Converting my 93 TD Transmission to TDI 02a

[Cheesetoast]

i was suggested this plan of action from a local shop.  My 020 tranny is blown, no holes in it, but i think the diff is shot.  These trannys are hard to find, he suggested maybe getting a similar ratio 020 tranny from a gasser, or even putting a tdi tranny, 02a.  The downside with the 02a is i have to change the clutch master cylinder, cable, pressure plate, clutch, and flywheel.  My 020 has a fairly new clutch, lightened flywheel and 16v pressure plate.  Think it's smart to switch it to a tdi tranny?

[burn_your_money]

If you are refering to switching over to a hydro clutch you can get a conversion piece from europe that will switch it to cable shift.

A 02A tranny is alot stronger then a 020 so depending on how you drive that may be something to consider. If you have a lightened flywheel I'd imagine it is more "spirited" driving. How did you like the flywheel BTW?

[Cheesetoast]

well the car does have 140hp/190 torque.

any more info on this conversion piece? anyone else done this conversion?

[Cheesetoast]

this is hte info i found so far, not sure how much applies to tdi-> td, most people are taking vr6 transmissions for 2.0's.

What I've picked up for a MKIII 020-02A you need:

VR6 Shifter box with cables
Master Cylinder
Clutch Hydralic Line
Slave Cylinder
02A trans
02A starter
02A front motor mount
02A starter bolts (these are longer than 020's)
02A rear trans mount



o I started my swap yesterday. Ran into some problems, rear main seal leaking a little, axles sticking in diff flange . I found after getting the trans in that you need longer starter bolts (the 020 ones are 1" too short) so I need to order some corrado bolts. The rear main was leaking (even though the engine only has 80k on it???) Have to get the shifterbox installed next time I can push the car in the shop. You need to extend the wires for the Diff speed sensor (all 3 wires about 1.5ft) and i need to rig my starter wire to work with the corrado starter (no biggie got the wires to splice on).
It took about 20min to get the clutch slave blead. I installed a new master and clutch line and re-used the old slave cyl. Also all the old parts are for sale!, i will start a FS thread soon here.
All in a days work. some pics!
Before:

After:

While in the process i swapped out my front upper motor mount with the bfi one i had (you have to remove the motor mount bracket to get the bushing out to replace). Just spray some lube on the inside and twist off.
--------------------------
yea, if you replaced the slave or master just do this:
1- open resivour cap and top off fluid
2- open the bleeder screw on the slave cyl (put a rag under it so fluid doesnt go everywhere)
3- press the pedal to the floor and leave it there, go back and watch the bleeder screw and watch the bubbles come out. when the bubbles stop and fluid starts coming out close the bleeder screw.
4- have someone pump the pedal slowly 3-4 times then hold to the floor
5- open the bleeder and let the air out and then close. you should be able to bleed it by now, if not just repeat step 3. if it still doesnt work check for leaks in the system.

[burn_your_money]

I'll try and get some more info on it for you

[Mk2Fanatic]

When you did the swap, did you notice that you have space for a passat dual rad fan setup(did you use the stock front rad support or a passat one.)  I did a similar swap on a gasser and by using the passat rad support you can run a full width rad with two fans.  Doing the same to my 86 td in the next couple of weeks

[scopefrfd]

When you did the swap, did you notice that you have space for a passat dual rad fan setup(did you use the stock front rad support or a passat one.)  I did a similar swap on a gasser and by using the passat rad support you can run a full width rad with two fans.  Doing the same to my 86 td in the next couple of weeks

I did the same dual fan swap on my MK2 jetta years ago.  Just take the passat VR6 fan/shroud assembly and cut off approx 1" from the bottom of the housing.  Use a circular saw with a metal blade..goes through like butter and makes a nice straight cut.  I have pics somewhere of the rad setup

[jtanguay]

the dual fan setup is pimp man.  i want to do one on my jetta.  VERY efficient!!!

[scopefrfd]

THe dual fan setup looks great but with a tdi in a mk2 it's overkill...but I wanted to make sure I didn't overheat the engine..too much money invested in it.