[?] 6-Speed PD Gear Output Shaft -> G3 VR6/GTI Hub

Hello,

I need advice from the community.

Some of you might be familiar with our racing diesel engine based on the G3 AFN platform. We used the winter to make a few modifications to the engine. This allows us to expect a bit more power (diagram will be available when it runs ), and since the original transmission made extremely strange noises during the last races, we thought, 'Let's just quickly install a 6-speed transmission.' Thought - Done. So far, no unsolvable problem.

However, we overlooked the fact that the power of the engine should also reach the wheels. To do this, one needs - as the discerning reader has already guessed - drive shafts...

Apparently, the waves are supposed to fit from a Seat Ibiza with 130-160 horsepower (newest model). Unfortunately, the friendly mechanic is completely overwhelmed and cannot help us. And, for the time being, neither we nor he want to order on suspicion.

Brief description of the problem: 6-speed PD gearbox needs to transfer power to the Passat VR6 wheel hub. The hub should be the same as that of the Golf GTI/VR6, according to our information.

Do any of you have any advice? If more information is needed to answer the question, please let me know. We can also implement robust 'DIY' solutions.

Greetings
Stefan

Hi,

At least, I can confirm, based on the fuse rings, that the diameter of all three wheel hub bearings is identical at 72 mm.

And the Ibiza ASZ/BPX waves are, in turn, identical to the ASZ-Polo wave. But is there another way, for example, that fits

You can, however, at least order all the Brocken models from the local VW dealer for viewing, but Seat doesn't need them.

Hi,

Quote:

However, you can at least order all the Brocken models from the local VW dealer for viewing, Seat doesn't need them.

Not all dealers can do this, but "Hauptändler" (I don't know what the equivalent is for VW) in Hamburg is Raffay, and they can. The others have to buy them, and they naturally won't do that.

Greetings
Dieter

Raffay? I can hardly believe they would do that. Even if they could.
I didn't find the parts sale there very exciting. Which branch, the one in Harburg?

I didn't say that they are doing it, but they could. Raffay manages the central warehouse for Northern Germany (in Norderstedt), and the Raffay companies can also receive parts in bulk. That's what someone told me, at least.
However, I had such bad experiences with Raffay (not in Harburg, but on Fruchtallee) that I will not go there anymore.

Dieter

Hi,

At least, I can confirm, based on the fuse rings, that the diameter of all three wheel hub bearings is identical at 72 mm.

And the Ibiza ASZ/BPX waves are, in turn, identical to the ASZ-Polo wave. But is there another way, for example, that fits
We also noticed the issue with the wheel bearings when we converted our bike frame from the 4-hole hub to the 5-hole hub. After we were finished, we realized that we could also have replaced the entire wheel rim. Well, if you have nothing to do, you make yourself busy...

It remains to be clarified whether the Polo ASZ axle with its splines will fit into our hub. Does anyone know the diameter and number of teeth?

We will definitely know then that there is a combination of New Gear to Old Hub. Then we just need to find one that fits the length.

Greetings
Stefan

Stefan Schlünder wrote:

The only thing left to clarify is whether the Polo ASZ axle, with its splines, will fit into our hub. Does anyone of you know the diameter and number of teeth?

Hi Stefan,

Currently, I can only tell you about the external nut: M16 x 1.5.

I'm going to remove a hub cap and see if I can spot anything else.

EDIT:
No, there's nothing more to see.
On the side of the wheel, the hubs are fixed with a strange 12-sided nut, which already looks like it has been precisely machined from the factory.
Maybe this will help you somehow...

Hello Stefan,

I have asked the same question here in this forum weeks ago. Unfortunately, no one has responded yet.

The ERF gearbox problem was the gearbox flange. In the VR6, the 100mm wave discs are installed, but they are too small.

You need to install the flange shafts 02A 409 343 C from the Touran, and you can continue to use the VR6 gearbox shafts.

Now I will proceed with the renovation as described below.

Could you please tell me, in the 'Gewgenzug' (presumably a specific train or vehicle), how you have implemented the gear/transmission and suspension systems? I currently don't have any ideas about what would fit there.

Hello
Christoph

You need to install the flange shafts 02A 409 343 C from the Touran, and you can continue to use the VR6 gearbox shafts.
Great, that also sounds solid! I'm going to build a sentence now.
Could you please tell me, while we're on the train, how you implemented the gear bearings and suspension? I currently don't have any ideas about what would fit there.
We have built it. Since it is a race car, the principle 'Form follows function' applies. The solution has not yet been implemented, as the engine is not yet 'inside'. I'll be back at the Nürburgring this weekend and will be taking some photos and posting them here early in the week.

Greetings
Stefan

(...) I will take some photos and post them here early in the week.
The digital camera isn't working. I would still like to try to explain it.

On the 6-speed gearbox, we have attached a construction made of flat iron, which is supported by the original front axle bearing once. The other 'end' of this construction is supported by the same (not the same) bearing, which we installed in the bracket directly next to the gearbox, on the left side, in the direction of travel. To this end, we cut a hole and reinforced the edge with plates.

This design has not yet been tested for functionality and durability. As this is a car that will only be used in competition, we will not have any issues with TÜV (German technical inspection authority) or other relevant certifications. I would advise against implementing this on a road vehicle, as I cannot assess how the structure will behave in the event of an accident, or what the modified spar indicates in terms of impact.

Greetings
Stefan

hello

@stefan
I just looked at the images on your website about the 6-speed transmission, and I'm still not quite clear on how you've implemented the suspension .
What type of transmission is it?

I'm currently trying to install a DRW (donor rear wing) on an Ibiza 6K (basically a Golf 3, but a bit narrower ).

The original recording of the DRW is completely different from that of the CYP (5-speed).
Therefore, I am trying to implement a similar mounting structure to that of the CYP, which was originally... The holder would also fit with the distance between the holes, but for some reason, the holder is then mirrored.
Have you ever considered adapting the 'mounting points' of the 5Gang system to the 6Gang system? This could allow the original mounting points on the chassis to be reused.
As far as I can see from the pictures, you seem to be planning to keep the 6-speed gear lever in its original position and modify the chassis accordingly.

Maybe your camera will work again soon, and you can then take some photos of detailed shots.

Think about it: the TÜV (which I unfortunately need) would prefer a change to the registration documents instead of a change to the bodywork.

(...)I just took a look at the images on your homepage about the 6-speed transmission, and I'm still not quite clear on how you've implemented the suspension.
What type of transmission is it?
Oops, I didn't realize we had already taken pictures of it. The gearbox is from a 130hp PD Golf (allegedly). I can't tell you the registration number right now, as the gearbox is in Nürburg and I don't have access to it.

http://www.mungo-racing.de/gallery/albums/album03/DSCF1894.sized.jpg

The connection between the gearbox and the chassis is then realized through a custom-made construction using flat iron. We also designed the engine mount near the turbocharger in this way. Worked wonderfully in 2004 and we now have more space when changing the turbocharger compared to the original bracket.

As it appears from the images, it seems that you are planning to keep the 6-speed gear lever in its original position and to modify the chassis accordingly
Yes, of course! If the transmission fails during the race, it is easier and faster to replace it with another one without having to re-install the mounts.

Greetings
Stefan

P.S.: Once my camera is working again, I'll share some pictures. The engine with the gearbox will be installed in about 2 weeks, then I will take a series of photos.