Sharkie's TSI Amarok Build

This is going to be a Awesome machine, maybe do the V6 diff id like to do that

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Originally Posted by Sharkie

That is the 1 currently on the car yes. Beware that it is (IMO) too loud with some drone in the midrange. At idle it is awesome, at full throttle it is LOUD. Too loud for me but OK for my son. We even had a custom resonator fitted which improved it a bit, but not enough I think. The X-Force we had before sounded tinnier but was less loud and build quality was below average whereas the Miltek's build quality is great.

When we go KO4 later this year, we will have a full custom turbo back (probably 2.75") made and fitted.

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Right ok good to know. I fitted a rear muffler delete pipe that drops at the diff and it's far too loud. I had already replaced the front muffler/resonator with a straight through Lukey muffler. Looking at fitting up a 2.5" Borla muffler And then dropping at diff. Should keep the noise down but still flow well.

Yeah I agree, when I was in my 20's I had a Mazda RX3 with a 13b Bridgeport that was about 100db but now days I can't handle a loud exhaust. Must be getting old haha!!

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Originally Posted by Sharkie

So as part of the path to getting a full Stg 3 motor build, we identified that traction will be a problem due to the fact the TSIs only ever came in RWD. With Big Red developing a 3rd gear synchro issue of late, and with us getting more adventurous with our builds, this arrived this week ....

Manual TDI400
Attachment 55121 Attachment 55122

Can a conversion be done? All research points that way, so we will found out over the next few months.

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Sharkie, have you started on the conversion yet?

If you end up pulling your diff I may be interested in buying it. My TSI doesn't have a diff lock and it's one thing i'd like to add.

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Originally Posted by EZZA

Sharkie, have you started on the conversion yet?

If you end up pulling your diff I may be interested in buying it. My TSI doesn't have a diff lock and it's one thing i'd like to add.

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Hi Mate

Yes, we have started, working on it about 1 day (normally a Sunday for a few hours) a week. Progress so far has been on the donor, stripping the interior to get to the transfer case controller (and all the wiring necessary to connect it) as well as the front driveshafts and propshaft. This weekend probably be pulling off the front diff on the donor. Next weekend fitting all of that except the proposhaft. Will be done by end July (maybe August) I think

Have a RF grab handle for sale with all the parts needed to fit to a TSI. Years ago I did mine already (Post 138 in this thread Sharkie's TSI Amarok Build), so this 1 is extra. Will also probably have a leather MF (left side only) steering wheel and the necessary controller/bits to add to a non MF Wheel TSI in due course available too.

Edit: also have a X-Force cat back for the Amarok that's been lying under the carport at the back of my house for a few years. Free to anyone who can pick-up. It has surface rust, but still completely intact.

Good to hear mate, can't wait to see the final result!

So sounds like you'll keep the current diff in place. I've read there's a few different gear ratios out there when it come to Amarok diffs. Have you used you're diff lock much and with the 2wd when does it disengage? Guessing it has a speed it unlocks for 'safety' haha!

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Originally Posted by EZZA

Good to hear mate, can't wait to see the final result!

So sounds like you'll keep the current diff in place. I've read there's a few different gear ratios out there when it come to Amarok diffs. Have you used you're diff lock much and with the 2wd when does it disengage? Guessing it has a speed it unlocks for 'safety' haha!

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The donor Amarok does have a diff that locks in the rear too, so that will be available eventually. I will use the gear surround switches from the donor as it has everything I need including the switch for the rear diff lock. So, the switch from Big Red and the rear diff from the donor will likely be up at some point.

Use the diff lock when accelerating hard and it auto disengages at 80km/h (I think). On light offroading such as dirt tracks it worked really well too. Was a worthwhile upgrade I think.

Did pull the front diff off this past weekend.
Attachment 55920
Attachment 55921

Anybody have any idea how to clean/restore a dirty exterior on any of these drive train parts? Want to either get them nice and shiny OEM metallic or clean and painted black.

All parts will get a thorough functional restoration as well before fitting.

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Originally Posted by Sharkie

Anybody have any idea how to clean/restore a dirty exterior on any of these drive train parts? Want to either get them nice and shiny OEM metallic or clean and painted black.

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Dry ice blasting makes the parts look new again.

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Originally Posted by Lucas_R

Dry ice blasting makes the parts look new again.

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Thanks Lucas, that looks promising. From Google, the machines are definitely too expensive to buy for what I need, so will get all the stuff I want cleaned, ready and then get the closest local cleaner to come out and do them all at once.

Yes its not a DIY type of process unfortunately, but its become very popular in recent years and plenty of places offer it now.