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Discussion Starter · #1 · (Edited)
I will add to this as I figure out more. This thread is here to consolidate the vast amount of (often conflicting) information about putting haldex awd into a Corrado. There are basically two major steps which can be completed separately. Do not pm me about things in this thread, I have written most of what I know and have not yet done the conversion. Also, sorry If I stole your pictures...

Fitting the 02m into a Corrado



Parts Needed
1.Custom Driveshafts (either shorten stock or buy for ~700 usd from DSS)
-For wide front, subframe from VR6, Gti and Tdi from Golf mk3 the driveshaft length is 327 mm. and 423 mm.
- For stock Mk2 subframe the driveshafts are 7 mm shorter.
- Measurements are taken from flange to flange on the inner side of the CV-joints.






2. Custom Mounts front and rear (available from sdezego http://www.generalprinciple.com/sd/shawnweb.nsf/02mmounts?openpage ~300 usd)



3. Modify Tunnel and Shift box or aquire Euro Shift Box from
CA '96-'03 Caddy
LU '99-'03 Lupo / Lupo 3L TDi
LU '04-'06 Lupo / Lupo 3L TDi
PO '95-'00 Polo / Derby
PO '00-'02 Polo / Derby
POC '00-'02 Polo Classic / Variant

Part #:
6N0 711 061 A House
6N0 711 090 A Ground plate
6N0 711 611 C Choise arm
(~70 euros)


4. Clutch cable for an 02m and mk2/3 master, can be purchased from USP or it can be custom
http://uspmotorsports.com/product_info.php?products_id=574



5. Correct bolt/studs for the 02m Starter

6. Flywheel and Clutch matched to transmission

7. Must have VR6 splined hubs. For 4 bolt non plus suspension you have to fill and drill vr6 hubs or have the 4 bolt hubs resplined. Resplining can be done by RCV performance of Illinois.
- The splines are NOT the same for o2m and o2a axles but the outer CV has the same spline.

Modifications required to car

1.moving the transmission mount cup on the subframe approximately 1/2" to properly clear the larger 02m CV flange



Miscellaneous

Speed Sensor:

02a MK3 VR6 Speed Sensor Harness ---------> 02M harness

Black ----------------------------------> Black/White
Blue/White ------------------------------------> Blue/White
Red/Green ------------------------------------> Brown


Nice part is you can fit the 02m and run fwd while you figure out the next major hurdle, the haldex swap.
Haldex Swap

Parts Needed
1. Syncro rear axle assembly converted to accept haldex dif with dutch build kit (around 400 usd)



2. Rear end options:

Axle (circled are the 3 bolt axle mounts):



a) 1992 Passat G60 (available in European and Canadian markets)
-A popular option for those in North America due to the relative ease of acquiring parts.
-Requires either modifying the rear of the car to accept 4 bolt axle mounts such as "MrDave" did:



or the purchase of 3 bolt rear axle mounts from overseas which look like this:




-The floor and rear end must then be grafted in.
-With this setup you can use the stock fuel filler location.
-The downside is that you have a 70l fuel tank which hangs below the rear bumper.



b) Rally/Mk2/Mk3 syncro rear end
-This setup is similar to the passat, but is tailored more to installation into the Corrado.
-Uses a smaller 50l gas tank which does not hang below the vehicle.
-Difficult to source because was never available in North America.

Rallye pan: 191813116 $244

c) The third method is to use a fuel cell.
-To do this you need the mk2 axle mounting brackets, as well as the differential support crossmember.
-Requires removing the spare tire well.




3. Haldex Rear differential. Must be from a generation one haldex car. In North America this is easiest to source from an Audi TT.



4. Centre propshaft must be shortened, but bolts up without modification. Requires hangers to be welded into the tunnel.

5. Custom haldex to wheel driveshafts. Syncro ones work with some motivation, but shortened ones original to haldex would also work.

6. Standalone Haldex controller, or mechanical screw in controller. Check ebay.de

That is all I have for now. If everyone contributes a little bit of information we should be able to make a definitive parts and information list for those looking to swap. I will update the original post as I get information for ease of access.:thumbup:
 

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Discussion Starter · #5 ·
Several hard to decipher setups:

Front 5x100, stock width, 02M gearbox
Front suspension: Golf Mk2, VR6 hubs in G60 spindles
Driveshafts: Left Seat Ibiza TDI, part# 6Q0 407 271 J. Right shortened 4Motion, hollow type.
Front brakes: VR6 288, Audi TT or bigger bolt-on kits, adapter needed. (ESC Tuning.)
Prop shaft: Passat G60 middle section with 100mm CV, shorted TT item front and shorted G60 item rear.
Rear 5x100, stock width
Rear left driveshaft: G60 Syncro shaft, shortened, inner CV joints 4Motion, outer VR6
Rear right driveshaft: G60 Syncro shaft, shortened, inner CV joints 4Motion, outer VR6
Rear trailing arms: G60 Syncro
Rear hubs: VR6 Syncro, optional VR6 front hubs and 4Motion outer CV-joints
Rear brakes: VR6 Syncro
Front 5x100, wide track, 02M gearbox
Front suspension: Golf Mk3 Gti 8v 16v VR6 / Corrado VR6, 5x100
Driveshafts: Custom driveshafts with 4Motion inner CV and Sharan outer CV. http://www.driveshaft.co.uk/index_content.cfm
Front brakes: Audi TT or bigger bolt-on kits
Prop shaft: Passat G60 middle section with 100mm CV and, shorted TT item front and shorted G60 item rear.
Rear 5x100, wide track, 4Motion outer CV joints
Rear left driveshaft: G60 Syncro shaft with CV joints from 4Motion
Rear right driveshaft: G60 Syncro shaft with CV joints from 4Motion
Rear hubs: 5x100 VR6 front hubs
Rear brakes: stock VR6 Syncro
Rear trailing arms: VR6 Syncro

Front 5x100, wide track, 02C / 02J gearbox
Front suspension: Golf Mk3 Gti 8v 16v VR6 / Corrado VR6, 5x100
02J 4Motion (from 2000) or 02C gearbox, optional upgraded internals.
Skoda Angle Drive, part# 02C 409 053M.
Driveshafts: Stock VR6 Syncro with Sharan outer CV
Front brakes: Audi TT or bigger bolt-on kits
Prop shaft: Stock G60 Syncro with optional 100mm CV's from Audi TT
Rear 5x100, wide track
Rear left driveshaft: G60 Syncro shaft with CV joints from 4Motion
Rear right driveshaft: G60 Syncro shaft with CV joints from 4Motion
Rear hubs: 5x100 VR6
Rear brakes: stock VR6 Syncro
Rear trailing arms: VR6 Syncro


Front 4x100, stock width, 02C / 02J gearbox
Front suspension: Golf Mk3, 4x100
02J 4Motion (from 2000) or 02C gearbox, optional upgraded internals.
Skoda Angle Drive, part# 02C 409 053M.
Driveshafts: Stock G60 Syncro
Front brakes: G60 280 mm, optional S2 callipers. 305 mm. Brembo from Seat Ibiza Cupra R
Prop shaft: Stock G60 Syncro, optional 100 mm CV's from Audi TT
Rear 4x100, stock width
Rear left driveshaft: G60 Syncro shaft, shortened, with inner CV joints from 4Motion
Rear right driveshaft: G60 Syncro shaft, shortened, with inner CV joints from 4Motion
Rear trailing arms: G60 Syncro
Rear hubs: G60 Syncro
Rear brakes: G60 Syncro

Front 4x100, wide track, 02C / 02J gearbox
Front suspension: Golf Mk3, 4x100
02J 4Motion (from 2000) or 02C gearbox, optional upgraded internals.
Skoda Angle Drive, part# 02C 409 053M.
Driveshafts: Stock Mk3 Syncro
Front brakes: G60 280 mm. Optional S2 callipers, 305 mm. Brembo from Seat Ibiza Cupra R
Prop shaft: Stock G60 Syncro with optional 100mm CV's from Audi TT
Rear 4x100, wide track
Rear left driveshaft: G60 Syncro shaft, with inner CV joints from 4Motion
Rear right driveshaft: G60 Syncro shaft, with inner CV joints from 4Motion
Rear trailing arms: Golf 3 Syncro
Rear hubs: G60 Syncro
Rear brakes: G60 Syncro
 

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Discussion Starter · #43 · (Edited)
Bump. Quick question for the pros: If I go the passat syncro rear for haldex and am going to run the big gas tank what other parts do I need to source from Europe? I know there are two brackets, but other then that I think I would be good.

My plan so far is: Passat syncro rear setup with notched spare tire well and hemmeroid gas tank. Although I have a couple ideas for solving the gas tank issue. If it is possible I would section it and plastic weld it so it didn't hang so low, or if that doesn't work I will do a custom aluminum fuel cell that will still go to the factory gas door.

Only parts I have so far are the ones for the o2m box to bolt up like factory :banghead: But I have a passat syncro locally that I should be picking up if I can get if for the right price... and more importantly somewhere to store it considering I already have a wrecker Corrado.
 

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Discussion Starter · #46 · (Edited)
FV-QR

Anyone have any insight into the subframe? I have a stock g60 subframe, but want to convert to the later vr6 style for strength while keeping the non plus suspension. From what I know so far I will need a Vr front crossmember from a Corrado or Passat and a mk3 k frame... I really don't have a great understanding of the differences between suspension. Would appreciate some insight so I can start gathering those parts.


I also added a couple pictures, and should have more to add once I get my syncro axle later in the month.

Finally, I know a couple other guys here are doing this swap as well- anyone want me to try and see if there is any sort of group price for dutchbuild haldex beam conversions, or if packaging them together can save on shipping? There might be jig floating around too, Ive yet to find out. Would be nice to also make a fb group or something to troubleshoot/ trade parts during the process.
 
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