daves16v

It really is only one screw, it's got a little hammer on it which strikes the door pin when you operate the handle - it's not directly connected to anything (except for a couple of electrical wires for the central locking). Yes this statement is correct, but getting the cable unconnected/unclipped is where you have to take the door card off.

You have to remove the door card to get the handle out as the handle wiring connector is attached to the inside of the door.

My 5 stud conversion is complete, just need to get the wheel alignment done. I'll post up some pics and details when I get chance.

I held the shaft with 2 hands, he held it with 1 hand with the other holding the gun so it was 3 hands. It was just resting at floor level, took just a fews seconds.

I had to do this recently, took it down to my friendly garage where he used an air gun whilst the shaft was held by a pair of hands - it came off :D

Yes that is correct, 357 615 301 A are the disks I have.

Just checked, they are 280mm, you need to look for earlier Passat disks. The G60 calipers use 280mm disks as standard and they are the same caliper as the VR.

Yes.

No, standard Corrado VR6 hubs.

The 16v CV's don't fit the VR hub but the 16v bearings do. The VR hub height and diameter (40mm bearing) are the same as the 16v. They've gone together ok so far, oh crap I've just tempted fate :lol: I just checked Etka and the early Passat VR6 has the same outer CVs as the Corrado VR6, so it looks like you do still need to swap them. Which calipers and carriers are you using with this? Presumably the VR6 ones to fit a 288mm disk? My intention was to use 288's, I had bought the calipers, disks and pads but the disk offset is not available to suit the 16v bearing carriers, at least I haven't found any. So Im using VR calipers and carriers and 280 disks, there isn't any other option if you want to go 5x100, not that I know of anyway.

I do have ABS. I bought new 4 stud rings from the dealer, modified and repainted them. Fit like a glove. Another problem I've found and to be honest I did read about it and had my suspicions is that the VR 5 stud hub outside diameter is indeed 6mm bigger so the new disks I bought didn't fit. This put a right downer on things as I've already pressed the hubs into new bearings, luckily I've been able to turn the hubs down to the 4 stud hub size whilst still in the bearing carrier. There is still plenty of meat left between bolt hole and the edge of the hub. Then it occured to me that there must be the right size 5 stud hub out there to fit the disks anyway so I know VW must have done this on the early VR Passat which the disks are for. So to summerise the only thing I've had to modify so far is the hubs and ABS rings. I'll guess and say there are hubs already out there to suit the disks I have, they may even have the 4 stud splines in them if that's what the early Passat VR used, i,e non plus suspension. So you may not even need the VR outer CV's. I'll post up as much detail as I can once I get it all done and hopefully find no more hurdles to get over. I wouldn't want anyone else going through this half blind as I have - it's been a little stressful. To be honest I've thought about throwing in the towel a few times.

Yep sure thing. I've stuck with a 5 spoke design but I'll keep it under wraps till it's all done, it's nothing special and it's been done before but it suits the Rado. Jim I thought you were going for a VR?

If re-drilled disks were to break and your car spun out of control and hit someone on the pavement I doubt you would be covered by insurance and depending on the damage caused to human life you may end up behind bars. Worst case granted but I don't think it's worth the risk so I won't do it. I've found the right disks now so it's all good. I will post up details when it's all done.

Just spoke to my mate and he's ok to leave the car on his drive for a while. Been doing some searching and found this - viewtopic.php?f=23&t=58675&p=692636&hilit=5+stud+conversion#p692636 I need to check part numbers but it maybe that early VR Passat 5x100 discs might fit.

If the 280's get me back on the road quickly then that's what I'll do but in the long run I still want to go 288. Not sure if the Passat disk offset is correct but it looks alot closer, modifying disks is not something I'm going to do tho. The most important thing for me to do right now is get the car off my mates drive and back home. To do this I can get hold of a pair of used G60 disks and re-drill just to get me the 2 miles back home. I think he can stand a week with the car on his drive, gives me time to find the correct disks in either 280 or 288.

Another thought - does the early Golf MK3 GTI use 5 studs that have a disc offset as per the 4 stud? - see below, the second one is a front on shot but looks like it might have the correct offset? The first one might just be a library photo. http://cgi.ebay.co.uk/Golf-Gti-2-0-16v- ... 286.c0.m14 http://cgi.ebay.co.uk/VW-GOLF-MK3-GTI-2 ... 286.c0.m14

Just been out to my Passat and the front discs are 288 with a bigger offset then the 288's I have although they are 5x112. So could the Golk MK4 288's or Audi TT's be any better as they are 5x100?

Yes that would work too. Thanks for your replies Tom.

The carrier would need to move toward the disc meaning machining both surfaces but I really don't want to go down that route, again for safety reasons. If it were the other way then yes I would space it out. The VR bearing carrier would do the job but it's the ball joint that's wrong. Ideally I need a VR breaing carrier with the ball joint central.

I thought I’d done all my homework before I started this conversion but I’ve hit a major problem. I’ve got all the parts including 288mm discs and calipers. The problem is that the 4 stud discs have a different offset in terms of the actual pad surface to the hub mating face as opposed to the VR set-up. It's about 10mm different Now this means that whatever 5 stud disc I use as part of my 5 stud conversion the caliper carrier is about 10mm away from the disc. Yes I could use a 280mm G60 disc and re-drill to suit 5 stud but I won’t do that for safety reasons. So what I need is a 5 stud bearing carrier/hub that has the ball joint centrally positioned to match my 4 stud wishbones. The VR bearing carrier/hub has the ball joint offset to suit VR wishbones so that’s a no go solution. Is there such an item maybe off an early Mk3 Golf GTI with 5 studs or maybe a Passat 5 stud? I’ve already installed new bearings and the 5 stud hubs into my 16v bearing carriers so I’ve already started to lose money. I could go down the complete VR subframe/wishbone route but that’s a little more costly and time consuming as I’ve got a mechanic friend helping me and I’ve already used up most of his day today. The bummer is that I’ve done the 5 stud rears first so I'm reluctant to go back to 4 stud. Any help is very much appreciated as I’m feeling lower than low about the whole thing and also the car is stuck on my mates drive with it’s nose on bricks. Thanks Dave

Yep 2 months for me but hopefully back on the road tomorrow.

Anyone?

What size are the screws that attach the ABS ring to the hub on a 2L 16v? I know they are M6 on a VR and screw directly into the ABS ring. I'm doing a 5 stud conversion very soon and have bought new 16v ABS rings that arn't tapped and was thinking how they are attached on a 16v. I can tap them M6 to suit the 5 stud hub but the holes are not the correct size for tapping M6 but should hold if tapped. Thanks Dave

Tom, I used 2.25" clamps for the very same joint on my Magnex. Got them from Ebay.

I'm doing 4 to 5 stud conversion so they'll have to come off anyway for modding but I think I'm gonna get new rings anyway. Already got new screws and yes I'll get it all aligned afterwards. Thanks for your comments.