MYP Gearbox 1.4tdi AMF (75) 6 speed MMXXIV

rotifer II said:

Home made​

Gear Cable Heat Sheilds Sleeves​

Both the alloy sleeves that cover each gear cable were showing signs of damage.
So before the one closest the exhaust fell apart I made a couple of sleeves from embossed alloy and self adhesive draught excluder.

This mod will work on any vehicle with or without the Audi heat sleeves being installed previously.
🙂👍
View attachment 135409
Click to expand...
Top banana!!
 

Fitting the gear cables​

Everything fits where it should.
It was like juggling cooked spaghetti.

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I miss-placed the clutch hardline mount so used the one that came with the new gearbox.

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I also needed to bend the clutch slave cylinder metal pipe by hand to stop it hitting that nut.

Another hitch.

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Vice grips used to widen the hook
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Problem solved.
 
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The after marker selector lever fits and works well however the Bowden cable end is not drilled to fit the TDI gear cable end.
Easy enough to sort out though stepped from 5mm to 6mm no bother at all.
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The gears all work but there is play in the tower bearing and the other Bowden cable end that will need sorting out.
I'm happy that the gearbox brace fits in there without fouling and counter weight.
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🙂
 
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Summary​

The project would have been easier if all I had to do was fit a gearbox. Making the alloy mounts and other little parts has been the most satisfying part of the project.

I keep finding other jobs to do because of the improved access to parts of the engine bay seldom see.

There are simpler ways to own a car with six gears, but nothing like an A2.
🙂
 
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Must say, it's been a fantastic thread! Very much enjoying it! Also to be fair very much enjoying @Little Dog thread with the AMF!

Wonder if we could have our own A2 awards at the end of the year perhaps??

How close are you to test drive, must be mega excited!!
 
Hi @Howey,
It is a great thread @Little Dog is creating and useful reference material for others to use.

Thank you for your kind words, glad you have enjoyed the gearbox journey.

... The recent weather has been great which has allowed me to pick up some momentum. There are a couple of pre MOT jobs still to do. When I finally lower the front of the car and lift the rear wheels the jobs will include, brake shoes alongside some new rubber for springs and shock bump stops.
Then an MOT and if it passes I may allow myself a moment of reflection 😂 before I start to remove the engine from the blue BBY and do a bit of MOT prep for the red colour storm.
🙂
At least these are much simpler tasks compared to six speed gearbox conversions.
 
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Champion!!
Certainly a full calendar of repairs ahead lol! Keep up the fantastic work!!
Are the handbrake cables in good order?
 
No sure, I can let you know tomorrow, I'll need to shift one cable out the way so I can gain access to the bolts to drop the plastic fuel filter housing and it's rusty mounting bracket.
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The cables are ok. 🙂

EDIT 20/03/25
I though the cables were alright but it turns out both needed replacing.
 
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Starter motor electrics​

The starter motor live feed required shortening by about 10mm. In a nutshell cut off the existing hole and drill a new one. Once connected to the threaded terminal the live feed cabling should sit flush against the starter motor.

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🙂👍
Don't forget to order.

A pig-tail electrical connector will replace the existing A2 electrical connector as the design is different. Price £8.95

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Pendulum Mount (Dog Bone)​

Way back in time the one of my first thoughts was,

"Does the pendulum mount fit without modification?"

Yes, 2 bolts fit.
There is no thread for bolt hole 3.
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I sort this out later on.
 
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BigBang said:
Is there a dome that maybe can be drilled amd tapped? How did you solve it?
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I need to give it some thought, not sure what to do just yet.
I guess all the other MYP converted A2s could also be running on two pendulum bolts?

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There is a gap between the fixing plate and the gearbox case which is possibly enough to accommodate a bolt head. If this is true a bolt fitted with threads pointing outward can be married up to an angled bracket joined the gearbox casing.
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As you can see in the pictures the bolt holes are in a straight line with the silent block. But on the A2 it is offset that will cause bending of the bracket.

From the supplied pictures there seems to be another empty dome to the left in the last picture that may be threaded and possible to use with some kind of extension 🤔
 
BigBang said:
From the supplied pictures there seems to be another empty dome to the left in the last picture
Click to expand...
Its a good suggestion and one I had not thought of.
Thank you.

I've added another picture above with a bracket drawing.
What are your thoughts on it please?
 
rotifer II said:
Its a good suggestion and one I had not thought of.
Thank you.

I've added another picture above with a bracket drawing.
What are your thoughts on it please?
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That would be my preference.
I think you need the three point fixing for stability. Two points just cannot provide it, especially with the nature of the pendulum movement.
Mac.
 
Wouldn't worry about a 3rd bolt, the later VAG's only have 2 bolts and no doubt the vast majority of A2's running alternative boxes only have 2 bolts (my 3 included)
 
Howey said:
Wouldn't worry about a 3rd bolt, the later VAG's only have 2 bolts and no doubt the vast majority of A2's running alternative boxes only have 2 bolts (my 3 included)
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Thanks Howey for this information.
How many combined years roughly have the three cars clocked up with the two bolts?
🙂

EDIT
I merit both sides of the discussion and personally think running 2 bolts is plenty🙂👍

EDIT II
Problem solving and making parts from scrap metal is like catnip to me.
 
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