[dubwerx]

MK4 Haldex swap using TT parts and oem wiring -IT LIVES!

I own VW/Audi servive and performance shop in Cincinnati, OH. One of our technicians has a 2001 Golf that has been modified quite a bit, including GT28 kit. Cininnati weather can be bad and the car currently has some traction issues so more grip is needed! Here is the recipient car...

We picked up a whole 2001 Audi TT roadster. We parted the whole car and saved EVERYTHING! We had heard mixed reviews as to how well the rear floor pan would work but we decided to try it before spending more money on R32 parts. Here's a few pics of our donor car...

So far the TT pan seems like it's going to work as well as any other. Since out donor car was a roadster, there are no brackets for rear seats so we may have to get creative there. Other that that, we had to cut some access holes to get the rocker welded in right, and we left the cars original rear wheel arches and are going to shorten them as it seemed easier. The pan is almost an oem weld-in. Here are some pan pics.

For the wiring, I removed the haldex wiring, the steerin angle sensor and wiring, and the whole ABS system including the accelerometers, wheel speed sensors, etc.

I'll post more pics as we get stuff done. <IMG NAME="icon" SRC="http://www.vwvortex.com/zeroforum_graphics/grinsanta.gif" BORDER="0">
Ryan




Modified by dubwerx at 5:40 PM 4-6-2009

 

[PowerDubs]

Re: MK4 Haldex swap using TT parts and oem wiring. (dubwerx)

http://****************.com/smile/emthup.gif

 

[RipCity Euros]

Re: MK4 Haldex swap using TT parts and oem wiring. (PowerDubs)

Oh yeah, that looks like fun

Do you need all of the wheel speed sensors, duosensor, steering angle sensor etc. for the haldex to function properly?

 

[dubwerx]

Re: MK4 Haldex swap using TT parts and oem wiring. (RipCity Euros)

As far as I can tell, you have to have ALL of the ABS system from a haldex car since the Haldex needs to know not only wheel speed but also the signals from the 3 accelerometers which are part of the ABS system and also the steering angle sensor which is not part of the ABS system but gets spliced into the CAN-BUS. When everything is installed properly, the Haldex ECU will communicate via the CAN-BUS with the engine ECU, ABS ECU, and steering angle sensor.
Here are some updated pics, the floor pan is almost done.

Ryan

 

[dubwerx]

Re: MK4 Haldex swap using TT parts and oem wiring. (dubwerx)

More pics!

Ryan

 

[NVmyVW]

Re: MK4 Haldex swap using TT parts and oem wiring. (dubwerx)

nicely done

 

[transient_analysis]

Re: MK4 Haldex swap using TT parts and oem wiring. (NVmyVW)

wow.. looks like the tt floorpan works perfect.. and matches up with the back of the MKIV tail just fine..
good work.. and thanks for sharing

Modified by transient_analysis at 11:47 AM 1-10-2009

 

[Gotsol]

Re: MK4 Haldex swap using TT parts and oem wiring. (transient_analysis)

fantastic work

 

[fatdubs fatman]

damn, thats a lot of wiring. Looks like a great start.

 

[DHill]

Re: (fatdubs fatman)

Nice. http://****************.com/smile/emthup.gif America should have had 1.8T's with Haldex from the beginning.

 

[Vboulderer]

Re: (DHill)

Nice work.

 

[Burnitwithfire]

FV-QR

This is gonna be fun!!!

Nice work! keep it up!

 

[IFIWASINMYVW]

Re: FV-QR (Black Smokin' Diesel)

Looks like tons of fun. I wonder what differences there are between the GTI and Jetta floor pans, if any...
http://****************.com/smile/emthup.gif

 

[orangea2vr6]

Re: FV-QR (IFIWASINMYVW)

Looking good love to see people taking on this kind of stuff. Keep us updated want to see how it all pans out.

 

[fouckhest]

Re: FV-QR (IFIWASINMYVW)

Quote, originally posted by IFIWASINMYVW »

Looks like tons of fun. I wonder what differences there are between the GTI and Jetta floor pans, if any... http://****************.com/smile/emthup.gif

about 8" of missing metal on the gti pan...it has to be extended out to fill in the jetta trunk...other than that fits right in...

 

[[email protected]]

Re: MK4 Haldex swap using TT parts and oem wiring. (dubwerx)

http://****************.com/smile/emthup.gif

 

[IFIWASINMYVW]

Re: FV-QR (fouckhest)

Quote, originally posted by fouckhest »

about 8" of missing metal on the gti pan...it has to be extended out to fill in the jetta trunk...other than that fits right in...

That's what I wouldve guessed http://****************.com/smile/emthup.gif

 

[fouckhest]

Re: FV-QR (IFIWASINMYVW)

Quote, originally posted by IFIWASINMYVW »

That's what I wouldve guessed http://****************.com/smile/emthup.gif

although im going to tie my rear haldex into my cage so i dont have to swap out the pan....just going to tie it into the entire car!

 

[dubwerx]

Re: MK4 Haldex swap using TT parts and oem wiring. (dubwerx)

Sorry I've been slacking on the updates. here's a few pics, we're getting close!
We had some lower than desired leakdown numbers so we opted for a minor overhaul using some stuff we had lying around. We had 3 good AMU pistons and 4 rods. We bought one brand new AMU piston, new rings and bearings for the block. For those who don't know, the AMU stuff is a bit beefier with a 20mm wrist pin, more area above the top compression ring and lower compression. Here are 2 pics showing the AWP and AMU stuff.
AWP wrist pin journal...

AWP piston...

AMU wrist pin journal...

AMU piston...

New stuff installed...

We also installed an AEB large port cylinder head that we had and did the usual gaskets, seals, and new timing belt and waterpump while we were in there. This was then mated up to the stock TT 6-spd O2M gearbox and transfer case and tossed into the golf....

While we really wanted to swap in a GT2871, the opportunity on this used disco potato was too good to pass up so it was added to the mix. Brandon is trying some tricks to make sure his manifold to turbo bolts don't come loose with the ATP manifold.

We took some pics and measurements of where the center support bearing had to be before removing the brackets from the TT. Here they are tacked into the Golf body...

Many people said certain TT parts would not work. We may be one of the few who has used the TT floor and are probably the only one to use the gas tank with minor mods. The center driveshaft on the other hand, is not going to work. When measuring the wheelbase of the TT and golf, the TT is definitely shorter by a few inches in the floorpan area right behind the front seats but ahead of the rear seat pan which we used. We'll need to either source an R32 shaft or modify this one.

Brandon and Chuck worked for awhile on his downpipe to get it to fit around the transfer box...

I have begun the wiring mess that hopefully will end up in an electronically happy car. Here is a pic of the Golf's ABS harness before I began splicing. This 2001 Golf used a version of ABS that was significantly different so I removed the whole system!

Installing the TT ABS and Haldex system is not for the faint of heart. It is one of the most challenging and tedious wiring tasks I've performed to date. These pics won't really show but it's a lot of work. Ths ABS harness was removed from the TT intact and has been very carefully installed into the Golf as if the factory installed it. I have carefully removed 99% of the golf's old system and run the TT wiring in it's stock location. If this pic looks normal, that's a good sign!

Not too much longer now, maybe a month or two. Main tasks remaining are to make the driveashaft and finish the exhaust. Then with a bit of wiring and finishing in the engine bay we should be running!
Ryan



Modified by dubwerx at 8:40 PM 3-9-2009

 

[RipCity Euros]

Re: MK4 Haldex swap using TT parts and oem wiring. (dubwerx)

AWESOME work http://****************.com/smile/emthup.gif