02J Mk1 Conversion Questions

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Boost
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02J Mk1 Conversion Questions

Post by Boost »

Hi Guys

I have a few questions around the Mk1 20V conversion.
I am installing an 02J gearbox along with the 20V engine

1) Inner CV's. Is there Inner CV's available that will fit the existing cups on the gearbox or will I need to source 100mm cups?

2) What master cylinder will work best for the hydraulic clutch?

I have also removed the brake booster setup. My current idea is to machine an adapter for my existing master cylinder and a push rod to suite, or is there a better idea of how to get it done?

Cheers, :hug:
Current: 2008 VW Caddy R-Line 20V BIG T :driving:
2009 CW 9n3 Polo Gti
2012 Holden Captiva 2.2d LX
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2007 Fiat Grande Punto
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Re: 02J Mk1 Conversion Questions

Post by PapaJo »

Search the forum, seen a few doing the boister delete option and speak to Torker. Think he did this on his car too.

I stand to be corrected, but think the o2j inner cv’s fit on the mk1 side shafts, same splines pitch.

Master cylinder, I have no idea.
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Re: 02J Mk1 Conversion Questions

Post by Boost »

PapaJo wrote: Thu May 03, 2018 10:48 pm Search the forum, seen a few doing the boister delete option and speak to Torker. Think he did this on his car too.

I stand to be corrected, but think the o2j inner cv’s fit on the mk1 side shafts, same splines pitch.

Master cylinder, I have no idea.
Thanks
I have tried going through Torkers thread a while ago but thanks to our wonderful Photobucket bomb previous threads are a tad useless.
Current: 2008 VW Caddy R-Line 20V BIG T :driving:
2009 CW 9n3 Polo Gti
2012 Holden Captiva 2.2d LX
Ex:
2011 Holden Cruze Equipe
2010 Great Wall V240 Ute
2017 Chev Captiva 2.2d LT daily
2000 Vw Citi 1.6i
2013 GW Audi A3 Sportback 1.8TFSI SE S-Tronic (POS)
2006 Volvo S40 T5
2004 Nissan 350Z Coupe
2000 VW Golf 4 GTI (247wKw @ 1.3bar)
2007 Fiat Grande Punto
1994 Fiat Uno Turbo
1994 Fiat Uno Pacer
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Re: 02J Mk1 Conversion Questions

Post by stig »

Use the photobucket chrome plugin to view the photos

Sent from my E6653 using Tapatalk

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Re: 02J Mk1 Conversion Questions

Post by saxo »

Thanks for that 1 Stig, images are working now.

Boost You will have to get the 100mm cups and new gearbox mounts.
Will you be fitting the cable shift linkages or modified rod shift linkages?
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Re: 02J Mk1 Conversion Questions

Post by Boost »

Tried that bloody plugin. For some reason this laptop just refuses.

Gearbox mounts have been sorted and yes will be running cable shift
Current: 2008 VW Caddy R-Line 20V BIG T :driving:
2009 CW 9n3 Polo Gti
2012 Holden Captiva 2.2d LX
Ex:
2011 Holden Cruze Equipe
2010 Great Wall V240 Ute
2017 Chev Captiva 2.2d LT daily
2000 Vw Citi 1.6i
2013 GW Audi A3 Sportback 1.8TFSI SE S-Tronic (POS)
2006 Volvo S40 T5
2004 Nissan 350Z Coupe
2000 VW Golf 4 GTI (247wKw @ 1.3bar)
2007 Fiat Grande Punto
1994 Fiat Uno Turbo
1994 Fiat Uno Pacer
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Re: 02J Mk1 Conversion Questions

Post by PapaJo »

Plugin only works if you have Google chrome as your default browser.
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Re: 02J Mk1 Conversion Questions

Post by kmg4real »

Boost wrote: Thu May 03, 2018 7:44 pm Hi Guys

I have a few questions around the Mk1 20V conversion.
I am installing an 02J gearbox along with the 20V engine

1) Inner CV's. Is there Inner CV's available that will fit the existing cups on the gearbox or will I need to source 100mm cups?
In my car I run 100mm inner cvs. The smaller ones kept breaking due to power. Straight fit on the drive shafts no mods needed.

2) What master cylinder will work best for the hydraulic clutch?
Golf 4 or Audi equivalent has served me well these past years. (Find the one that comes with the pedal bracket)

I have also removed the brake booster setup. My current idea is to machine an adapter for my existing master cylinder and a push rod to suite, or is there a better idea of how to get it done?

Cheers, :hug:
Not sure about the brake booster question.
'02 CITI Golf 2l 16VT 243hp 306Nm @0.8 bar on M.R.D. Dyno - Thread url=http://www.vwclub.co.za/forum/viewtopic ... BlaqSmithe

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Boost
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Re: 02J Mk1 Conversion Questions

Post by Boost »

Thanks for the info.
Current: 2008 VW Caddy R-Line 20V BIG T :driving:
2009 CW 9n3 Polo Gti
2012 Holden Captiva 2.2d LX
Ex:
2011 Holden Cruze Equipe
2010 Great Wall V240 Ute
2017 Chev Captiva 2.2d LT daily
2000 Vw Citi 1.6i
2013 GW Audi A3 Sportback 1.8TFSI SE S-Tronic (POS)
2006 Volvo S40 T5
2004 Nissan 350Z Coupe
2000 VW Golf 4 GTI (247wKw @ 1.3bar)
2007 Fiat Grande Punto
1994 Fiat Uno Turbo
1994 Fiat Uno Pacer
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