B4 80 TDi box into B2 80 GL

markb · 02-09-10, 03:13 PM

Following on from this thread: http://www.classic-audi.co.uk/forum/...ad.php?t=12456

I have now got a 1995 B4 80 TDi to transplant engine and 'box from.

The engine is already out and the gearbox is likely to be extracted tonight.

My question is, since I've never had a B2 box out, does anyone know how much work is involved in fitting this B4 box to my B2? will the mounts line up? are the driveshafts the same size? I know I will have to convert to hydraulic clutch and I am hoping to use/modify the B4 pedal box.

I'm sure I can overcome any problems, but I'm just after a quick heads up so I can better plan for it.

Many Thanks,
Mark.

JMLAudi · 02-09-10, 04:27 PM

Hi Mark

You going to need part of the tdi pedal box as you got the throttle penetionter on it as well as master cylinder for clutch
I think its best if you try using pedal box assembly unless you good at fabrication

grab the front struts as well for hubs to use with driveshafts as flanges will be different to the tdi box

there are possibly more to worry about .....keep donor car for as long as possible incase you need to strip more

my 2 cents
cheers
john

best if you p

markb · 02-09-10, 05:27 PM

Thanks for the advice John.

I'm converting the engine to use a mechanical pump so I won't need to retain the throttle pot, so some mods of the pedal box will be required.

If I have to change the front hubs it will end up being 4x108 rather than 4x100. Do you happen to know if there's a way to use the standard hubs? will the inner CVs swap between shafts?

Mark.

JMLAudi · 02-09-10, 05:40 PM

HI Mark
if you using mechanical pump .........do you have one.............i got a pump not sure if 1.6 td or 1.9 td you can have it.even if used for spares

then only other reason why pedal box to be modified is if you use hydraulic clutch

.cant help out there lol

If you using diesel gearboix the flanges are different to the set up you have nw.........if you can see if the driveshafts expecpt your outer cv joints and shafts same lentgh as your B2 ones you got it easy..............there are others here that could advise you on the number of spines on shaft and your joints

Good luck with change you have best of both worlds

cheers
john

markb · 02-09-10, 06:00 PM

Yeah, I've already got a pump to use, it's from a land rover discovery. The 1.6/1.9TD pumps can be modified to work, but it takes a lot of work. You shouldn't give it away though, those pumps are always sought after! Thanks for the offer though!

I'll keep my fingers crossed on the CV joint issue.

I'll post my progress here or in a readers resto thread if i get round to making one later.

msh · 02-09-10, 07:54 PM

What's the reason to install TDI engine if biggest advantage is already lost when u install that mechanical pump?

markb · 02-09-10, 08:18 PM

a mechanical-TDi and a TD are not the same thing.
Yes, you lose the computer control, but bosch did a pretty good job on their mechanical pumps and there is a huge amount of tuning potential, you just don't need a computer to do it!
The advantage over the TD engine is that you still have a much higher injection pressure and Direct injection which both bring improvements to power output and fuel economy.

Lastly, why the hell not? I've done plenty of TD conversions and TDi(electronic) conversions but no TDi-m yet and this seemed liked a good candidate for it

whatalotafun · 24-09-13, 09:49 PM

this car now belongs to me, i cant explain how well done it is!

02-09-10, 04:27 PM	#2
JMLAudi Grown up member Classic Audi Club Member Join Date: Jan 2010 Location: Knaresborough/Shipley Posts: 951	box changed Hi Mark You going to need part of the tdi pedal box as you got the throttle penetionter on it as well as master cylinder for clutch I think its best if you try using pedal box assembly unless you good at fabrication grab the front struts as well for hubs to use with driveshafts as flanges will be different to the tdi box there are possibly more to worry about .....keep donor car for as long as possible incase you need to strip more my 2 cents cheers john best if you p

02-09-10, 05:27 PM	#3
markb Grown up member Join Date: Feb 2010 Posts: 20	Thanks for the advice John. I'm converting the engine to use a mechanical pump so I won't need to retain the throttle pot, so some mods of the pedal box will be required. If I have to change the front hubs it will end up being 4x108 rather than 4x100. Do you happen to know if there's a way to use the standard hubs? will the inner CVs swap between shafts? Mark.

02-09-10, 05:40 PM	#4
JMLAudi Grown up member Classic Audi Club Member Join Date: Jan 2010 Location: Knaresborough/Shipley Posts: 951	HI Mark if you using mechanical pump .........do you have one.............i got a pump not sure if 1.6 td or 1.9 td you can have it.even if used for spares then only other reason why pedal box to be modified is if you use hydraulic clutch .cant help out there lol If you using diesel gearboix the flanges are different to the set up you have nw.........if you can see if the driveshafts expecpt your outer cv joints and shafts same lentgh as your B2 ones you got it easy..............there are others here that could advise you on the number of spines on shaft and your joints Good luck with change you have best of both worlds cheers john

02-09-10, 06:00 PM	#5
markb Grown up member Join Date: Feb 2010 Posts: 20	Yeah, I've already got a pump to use, it's from a land rover discovery. The 1.6/1.9TD pumps can be modified to work, but it takes a lot of work. You shouldn't give it away though, those pumps are always sought after! Thanks for the offer though! I'll keep my fingers crossed on the CV joint issue. I'll post my progress here or in a readers resto thread if i get round to making one later.

02-09-10, 07:54 PM	#6
msh 4 ring whore! Join Date: Jun 2008 Location: Rucava, Latvija Posts: 3,816	What's the reason to install TDI engine if biggest advantage is already lost when u install that mechanical pump?

02-09-10, 08:18 PM	#7
markb Grown up member Join Date: Feb 2010 Posts: 20	a mechanical-TDi and a TD are not the same thing. Yes, you lose the computer control, but bosch did a pretty good job on their mechanical pumps and there is a huge amount of tuning potential, you just don't need a computer to do it! The advantage over the TD engine is that you still have a much higher injection pressure and Direct injection which both bring improvements to power output and fuel economy. Lastly, why the hell not? I've done plenty of TD conversions and TDi(electronic) conversions but no TDi-m yet and this seemed liked a good candidate for it

24-09-13, 09:49 PM	#8
whatalotafun Grown up member Join Date: Sep 2013 Posts: 27	this car now belongs to me, i cant explain how well done it is!