Floor Pan Swap - haldex to come...

[kujiwara]

Re: Floor Pan Swap - haldex to come...

You should at least resurface the flywheel before you put it back together.

If he has a dual mass flywheel he can't resurface it

[GTi]

Re: Floor Pan Swap - haldex to come...

I may just know someone that needs your trans and axles...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

You should at least resurface the flywheel before you put it back together.

If he has a dual mass flywheel he can't resurface it

I haven't done it myself but I've heard of people successfully resurfacing DMFW's... the one on my car looks to be in fine shape though so I'll leave it alone. The new OEM clutch plate that's going on the car is just meant to get me through until I install an LSD or make more power than it can handle. Should be a few years till that happens

[All_Euro]

Re: Floor Pan Swap - haldex to come...

I may just know someone that needs your trans and axles...

Sure - the axles are tentatively sold but the 02M is available.

I do have some other parts available as well but I just haven't made a for sale thread yet... it's on the to do list though. In the meantime - please just shoot me a PM if you're looking for something.

[bobkatkat]

Re: Floor Pan Swap - haldex to come...

If he has a dual mass flywheel he can't resurface it

I had a dual mass resurfaced before I decided to go LWFW. Was 65 bucks.

[All_Euro]

Re: Floor Pan Swap - haldex to come...

I'd originally planned to do some porting work on the "new" turbo and exhaust mani that are replacing my K03... two studs came out of the manifold fine but the third - no so much. I'm not sure I'll have time to port anything now but I still need to replace the hardware that I had mostly out. I tried welding a cheap wrench to the head of the stud but the wrench metal is junk and just broke away. Looks like I'll have to dremel the head of the stud off and then hopefully I can vice-grip the rest out...




With respect to the driveshaft - I decided to just source one that's the proper length and then, later, if I move the engine closer to the firewall I'll modify the short section of the driveshaft to suit. Sourcing just the rear section of the centre driveshaft from the U.S. turned out to be more expensive than what I paid for the full driveshaft and shipping from the UK... it should be here in two weeks.

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Driveshaft came in yesterday. As Colin mentioned, the front sections are the same length and the back halves are different. The new driveshaft was split before it was shipped and the ends weren't sealed up at all so it was pretty messy. Didn't feel like cleaning it up at the moment so I just took a rough measurement and it looks like the difference in length is 11cm...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

So, I tried welding a bolt to the bolt - but it broke away just like the wrench did...



Ended up sectioning the top like a pizza...



Then the bolts I had available didn't fit. The grade, thread and pitch were good but the bolt head was too big and they had way to many threads. It was a little tedious but I decided to just machine to fit...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Added a 12.5 lb spring to the wastegate to increase the cracking pressure a little...



As much as I've been trying to put things back together, I ended up having to pull pretty much every ancillary off the head/block. The coolant lines that attach to the block,turbo, heater core, etc are different. Thankfully I still have what I need from the TT teardown...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Was having some trouble getting a bolt off my Fluidampr and I don't have a crank locking tool - pry bar did the trick though...



This timing belt kit is pretty cool - just align tension marks and lock it into place. No guess work...



The TT 225 oil drain line doesn't work with the hybrid oil pan that came with my car and the K03 line is too short. I tried bending the TT line to fit but no dice. Ended up having to cut the K03 line and splice in a rubber piece - will add heat shield tomorrow...

[onceover]

Re: Floor Pan Swap - haldex to come...

Added a 12.5 lb spring to the wastegate to increase the cracking pressure a little...

Surely you're not serious about this

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Surely you're not serious about this

I normally run more spring pressure than this but I'll be on low boost for a while so this will do. Depending where this canister cracks the WG, the additional spring should net me 17 lbs. An adjustable Forge unit would be nicer but I can get the same affect for a fraction of the cost this way.

[onceover]

Re: Floor Pan Swap - haldex to come...

Or you can allow the ECU to control it with the N75 valve as it was intended. Not sure what the benefit of doing it this way is?

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Or you can allow the ECU to control it with the N75 valve as it was intended. Not sure what the benefit of doing it this way is?

Yep, and that's fine at lower boost levels. At higher boost the wastegate ends up cracking open early because of inadequate spring pressure. Then the turbo has to spin harder and harder to try and meet boost demands - overworking turbo in the process. This is why the EFR lineup, for example, offers different wastgate canisters.

[bobkatkat]

Re: Floor Pan Swap - haldex to come...

Unless you are going to remove the n75 and run a MBC or aftermarket EBC and boosting over 30lbs (poor little KO4)then you are over thinking this a bit too much. If not, as Pat said just let the N75 control the boost to what ever level you want. I looks like you have a lot of room for adjustment of your actuator arm. Just preset the tension with a Mighty Vac to 12-14lbs cracking pressure. In any even you should be using a Mighty vac to set test the actual cracking pressure with or without a spring.