CaiosG60 PWR

Think you should start with a front mount intercooler to get the best from your current mods and any done in the future. There a Golf G60 setup in the for sale section for good price.

Nice one Vince!! Said it will fit and I will be able to retain the better designed 02J diff. Resonable price too, £200 labour to fit if I remove the gearbox from car and the final drive from G60 box first. Could cost £50 more depending on design of some pins that may need drilling. Do people think I should ask the guy who sold me the gearbox for half my money back? But still keep it and get G60 final drive fitted.

Nice one Kev, I think my box will end up pretty similar to yours when done, minus the LSD. I should really get a Quaife or Peleqin fitted if I'm swapping the final drive. But I've just quite my job though so really skint! :lol: I'm taking a month or two off to decide on a new career. So I’m going to have ago at swapping the final drives over my self!!! Well I’ll see how removing and refitting it on my knackered box goes and take it from there. Phoned Stealth and Vince is busy with rolling road. Said to ring back about 3pm.

Kev, is he like Darren and Steve, okay about ringing him for info? Just looking at your sig. You've had a 3.6 final drive fitted to your VR6 box. How do you find the ratios now? How much did it cost you to get fitted?

Cheers Joe M Ratios should work out about right. I'm pritty sure that I've heard somwhere that the same LSD can be fitted to 02A and 02J as long as the 02J is pre 2004. If thats true then my G60 final drive should fit to the 02J diff, right? Anyone know if it will fit? I'm tempted to ring Vince at stealth but have never spoken to him before.

Aren’t you jumping the gun a bit getting a new rack. Just wipe off the fluid and have a look where its leaking first. Mine was leaking slightly from the end of one of the pipes that screws into it. There's a metal pipe that fits into the rack and has a bolt over it like that on a Speedo cable. I tightened this about 1/16 of a turn and its been okay since. If that hadn’t of fixed it I would have tried a bit of silicon before getting a new rack. I think my problem wouldn’t have been solved by a new rack anyway. Think the leak was caused by the pipe going into the rack and not the rack itself. Also check that you have the correct GREEN powersteering fluid from the dealers. Having the wrong fluid can cause a rack to leak or damage it in the long term.

Right now that the 02j box is fitted I've found that the ratios are bloody awful! There really short! The guy has sent me the wrong gearbox. :-( :brickwall: :iamwithstupid: I've found the code on it which is CZM. The ratios are as follows; 4.24 Ring-Pinion 1st. 3.30 2nd. 1.94 3rd. 1.31 4th. 1.03 5th. 0.84 Which with my tyres means around 100mph at 5500rpm in 5th!! Awful!! :-( I found this info on Dubforce; Mk3 16V box ratios should be: 1st = 3.30 2nd = 1.94 3rd = 1.31 4th = 1.03 5th = 0.84 Final Drive = 3.68 (These are the same ratios as in the VR6 Box) Golf G60 (FWD) 1st = 3.78 2nd = 2.12 3rd = 1.34 4th = 0.97 5th = 0.76 Final Drive = 3.67 Notice how all the gear ratios in my new box are the same as that listed for 16v mk3 and VR6 apart from the awful 4.24 final drive in my 02J box. So If I take the 3.67 final drive out of my old box (providing it isnt damaged) and fit it to the new 02J box It should be just like the VR box's ratios above right? Is it possible to fit a final drive from my G60 box 02A to the 02J box? Can some one give me some mph/rpm/gear firgures for the box I have now with a 3.67 or a 3.94 like that BigTartanTimmeh is selling? (tyres are 15" 195 50) Cheers

yes he is I think, same post on Dubforce

I've got the 20vT 02J box on now. Flanges where spot on and shifter is fine too, although I haven’t connected the cables yet. There are a couple of bits I need to complete the job though. Firstly the under side gearbox guard wont fit on new box. (Don’t know what its called) Its a metal plate that fits underneath between the engine and gearbox and protects the back of the fly wheel. The bolt pattern on the under side of the 20v box is different so old plate wont fit. Hopefully a new plate from a 20v box will fit, anyone know if it will? The other thing is that the metal brace thing (once again don’t know what its called :-) ) that goes from the rear gearbox mount to the right hand side of the gearbox needed slight adjustment (read whacking with hammer) to fit over the new box. Also the two holes on the gearbox where this brace bolts in have a thread on them. The old 02A box's weren’t threaded. So the old bolts wont fit as they only have a thread going half way up them and wont go in far enough. I think some bolts of the same size with a thread all the way up will sort this. Don’t know how this end of gearbox is mounted on mk4, hopefully it’s the same as mine and I can order some appropriate bolts. Also, one of the three bolts around the starter motor that fit into the front gearbox mount is too short. Its not the long two but the short one. The reason is that the 20v box has a much thicker bit than the old box. Once again a longer bolt will sort it. These small problems are giving me the impresion the box is a bit more meaty than the old box, well the caseing anyway. Fixings on it are thicker and extra thread in bolt holes, etc. I hope that makes sense to someone, its hard to explain when you don’t know the name of anything!! :lol: :lol: Anyway thought I’d better post this info incase anybody needs it in the future.

Here you are! I finally spotted what was wrong with my gearbox!! :-P

Sweeeeet! Got it off after some advice from Henny. You where spot on Henny. Lifted the diff, gave it a waggle about and it dropped into a better position. Then allowing me to get at that bolt through the wheel arch. Still took a while to get out though. :x Problem is as you said you need to lift the diff a lot and access from above to lift it is hard because of the ABS gubbins. Got the new one on almost straight away. Was lucky because spline lined up perfect first time! :D :D Have just got to put all the bolts back in tomorrow. One problem is the left hand drive driveshaft is on the floor so I'll have to undo the suspension to get it back on. Doesn’t really matter though as I planned to get the camber set anyway. Picture below of Benji16v after wining battle with the gearbox! Not bad for us novices!

Anyone? Gonna try finish the job tomorrow. Could really use some suggestions to the problem I described above. Cheers

Think that is what I may end up doing, not much access for hack saw though. Unless anybody has a better idea?

Found a picture in the Lindsey porter manual. Posted below. It shows exactly what I'm having problems with. Its bad qaulity as I've taken picture of book with camera phone. It recomends jacking up the engine untill the downpipe hits the bulk head. Is that the best way to do it?

Here's apicture of the bolt in qestion. Have undone it since picture taken but as you can see there's no room to slide it out.

HELP, I'm stuck! Stuck on the removal of one bolt to get the gearbox out of the car! The one bolt that I’m stuck on is undone but there’s no room to slide it out of its hole. It’s one of the three bolts that screw through the bit attached to the rear gearbox mount and into the bell housing (diff case). The problem is that I can’t slide it out because the rear gearbox mount is in the way. I have undone the bolt that secures the block to the rear gearbox mount but the gearbox just wont drop with the block thing still attached to it. Looking at an 8v rod change box as a comparison and the bolts are put in from the other side on the diff casing which would make the job a bit easier. Bit worried some ones had the box off mine and put the bolts in from the wrong side. I could try jacking the engine up enough so that the bolt clears the top of the rear gearbox mount but I think the down pipe will hit the bulk head before the bolts clears the gear box mount. Don’t think this is the way to do it. Just to be clear about situation, inner cv’s removed, all other bolts holding gear box on removed, one side of car jacked up, engine supported on jack. The gearbox will slide off its spline but wont drop out. Any advice would be really help full. Not sure if I’m having problems because it’s a left hand drive golf.

Nice one oxfordpaul! I did check with a mate before ordering them. He has them on his mk2 16v and mk3 8v and says there great and last for ages. He couldn’t believe the price they are from mytyres at the moment! kevhaywire give those SP9000s a go. Think there the daddys!! I'd have gone for those if I wasnt on a budget.

I dont rate Toyo's. There grip is okay but they dont last five minutes. I've just ordered a full set of Goodyear F1 Eagles (195/50/15) from mytyres for £33 each! That cant be bad!

I forgot to add there surprisingly good off-road. Think its because of rear wheels drive with engine right above wheels.

I can promise you campers are cooooooool as fuck!! We've got two, one has absolutely had it and was rescued from a breakers before it was crushed. Some of the panels on it are okay though. :lol: The other one drives great for a camper but is in need of major body work restoration. Which will hopefully be done for next year all types show. Picture of it posted below, rat look or what!!! There really good fun though no mater what condition there in. You can drive to a beach with your mates go swimming have a barbecue, drink, etc then sleep in the camper and drive home next day. Its also the best thing you can have to take to music festivals always attracts a party. It would be great to take to inters or something but I couldn’t be arsed to drive it that far.

You calling me an anorak!! I've noooo idea, honest!! :-P

Kev, wtf does that mean? :lol: punchy and peaky? I dont understand :oops:

What you need is a reprogrammed EPROM, like an SNS chip or similar. Fit this chip into your G60 ECU. To go with this you need a smaller supercharger pulley, 68mm is most popular. The chip will account for the increased boost generated by the smaller charger pulley and result in a significant power increase. You can get an SNS chip and smaller pulley from G-MAN (Darren) on this forum. Its by far the most popular setup on this forum. Does that answer your question?

uuuum. I thought it would have been more bhp. Suppose they have to keep 150+ back for the GT TDI model. Remap would hopefully see big gains though!!

Thats sweet Beal!! :-) :-) 3 door would have been nicer though. :-( Whats the preformance figures on it?