o2a into an a1rabbit tdi-m

[Ron Burke]

O.k. here it is-my first post ever.  I'm really not computer literate but I can learn I guess.  Thanks to Joe and Karl-M who personally talked to me and all the rest of you guys that make this forum like a diesel clinic.  I'm ready to put most of the pieces together, and hope to be on the road this spring.  The questions is:
Does anyone know of a source for the left side trans mount needed to fit an O2a into an A1.  I purchased an o2A and decided to forget about the 020 transmission, so it appears I may have to fabricate this mount if someone doesn't already make and or sell it.  
Thanks.

[RabbitJockey]

patatron.com there are a few other places too.  good choice tdi with an o2a in a bunny,  i plan to do the same

[RabbitGTDguy]

when I can afford the 02a, it'll be a nice way to go as well.

You'll need a handleful of things...namely, dual mass flywheel from the 02a setup, shift cable box, starter, modified trans mount (side one) and a trans bracket from a 'rado/passat setup if I remember correctly for the proper rear/lower mount on the trans. Clutch/brake pedal assembly, master, slave, etc...

From there... you'll need to reinforce the firewall on the MK1 to handle and adapt the clutch pedal too as the metal that is there stock is kinda thin to be pushing that kind of pressure against all the time. The standard reinforcment bracket from an 02a setup that you'd use on a MKII, B3/B4, MK3, etc... (large bracket... bolts behind the booster, has a spot and reinforces the "clutch master" area of the firewall and wraps slightly towards the d side strut tower)

I've seen instances of the 02a install where people HAVE NOT had to use the 02a style pedal assembly and have adapted a way to operate the clutch master via the stock pedal assembly.

Patatron is  a good source for the mounts...good stuff. I've seen templates out there for 'making your own' though if you wanted to go that route.

Of course, you'll also need to use 100mm axles as well with the 02a too...

Hmm...can you tell I've thought about it. Just wish I had the $$$ for the ctn TDI tranny that I'd like to get from someone fairly local...

Joe

[RabbitJockey]

i thought it was possible to convert to cable clutch also, thats the route i would go, eff switching to hydro

[Audi80]

I used clutch cable setup from ´88-´89 1,6 gasser Passat. Cable is a bit long but will do the job. Speedo cable came from 70´s Passat (or Audi 80)

[RabbitGTDguy]

cable clutch is possible as well. If you can get the entire setup thats even better. The Eurovan setup works as well. Biggest thing is the mech for the cable clutch that replaces the slave...but more importantly, the bracket that holds the cable, etc. NLA from VW now...used to be able to get it for a pretty decent price. Many use a cable from a Honda Civic as well with slight modification and it works great. This is the route I may take. I'd be interested in a Passat cable clutch setup if they are fairly easy to find up your way! Usually...they aren't easy for us to find.

Joe

[Ron Burke]

Thanks  guys for all that good information. I had not even thought about the firewall strength- makes sense though. I do have most of the pieces you mentioned. I got them from a salvage yard in allentown Pa. that had about 200 vws. - prices not as good as ebay but they have everything. If anyone needs more info on contacts PM me for details. I will keep you posted on details and or problems with my progress .

[935racer]

You'll need a handleful of things...namely, dual mass flywheel from the 02a setup
Joe

I believe all the o2a equipped cars came with a single mass 228mm flywheel.

[RabbitGTDguy]

true....specifically you need an 02a unit. 02j's came with a dual mass and many doing the swap find the dual mass units easier to find because most TDI guys changing out their clutches, going for performance, etc. swap out the dual mass for the single mass. Thought I'd specify so he got the right one the first time....

Thanks for the clarification though Dave...

Joe

[935racer]

Yeah I would think the the o2j dual mass ones would be cheap, I throw them away all the time! :lol:  I don't like the feel of the dual mass flywheels nor are the clutch options as good so I prefer the single mass. Plus they are half the weight, but some people say the single mass is too noisy for them. :roll:

[Ron Burke]

Made up a set of trans mounts the other day.  Patatron  no longer is making them.  I made up a set of templates is 3-d  from an old o2o trans that can easily be set up on the O2a trans with a couple of pieces of all-thread. I also ended up making the rear mount .  Job was,nt to bad ,but as with all fabrications I learned a lot as you go to shorten the process. I will  keep the templates if anyone is interested.   I also started today on the hydro clutch .  Looks like it will be easy to modify the brace on the left shock tower ,fit the master cylinder there and use the original clutch pedal with a slight amount of modification to pedal itself -sure looks a lot then using the O2a pedal assembly.                                                                                                                                                                                                                      Ron

[RabbitGTDguy]

if you need help on the modifications to the stock pedal cluster, etc. Let me know. I think i have a couple of detailed threads over on the vortex that actually showed pictures of "how" its been done using the stock pedal assembly if you want them for reference!

Good to know Patatron isn't making the mounts anymore...will have to look elsewhere when i go to do mine eventually I guess!

Joe

[lord_verminaard]

Ron, I may be interested in your templates.  I have an 02j tranny and I've never really been able to get a clear answer if the mounts are the same or not.  Most are saying they are a little different but who knows.  Thanks!

Brendan

[Ron Burke]

Yes joe, it would be helpful to see those threads and compare to what I had in mind.  I would like to see if they thought it was necessary to  include the large pedal  spring on the O2a assembly.  I think I will put the motor in in a week or two and I will see how close my mounts are as far as accuracy.  I have  a tendancy to over build fabricated items for strength, and it may be possible to really simplify the left trans mount. As far using the O2j for the  A1 application , I am not familiar with weather or not that is identical to the O2a trans.  as far as mounts.  What I did with the left mount was use the five speed O2o mount  by drilling two new holes in it  to line-up to the O2a trans, weld in two sleeves on the mount itself  between the holes , add a couple of spacers , trim mount slightly and bolt it on. That maybe all that is necessary .  I Reinforced mine in other ways as well.  Like I said, if anyone is interested I be glad to assist them with templates or information.

[RabbitGTDguy]

Ron, here are a few to start with. Some different ways, ideas...quite a few pictures. I'll file through here later when I have more time...

http://forums.vwvortex.com/zerothread?id=1060826
6 pages...but to the nitty gritty...

This page in the thread really goes after the stock pedal cluster...some pics crude... but it appears to work and could be cleaned up even more!

http://forums.vwvortex.com/zerothread?id=2502273&page=5

Both are really good threads, IMHO Full of alot of good info...

Joe