VW Golf Mk2 Owners Club

Re: G135EPB 8v GTI

Reply #225 – September 19, 2025, 07:13:23 AM

Great update!
I really like those wheels on the car, makes it look tough.

Re: G135EPB 8v GTI

Reply #226 – September 26, 2025, 02:31:42 PM

I took it for its MOT on 20/9/25 as it had ran out for the 1st time since my ownership. Glad to say it passed with no advisories 


I only drove it too and from the garage about 8 miles all in but car drove fine. Coolant needs topping up which i really hope is just some air left in the system!

Later in the week I decided i was going to get ready for the Quaife to be fitted. So back in the air and gearbox off. Although its been in and out more time than i care to remember, I've never done it alone. Mainly due to a lack of confidence and the gravel driveway. I felt that it needed to be done at home so I'm not leaving it somewhere other than my own driveway to remove the need to get it back driving asap. I was amazed the time i took the first photo with the bonnet up and to the time i took the photo with the box on the floor was 1hr 20 mins. The hardest part was lifting the box at enough of an angle to get the cup over the flywheel. I have to admit when the box came down onto my chest i got myself a bit stuck 😂 the weight combined with the car sitting fairly low to the ground meant i didn't have much room to actually get myself out from under the car. After a short struggle I freed myself and dragged the box out- had to remove the splitter for it to come out the front!
Started 11:50

Finished 13:10

There was 1 casualty - gearbox bracket collared bolt m8x92 which i need to get hold of a spare if anyone has one?


As i had some free time I decided to fit the missing flaps of the fan cowl and my new Febi fan. I know the cowling needs a paint but this is way down the list of priories at the minute!



Also picked up an induction kit for noises! I'm not sure if i will keep it yet but it's a bit of fun. Its meant for a mk4 golf with an 80mm maf. I've trimmed down the heatshield and used the off cut to make a temporary bracket to secure it the the chassis leg and removed the lower blank to allow some more cold air through. I've got a cleaning set from Rami Air so will do that when i get the opportunity. the ABF intake is 70mm so fitted and 80>70mm reducer and some alli pipe to join them together. The intake temp sensor has been mounted to the heatshield for now. I still need to trim the pipe down but i might see about replacing the whole intake with 90 degree silicone elbow for a nicer look but so will hold on for now.






At the weekend i'm hoping to rip the old 02a apart to remove the Quaife ATB and maybe take the new 02j apart to ready to remove the diff rivets from the crown wheel (horrible job). I've got new diff bearings as well. All of this is best done with some help if i ever want it to work again! So going to rope in Dan, hopefully for guidance more than just taking all of his spare time.

Re: G135EPB 8v GTI

Reply #227 – September 29, 2025, 08:50:58 AM

28/09/25 – 02A & 02J Gearbox Stripdown for Quaife Swap

After a few months of it sitting at Dan’s place, I finally went over to strip down my old 02A gearbox with the Quaife LSD(with help). I'd swapped this box out for a 02J with a 3.9 FD a while back, but now it’s time to move the Quaife across to the new box.

I also brought the replacement 02J gearbox with me — this one had never been opened before. Stripping both boxes down was actually easier than it probably looks in the photos, but the 5th gear on the 02J was a nightmare to get off. Took a lot of persuasion and finally came off with a puller.

The diff rivets can now be drilled out that’ll be the next job.

Since the seals have been disturbed, I’ll be replacing:

Input shaft guide sleeve 02A141180A

2x Output shaft seals 084 409189B

Interestingly, the input guide has an 02A part number and a late 1999 date stamp, which is interesting to see, maybe a crossover period for early 02J parts?

I’ve ordered the new seals and bits and should be collecting them on 30/09/25, with a view to rebuilding the box on 01/10/25, if all things align.

After that, it’s just a case of getting it fitted back into the Mk2 and seeing how the 3.9 FD and Quaife feels on the road.

🙂

Re: G135EPB 8v GTI

Reply #228 – October 02, 2025, 09:40:20 PM

A little bit more time spent on the gearbox. I took the crown wheel and open diff down to a mates and used their neighbours pillar drill to drill out the rivets.

I snapped the drill bit on the last one 🤦‍♂️ so ground the rivet down with a finger file and tapped it out. Also tapped my hand in the process!

Went to Dan's and fitted the Quaife to the crown wheel and torqued the ARP bolts to 54 lbft.

Gave the casing and gears a reasonable clean down with brake cleaner.

Sealant applied to the casing and bolts all torqued down.

We stopped for a cheeky burger before calling it a day for other commitments. Just needs 5th gear fitting, the new seals and cups and selector I think. Then it can go back in. I'm not looking forward to lifting it again!

Re: G135EPB 8v GTI

Reply #229 – October 03, 2025, 07:01:03 AM

Witchcraft I tell you!!!