A long time coming, Rob's 4motion turbo build!

**WhO** · 09-01-2011, 10:00 AM

Time for an update?

Well i got down and dirty a couple nights ago with the bora and off came the gearbox!

Followed this guide VWVortex.com - Transmission Removal Clutch Replacement diy Quick Version and its pretty much spot on. Note that when seperating the transfer case and gearbox you can expect a flood of transmission oil to spill out. I'd recommend draining the box before doing this to save getting covered in oil... doesnt taste great

Two of the trickiest bits was manouvering the gearbox off after unbolting it and also getting the 6mm allen bolt from out of the transfer case, although not hugely tricky just frustrating (the one buried deep in the drivers side driveshaft, step 21 in the vortex guide) Initially i bought several allen key extension shafts however i broke all 4 that i bought!!! In the end i ended up making my own by welding a 6mm hex head with a drive adapter to the threaded rod from a spring compressor... Believe me, this one will NEVER break!

For removing the gearbox personally i would recommend using an engine hoist to support the engine or having an engine support brace like seen here http://www.lonestarminiclub.com/gall...0/DSCN0648.JPG
It's not completely necessary, the Vortex guide uses a jack to support the engine, however in honesty its not hugely stable like that and could easily slip out of the drivers side mount, especially when your rocking the gearbox / engine assembly to get the bastard out. So between an engine to the face or 5 minutes rigging up my engine crane, i decided on the safer option!

Upon getting the box off i was pretty happy to see the clutch seems quite new. Even though its going to be replaced it means that the rear main seal didnt just look new, it probably is. I'm not a fan of replacing rear mains when they're not leaking as sometimes they then leak! Luckily this means somebody else has risked changing it and won. The dual mass flywheel also looks to be in good nick, not rattly and smooth. Again this is also going though as i have a lightened chromoly flywheel and carbon ceramic clutch to go on

For getting the box back on i'm actually almost contemplating dropping the motor, there really doesnt look like theres much left attached to it other than some cooling lines and a couple wiring looms and being rigged to the engine crane means it might only take an extra 10-20 min vs wrestling a gearbox for the better part of 30m-1hr! Hrmmm decisions decisions.

Next steps from here is to order in the seals for the trans - transfer case, pull the sump to weld in a oil return, put the new clutch on and after that just paitiently wait for my intake, head spacer and a few other bits from C2. Might give them a call monday their time to assess where they're at. Once i've got the final bits from them i'll hopefully have it all running within 2 weeks

I'll update this with pics shortly when i get home from work

Pics:

The damnn 6mm hex buried in one of the shafts

The broken extensions

The solution

Safety first!

Happy days

**Dyldo** · 09-01-2011, 11:20 AM

Originally Posted by WhO

Once i've got the final bits from them i'll hopefully have it all running within 2 weeks

2 weeks? you're the friggin' man, i love this build. but we do NEED pics. I can't wait to see this.

Would you be ok with a visit one day when she is running? I'd love to swing by and take a look, cause i've been trying to get the missus and baby down to the Barossa anyway for a weekend so might fit well.

**Mr. JLT** · 09-01-2011, 01:50 PM

Gabes DIY is pretty handy. I have the clutch alignment tools if you need to barrow them. Are you going to replace the throw out bearing assembly.If so will with a syringe it make the bleeding a little bit easier.(I also have a power bleeder to u want to barrow) Also when you disconnect the slave cylinder make sure the o-ring stays on the end of the nipple or you may not get a good seal when you put it back in as it super hard to push in since the o-ring is still in the tranny(TO bearing assembly line). Also it would be a good time to clean up the tranny and engine bay since you have less stuff in the way. Keep up the good work and let me know if you have any questions.
Cheers J

**WhO** · 10-01-2011, 12:06 AM

Originally Posted by Dyldo

2 weeks? you're the friggin' man, i love this build. but we do NEED pics. I can't wait to see this.

Would you be ok with a visit one day when she is running? I'd love to swing by and take a look, cause i've been trying to get the missus and baby down to the Barossa anyway for a weekend so might fit well.

Realistically once i've gotten the last few bits from C2 its just a mater of bolting everything up and fabbing up an exhaust and the rest of the cooler piping, maybe i'm being ambitious but we'll see! At this stage i have no idea when they'll get the rest of my gear out but hopefully soon *fingers crossed*

Definitely welcome to come past if your in Adelaide at any point mate, just let me know in advance and we can organise a time!

Originally Posted by Mr. JLT

Gabes DIY is pretty handy. I have the clutch alignment tools if you need to barrow them. Are you going to replace the throw out bearing assembly.If so will with a syringe it make the bleeding a little bit easier.(I also have a power bleeder to u want to barrow) Also when you disconnect the slave cylinder make sure the o-ring stays on the end of the nipple or you may not get a good seal when you put it back in as it super hard to push in since the o-ring is still in the tranny(TO bearing assembly line). Also it would be a good time to clean up the tranny and engine bay since you have less stuff in the way. Keep up the good work and let me know if you have any questions.
Cheers J

Thanks for the offer mate, the clutch kit i got from the US included an alignment tool so i'm pretty sorted there. I did get a new slave cylinder and was thinking along those lines, just need to find a syringe. A while back i made a power bleeder from a garden pressure pack and a spare master cylinder cap so i'm also sorted there, it's a bit ghetto but it works well! Again many thanks for the offer though

I'll definitely look out for the o-ring, didnt cross my mind so you might have saved me a bit of heartache!

Thanks for all the advice and support guys! Hopefully it all comes together like planned!

Uploading photos now from the other day's work, sorry if they're a bit blurry, might get a few fresh ones in the daylight!

I'll also add a few photos of the bits and pieces ready to be bolted on

**WhO** · 11-01-2011, 11:40 PM

Ordered all the stretch bolts and seals between the transfer case and gearbox today, might even get the box back on before the weeks out

**Dyldo** · 24-01-2011, 08:08 PM

am absolutely STINGING for an update here my man

**doc dogg** · 24-01-2011, 09:01 PM

NIce, I love a build thread

**qsilverza** · 25-01-2011, 02:37 PM

not to jack the thread but something I have been enjoying reading !!! VWVortex.com - MK4 Bora R32 Coupe

**WhO** · 27-01-2011, 12:05 AM

Haha ok quick update! Gearbox went back on a couple days ago, took me the better part of a couple of hours working alone which was a lot easier than getting it off! Made my life a lot easier by supporting the engine on a jack then using my engine crane to lift the box thus avoiding the need to struggle lifting it and aligning it at the same time. One tip for anyone doing one any time soon... if you fill the slave cylinder with fluid, DONT look towards it as you slide the gearbox spline through the clutch. As you give it that last heave on when the pressure plate springs come into contact with the slave it'll shoot a shot of oil out of the connector outside the gearbox. If you happen to be looking directly towards it when it happens, i can tell you... its not plesant... brake fluid to the eye = ouch... trust me!