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Right, been at an Audi friendly garage all afternoon with a mechanic friend taking the 6 speed 'box off and getting all my shiney new parts fitted. The car came apart really easily and all was going well... Got the 3B flywheel, friction plate and pressure plate all on the engine, changed the rear crank seal and a few other bits whilst it was apart. 
The dual mass flywheel, completely dead friction plate and general dual mass gubbins were removed from the car and the dual mass spacer was also disgarded as per what I'd read here.
Then the fun started, things never go smoothly when working on an S2, especially not the Alpinweiss variety. We got the 'box back on the car and started to put the bolts back through the bell housing. This was where the first problem arose, due to the spacer being removed the bolts are mainly too long, suprisingly enough by approximately the length of the thickness of the spacer
So a few washers to space the bolts back a bit and then continued with the rebuild. Got the box alinged and dowels engaged before my mechanic friend began going around the bellhousing bolts and tightening them while I held the box in place.
C R A C K ! ! !
Oh S**T...
A quick inspction with a torch identified that the bell housing had cracked in quite a major way. At this point I had to go and get some fresh air for 5 minutes. Many will have read that the last 2 weeks have been far from great and this really was the last straw. I returned 5 minutes later, still shaking with panic and began to work with the chap doing the job to identify what the phook had happened and then begin to devise a solution to the problem.
Basically the two dowels that locate the gearbox are elongated (you've guessed it) by the thickness of the plate over those from a 7A that was lying nearby. The 'box had bottomed out on teh dowels and then the brittle cast alloy had been effectively bent to the point of fracture at a quite obvious stress concentration point. The crack had then propogated along the path of least resistance, down a rib or two and back out to the mounting face. There had not been the chance to learn the easy way by there being a gap, no this was almost the hardest way to learn that there could have been
I have pictures but the dowels are approximately 5mm too long when the plate is removed. I also have pictures of the bell housing and will post them when I can download them from my phone.
Moral of the story - leave it the phook alone.
If you're planning on doing the single mass flywheel conersion then you will need the 3B block to bell housing dowels and all bell housing bolts (or an angle grinder). Everything else seems to lign up OK as per other peoples' experiences... I'm sure there's something else that can go wrong though... and it will. The nightmare that is my love-affair with the S2 continues...
The dual mass flywheel, completely dead friction plate and general dual mass gubbins were removed from the car and the dual mass spacer was also disgarded as per what I'd read here.Then the fun started, things never go smoothly when working on an S2, especially not the Alpinweiss variety. We got the 'box back on the car and started to put the bolts back through the bell housing. This was where the first problem arose, due to the spacer being removed the bolts are mainly too long, suprisingly enough by approximately the length of the thickness of the spacer
So a few washers to space the bolts back a bit and then continued with the rebuild. Got the box alinged and dowels engaged before my mechanic friend began going around the bellhousing bolts and tightening them while I held the box in place.
C R A C K ! ! !
Oh S**T...
A quick inspction with a torch identified that the bell housing had cracked in quite a major way. At this point I had to go and get some fresh air for 5 minutes. Many will have read that the last 2 weeks have been far from great and this really was the last straw. I returned 5 minutes later, still shaking with panic and began to work with the chap doing the job to identify what the phook had happened and then begin to devise a solution to the problem.
Basically the two dowels that locate the gearbox are elongated (you've guessed it) by the thickness of the plate over those from a 7A that was lying nearby. The 'box had bottomed out on teh dowels and then the brittle cast alloy had been effectively bent to the point of fracture at a quite obvious stress concentration point. The crack had then propogated along the path of least resistance, down a rib or two and back out to the mounting face. There had not been the chance to learn the easy way by there being a gap, no this was almost the hardest way to learn that there could have been
I have pictures but the dowels are approximately 5mm too long when the plate is removed. I also have pictures of the bell housing and will post them when I can download them from my phone.
Moral of the story - leave it the phook alone.
If you're planning on doing the single mass flywheel conersion then you will need the 3B block to bell housing dowels and all bell housing bolts (or an angle grinder). Everything else seems to lign up OK as per other peoples' experiences... I'm sure there's something else that can go wrong though... and it will. The nightmare that is my love-affair with the S2 continues...
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