pump bracket so that the belt would track straight. I'm set to 0.95mm right now with the pump. I installed a weighted shift rod, new bushings, and a short-throw shift kit from "missing linkz".
  
  No pictures of that, but it improved the driving experience.
  
  
  I installed the upper radiator mounting bracket from a 1g Dodge Neon, it's perfect in the mk1, all I had to do was drill a hole and install a rivnut. I'll figure out something for the other side of the radiator to reduce potential damage from vibrations, but for now, this is great.
  
  
  
  Then I installed the 2.5" Techtonics tuning exhaust I've had all winter. They make great stuff and are so easy to deal with, plus they have so much experience to help guide you in the right direction. It came with some high-quality U-bolt style exhaust clamps, but I replaced them with band clamps because the U-bolts would catch on the edge of my garage as I pulled in. Also, the tail pipe on TT exhausts is always weird, I never know which direction it's really supposed to go.
  
  
  
  
  
  Finally, I could start using it for errands and having fun driving around town, shaking down small issues like shift linkage alignment and exhaust rattles, and I put that hood back on as well.
  
  
  
  
  
  Here I am giving it some revs to test the sound of the new exhaust. I was hoping for a better sound since I paid more for the Borla muffler, but it just sounds like a diesel, oh well. It does smoke a little in the video, I have the fueling adjusted pretty well, it rarely smokes unless the engine isn't warmed up yet.
  
  
  https://imgur.com/xGxzP2w
  
  
  In my last post I was concerned about not being able to get into reverse. this is still an issue. For now the solution has been to put the car in second gear then quickly shift to reverse and then it goes in smoothly. Something about the clutch isn't fully disengaging. I'm hoping with some more miles it will loosen up and start operating normally.
  
• #151 by ORCoaster on 27 Apr, 2025 18:25
• Nice work on all of that!
  
  I would be checking the alignment of that rod for the shifter.  Just as a first place to start.  Getting it aligned is kind of a pain but I use a 17 mm socket to get the distance from the shifter under the car about right and then reach with my money arms and mark the rod with a Sharpie.  Then I can reposition myself to tighten it all up using the mark as my focal point. 
  
  Pulling the trans is such a pain.  But if that is what is needed then do it. 
  
  
• #152 by RabbitJockey on 28 Apr, 2025 09:24
• Thanks. Yeah I've tried adjusting it to a few different points, and once I thought I had it but I guess it was just a fluke. I've given up on the adjustments and I'm 99% sure it's a clutch issue now. The pressure plate is triple strapped so that could be the issue too, although it never was before maybe some rust from sitting made the straps stiffer and don't allow the pressure plate to fully release. We'll see, if I have to pull the trans I will, the 4 speeds aren't too bad they're pretty light and I've got the process down well from all the clutch issues I had years ago (covered in this thread)
• #153 by drrtybyl on 30 Apr, 2025 08:37
• congrats getting it back on the road. take it you've tried tightening the clutch cable tension adjustment as far as possible? is the firewall grommet for the cable intact? trouble engaging any other gears? reverse lockout tab?
• #154 by RabbitJockey on 01 May, 2025 06:14
• Yeah i have played with the cable adjustment and that had no effect. I also replaced the metal retainer things that go on the end of the clutch cable at the transmission end. The other gears are fine, sometimes first can be a little resistant but it never grinds.
  
  What do yuo mean by the firewall grommet? I did check the metal tube on the pedal cluster and that looked fine. I know they commonly break off especially with a heavier pressure plate like i have.
• #155 by RabbitJockey on 01 May, 2025 06:16
• The sound of a mk1 TDI https://imgur.com/gallery/u9YuWU2
• #156 by Dennis Froelich on 01 May, 2025 07:53
• Sounds great!!
• #157 by RabbitJockey on 03 May, 2025 10:36
• Breakfast and a car show with some friends
• #158 by ORCoaster on 04 May, 2025 16:53
• Well, there you have it.  Two cars were built for speed and one for economy. 
  
  I say that beige one is the best of the lot but I have a bias that is sort of whacked.