New 6 speed gearbox method - passat '11 onwards MYP gearbox

Just finished installation of MYP to my a2 1.4 TDI 90hp version. It was not a direct bolt on I had to grind some aluminum off to make roof for the big flywheel.
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Well done. I’m surprised you had to do this grinding as I didn’t have to do any on my MYP ATL conversion. Did you transfer the 2 alignment bushes from the old gearbox to the new one? Leaving one or both out will affect alignment of course; maybe they stayed attached to the engine). Which starter did you use and does the starter sound like it used to?
Matt


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The case which is bolted to engine came from 75hp version car as previous owner had built it. The case on the 90hp had machined that surface bigger and that would not have needed no machining. The starter motor on the car where this came from sounded slow. Did not notice nothing unusual on first starts will check tomorrow. On the 90 hp I am using the 90 hp starter

I had all the metal bushes on place all of them which are between the engine and gearbox
 
I am talking to a someone selling a MYP and he’s asked if my car is stop start?? Is there a difference that I should worry about? I thought they all were stop start!


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They're stopped when you turn the key off, and started when it's making a chugging noise. Does he need any further explanation?
 
They're stopped when you turn the key off, and started when it's making a chugging noise. Does he need any further explanation?

He’s talking about the original 1.6tdi Passat the gearbox came from, to my knowledge all the BlueMotions were stop start?


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One to add to this from my own experiences. I used the original starter motor which was fine from install till the other week. I am nut sure if the starter became "lazy" or in time was not engaging with the flywheel but in essence it had worn the teeth of the flywheel so that it was just spinning. I have now replaced with one from an audi A1 1.6TDI and all so far is well but for how long I dont know but prepared to risk it as flywheel (TDI 90) was new 2 years ago. The newer starter motor is much better and even starts the car better than previous A2's. Part number I used was 02Z911024H. It did need a new connector for the control (exciter) wire which came with mine from the breaker. It is actually a better design than the original as it prevents the wire bending.
 
One to add to this from my own experiences. I used the original starter motor which was fine from install till the other week. I am nut sure if the starter became "lazy" or in time was not engaging with the flywheel but in essence it had worn the teeth of the flywheel so that it was just spinning. I have now replaced with one from an audi A1 1.6TDI and all so far is well but for how long I dont know but prepared to risk it as flywheel (TDI 90) was new 2 years ago. The newer starter motor is much better and even starts the car better than previous A2's. Part number I used was 02Z911024H. It did need a new connector for the control (exciter) wire which came with mine from the breaker. It is actually a better design than the original as it prevents the wire bending.

Thanks Paul, I found one on the bay for £24 so I have ordered and will use this!

Could you give more information about the wire required?


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It’s the single wire that currently has the black square connector on. You may be ok using a sped terminal in its place. Will see if I can photo a part number of my connector later. This is what I got on mine:
 

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It’s the single wire that currently has the black square connector on. You may be ok using a sped terminal in its place. Will see if I can photo a part number of my connector later. This is what I got on mine:

I see so it’s connecting with the Bosch connector?


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It’s the single wire that currently has the black square connector on. You may be ok using a sped terminal in its place. Will see if I can photo a part number of my connector later. This is what I got on mine:

This part?

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Basic checks for starter motor compatibility
. On old starter, measure distance from mounting flange face to leading edge of starter pinion teeth.
. On old flywheel housing, measure depth from starter mounting face to ring gear teeth
. Subtract to get static starter pinion clearance of original set-up

. Compare new flywheel housing measurements to see if starter pinion clearance is similar. If the clearance is significantly more then repeat the
process with one of the recommended starters but check number of teeth on starter pinion are the same

Cheers Spike
 
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No the bit to the right of that that forms part of the wiring loom in the engine. You can just see the cut wire in the plastic sleeve
 
No the bit to the right of that that forms part of the wiring loom in the engine. You can just see the cut wire in the plastic sleeve

So does this bit go on to a plug like a Bosch connector with the clip? If so I make this up?


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I just wondered whether anyone knows of somewhere that will make the required brackets up. I baulked on the idea of changing the box myself and am thinking about paying a local workshop to do it. Having the brackets ready made would make that much easier to convince them to do the work.
 
Andy, the brackets are not hugely challenging to make to be honest, you really need a box and cable mechanism to hand to make the brackets. A workshop should be able to cope with them.
 
Andy, the brackets are not hugely challenging to make to be honest, you really need a box and cable mechanism to hand to make the brackets. A workshop should be able to cope with them.

I'm sure they can but lots of places don't like to take on unknowns, which is quite understandable and they want to know the vehicle will be in and out in a predictable time.
 
Guys,regarding the speedo drive.
Is there anyway of getting a signal from the abs/speed sensor wired into the clocks?
I’m a mechanic and I’m going to go with this 6 speed conversion for both of our a2’s,but I need to know if it’s possible.
Thanks and keep up the good work
 
What year are your A2's? I believe people have looked at changing the ABS systems on early cars that use the gearbox to get the speedo drive but this is a lot of work and dont recall if anyone has documented this yet.
 
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