G135EPB 8v GTI

Topic: G135EPB 8v GTI (Read 11177 times) previous topic - next topic

Re: G135EPB 8v GTI

Reply #45 – January 03, 2022, 09:59:24 PM

Having changed from an AGC box with a 3.9 final drive to a CDA box with a 3.6 FD, I really liked the cda! It made it a lot easier to drive on a day to day basis. The previous box I would screaming around everywhere plus with my noisy exhaust I felt a bit silly

I noticed i was actually driving differently to try and keep the revs down around town and where i lived which sounds ridiculous!

So I did some more research into ratios to see what was available to me for a permanent solution. 02J was now an option also but i found a lot of adverts didn't specify the exact gearbox codes and most responses were "its an 02J mate"

The more i drove with the cda box the more i liked it. Its actually the correct box for an abf. I had read the ratios were too long but i didn't find this at all, maybe with the added weight of a mk3 it might have sucked the fun out slightly?

I had done a few gps runs with my previous AGC box and the original 020 box too. When I did the same test with the temp cda box the times were pretty much the same. Gps accuracy probably played a part and weather etc.
   0-60 0-100   1/4 mile
020 AUG box    6.9    20.2 15.6
02A AGC with quaife    6.8    18.3 14.5
02A CDA no quaife    7.0 17.7    14.9

With no real difference in a basic sprint I wasn't too fussed about tenths of a second. I'm sure there are better ways to test but the main thing for me was the way the car felt. My preference was the 020 ratios as the rev drop was great but there was no way I was returning to cable clutch and rod shift gears. I did consider combining the 3.9 FD with the cda box as this would make more or less the 020 ratios but this would mean a rebuild that i didn't have funds for.

Re: G135EPB 8v GTI

Reply #46 – January 03, 2022, 10:23:50 PM

The temp box had a 1st gear grind so wouldn't be staying long term. I decided a decent 02a cda box with the quaife box was going to be the way forward. Another box was purchased from a reliable source.
Back into Henry's garage

Quaife fitted to the ring gear? This was a terrible job removing the original, trying to get the diff rivets out was a job I would not wish upon anyone!

All torqued to spec

Photos seem to have gone astray from here but it was a success

Very happy with the ratios and to have the quaife again. Driving day to day without was fine but makes such a difference when driving harder.

Re: G135EPB 8v GTI

Reply #47 – January 04, 2022, 08:18:42 AM

I used to do a fair few conversions back in the day, CDA was my go-to box, can't really beat it.
Do you get much torque steer with the diff in?

In both my 3.2 and my 20v before, under full load, the car will pull on bumpy roads, though I may be trying to send too much torque through the front wheels!

Re: G135EPB 8v GTI

Reply #48 – January 04, 2022, 09:15:15 PM

Quote from: Monkey on January 04, 2022, 08:18:42 AM

I used to do a fair few conversions back in the day, CDA was my go-to box, can't really beat it.
Do you get much torque steer with the diff in?

In both my 3.2 and my 20v before, under full load, the car will pull on bumpy roads, though I may be trying to send too much torque through the front wheels!

It doesnt torque steer on a straight road no, but it really makes a difference in corners and I do like some back road and roundabout fun when the moment is right!

I would think an lsd is a must have on 3.2's and 20v's? They're so much fun, so easy to light the tyres up. Do you have one in your 3.2?

Re: G135EPB 8v GTI

Reply #49 – January 04, 2022, 10:24:59 PM

A small cosmetic update and probably a slightly controversial one. The dash surround was cracked around the head unit and down the side of the headlight switch. Also the external door trims had become scratched where i had them painted black previously

I sent them of to a guy called JH Hydros to hydrodip

He did a good job and its better than looking at cracks, maybe i should have just bought a replacement surround. Also the cassette player was only briefly fitted, the quality was awful.

Steels where powder coated in silver with some added sparkle. I prefer my ra's but these are so easy to clean

Also tried to refit my strut brace but its a little bit close. The custom front cross member was causing a lot of vibration so was swapped for the original cross member and must have changed the angle the engine sits slightly

Re: G135EPB 8v GTI

Reply #50 – January 04, 2022, 10:48:17 PM

Managed to get a friend to make some spacers to fit over the turrets to bring the strut brace away from the engine a little.

September 21- I arranged to do a track evening at Donington with Henry in his e36. This was the first time i had driven on track other than Curborough in 2019 and a copuple of driving experiences. The golf gave me no problems and was so much fun. The grip the r888's gave was amazing. Poly rear beam bushes were identified as the most obvious part to improve next.

Re: G135EPB 8v GTI

Reply #51 – January 05, 2022, 08:15:25 AM

Quote from: ianmac86 on January 04, 2022, 09:15:15 PM

Quote from: Monkey on January 04, 2022, 08:18:42 AM
I used to do a fair few conversions back in the day, CDA was my go-to box, can't really beat it.
Do you get much torque steer with the diff in?

In both my 3.2 and my 20v before, under full load, the car will pull on bumpy roads, though I may be trying to send too much torque through the front wheels!
It doesnt torque steer on a straight road no, but it really makes a difference in corners and I do like some back road and roundabout fun when the moment is right!

I would think an lsd is a must have on 3.2's and 20v's? They're so much fun, so easy to light the tyres up. Do you have one in your 3.2?

Yeah, I fitted it a year or so after the initial conversion.
I find where before, I'd get a single wheel spin and I'd just lose acceleration.
Now, if I hit a slight bump/drain under heavy load, the diff will shive the power over to the other wheel and it'll push the car about.
On the track or in corners, it's amazing though, so much grip. Can't wait for the National Meet up at Curborough again!

Yours looks awesome on the track. Loving the rear wheel lift too!

Re: G135EPB 8v GTI

Reply #52 – January 07, 2022, 11:06:21 PM

Some help from friends and rear beam bushes went in quickly. I went for Powerflex to match the front and they seem to have a good reputation. I was surprised how well this went, the old bushes were only a few years old but they came out very easily. The worst part was getting the old flexis off to remove the beam, these were swapped for braided.

The only photo I took but proves them made it on the car!

They made a definite difference when pushing it. The rear end feels less floaty so very pleased.

I had been keeping an eye out for a Miltek/TSR abf manifold and luckily one appeared locally on ebay. I've heard its hard work removing the old studs and nuts so not too sure when this will be fitted.

I'm also on the look out for a power steering setup if anyone is selling? I've been told mk3 racks work too so hopefully I can make that the next job. Also I really need to address my exhaust, its so loud! Beyond that I am going to be looking for rust and some paint repairs

Re: G135EPB 8v GTI

Reply #53 – January 10, 2022, 10:23:25 AM

I'd be a little careful with the manifold.

Because the ABF is a tall block, it can foul the bulkhead.
I've fitted a couple now and found spacing the front engine mount up a little (roughly 10mm) and then taking a hammer (carefully) to the bottom edge of the bulkhead leaves plenty of room.

Re: G135EPB 8v GTI

Reply #54 – January 10, 2022, 02:09:37 PM

Quote from: Monkey on January 10, 2022, 10:23:25 AM

I'd be a little careful with the manifold.

Because the ABF is a tall block, it can foul the bulkhead.
I've fitted a couple now and found spacing the front engine mount up a little (roughly 10mm) and then taking a hammer (carefully) to the bottom edge of the bulkhead leaves plenty of room.

Thanks for the heads up. What brand manifold did you use? This one should be specific for mk2 abf conversions MSVW3008. https://tsr-performance.com/tsr-milltek-vw-mk2-golf-2-0-16v-abf-conversion-manifold/

I had issues with the standard abf downpipe fouling the bulkhead so hammering has already happened! I also had to play around with different front and rear mounts to tilt the engine back as far as possible. I've ended up with a vibra technic rear mount and oe front

Re: G135EPB 8v GTI

Reply #55 – January 10, 2022, 02:35:33 PM

I was just using standard KR 4 branch manifolds as there were everywhere at the time.
I'd say you're already well prepared for the manifold with what you have done.

Word of warning, it's a right pain in the ass to fit a four branch when you have the engine still in the bay!

Re: G135EPB 8v GTI

Reply #56 – January 10, 2022, 04:41:52 PM

I tried removing the heat shield off the manifold the other night and the allen bolts were rounding off, not looking forward to seeing what the studs an nuts will be like!

Thanks for the advice, maybe that the engine will come out then. I could do the power steering swap and exhaust manifold altogether.

I have read that some people reckon the 4-1's aren't worth the hassle. Did you see any gains?

Re: G135EPB 8v GTI

Reply #57 – January 10, 2022, 04:49:50 PM

Yeah, I saw a little, seemed to be a little more torque in places, but I think I had a 4-2-1 manifold.
I would 100% take the engine out, especially if you're doing the steering rack.
It takes all the pain out of getting on those manifold bolts.
That being said, did you take it off when you done the conversion?

Re: G135EPB 8v GTI

Reply #58 – January 10, 2022, 06:47:25 PM

Thats good to hear. I think 421 make more low down and 4-1 is top end? Either way I'm sure it will sounds nice if nothing else

No it wasn't touched during conversion, It's got an abf manifold and downpipe. 1997 engine so good chance its all 25 years old.

Re: G135EPB 8v GTI

Reply #59 – January 10, 2022, 08:05:37 PM

The Miltek/TSR 4x1 manifold should be OK with your ABF. I recently emailed TSR to confrim as have an ABF block under KR fuelling in mine and the generic 4x1 hits the bulkhead. I'm ripping mine out and replacing with a stock downpipe and front section as find the 4x1 too raspy.

Question - I was looking at your tensioner on your cambelt pics when it was in the engine stand a few pages back and noticed it's 45degrees off anticlockwise to mine. I have the same tensioner and the arrow points upwards and lines with a mark on the white plastic part but I am now doubting myself seeing yours (this is the first time I've ever done a cambelt...)