UrS4 2.2T Avant project

[quattro-nick]

where did you buy that stuff thomas?

[Thuppu]

We have now tried to fit the custom gearset, maybe 10+h used on this first set. Problem after problem...

First custom set was going in Tempo's box. First trouble was getting of the 5th gear from the main shaft end. Seriously hard fit. After pulling, hammering and heating we finally got it off.



Second problem was the pinion roller bearing, it would need to be replaced, it was badly damaged. Expencive bearing, ~250 euros. Couldn't put the box together before the new bearimg was here, but soon we realised that there was no hurry in puttimg this together...



We fitter the gearset and other parts on the input shaft, and then we saw that the dog collar was only making very little contact with the inner spline on the dog "teeth"(don't know the right word), they where making contact about 4mm on six spots. This with the first gear engaged. No way this gona hold... Sending the parts to the machine shop for inspection and they say it's fine, it gona hold. Ok, what can you say. Putting parts together untill next issue...





Next was that the reverse gear didn't fit in it's place. The first gear on the input shaft was so wide that the reverse gear hit it. Needed to machine off 4mm of the back of the gear. After some driving 20km to my garage and machining on really hard material, driving back and it finally fitted in place.

Then the C-clip groove in the shaft was too small, the clip didn't fit. On the left side of the first gear you can see the groove, upper stock shaft, lower custom shaft.

Also the bushing that comes between the first gear and C-clip needed to be shorten 4mm, as the first gear is so wide.



C- clip groove machined and clip fitted. But this part wasn't the only issue here. The 6th gear needle bearing didn't go over the shaft. It was too tight. So needed to get few thous off, 240, 400, 1000 grit sandpaper and finally it feeled like the orginal...



We shall see what comes next. Second box hopefully goes faster. Second shaft is also now machined, so it should be alright. These kits was PnP... almost.

[Majorcina]

This is awesome Thomas

Послато са G7-L01 уз помоћ Тапатока

[david1980]

will you be selling this as a kit once you've finalised it all?

[Thuppu]

I will try to get the links done next soon, so I can test how the gear chang will work. Can need some adjustments here and there.

Here's a pic of the gear indicator, found it from ebay. Did also order a sealed potentiometer for it, Contelec VERT-X 2831-736-221-102. According to the display maker the 5V power output isn't enough for this type of potentiometer, so I used a cheap ebay 12V->5V regulator as power feed. The display itself takes 12V.

[Billman]

Very nice!!!! Keep us posted please!

[Henkjan]

[Thuppu]

Shift indicator works! Really simpple solution with a potentiometer.

https://www.youtube.com/watch?v=sl8dmtqspTs

[Henkjan]

I've not had any cooling issues but, as always, planning the next (potentially unnecessary) modifications

[Error404]

Cool let me know how you get on with it
I've not had any cooling issues but, as always, planning the next (potentially unnecessary) modifications

[Thuppu]

I was thinking of to first go with the Davies Craig controller.

[Error404]

ahha! Did you go with the PWM module for the MaxxECU? I have considered running a Davies Craig pump controlled from a PWM module, but it all adds up to be quite a lot of money quite quickly!

[Thuppu]

Haha Alex, it's just a blank off flange with a Subaru pulley. I will run electric waterpump.

[Error404]

Nice How did you seal the bearing?

[Thuppu]

New waterpump