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Discussion Starter · #1 · (Edited)


If you enjoy modding your car as much as I do, this thread is for you. If you love performance, handling, track days and twisty back roads, this thread is also for you. In this thread I'll give you an inside look at New German Performance, how we work, how we play, and why we love to do what we do.

Have you ever had an idea, some really crazy idea of how you'd like to build your car? Like, sky's the limit kind of big. Like you could throw all the parts you could think of at it. You guys know what I mean: Build your car the way you thought it was mean't to be from the factory.

Well, the plans for my car didn't completely start off like that, originally the CC was just to be a nice daily driver while I was going to finish building up my '93 SLC Corrado. That didn't last long. I'd owned the CC for less than 12 hours before she was flashed to APR stage 1 software and of course the Carbonio Stage I and II intakes were installed shortly thereafter. It didn't even make it to the weekend before a fresh shipment of our Type I coilovers arrived at our shop (which just had to be installed). And then of course we had some Rotiform BLQs in on the shelf and all it took was a few days and some nice sticky Falkens made everything ride nice. Fast forward about 2 years (and a lot more parts as you may or may not read below) and the car was a real daily driver beast with the capability to go to the occasional track day as well.

But it just didn't feel enough, there was something missing. Part of this mentality draws from where I work. At NGP, you are constantly surrounded by show cars, high-end supercharged V8 builds, engine swaps, $180,000 V10 R8s, the list could go on. You also have the wonderful opportunity to work with some of the most knowledgeable mechanics in the VAG field. Being around all of this and having so many resources available to you, it really just boils down to what your imagination can dream up and how much money is in your pocket.

That being said, one night, I was hanging out with some co-workers after work, just doing an oil change on my car. Somehow that ended up with us looking at the rear subframe of the car and thinking, "We can totally swap this thing to AWD easily.So lets do it." Now, to preface, we get all kinds of stupid crazy ideas at the shop that don't usually turn into anything. The idea to build a rear wheel drive Scirocco 1 with a longitudinally mounted big turbo TSI along with DSG is the current popular crazy idea. Well a few days, some more brain-storming sessions (along with the wonderful information in lour32's build thread, ever so helpful!), and some more down to earth thinking (originally the idea was to find a 3.6 VR6, turbo it and swap it into the car along with a manual transmission) the decision was made to build the car the Volkswagen never gave us, a real "CC R" if you will. I'll stop waxing sentimental at this point and get on with the build. I hope you guys enjoy it as much as we enjoyed putting it all together.

To help those new to this thread, directly below is a timeline of sorts of all the parts installed up to this point. If you'd like to skip to where the story is at so far, just scroll down to where the 4motion build starts.

Most of the upgrades were done in stages and we will be presenting them in the same way. If anyone has any questions about the work we've done to the car or any of the parts installed, please feel free to PM me or contact me directly. I'm always available to talk to fellow car enthusiasts.

To make it easy for anyone that wants to see any previous upgrades done to the car, I'll save you some reading by giving you the link to the mod list on the NGP Racing website. I'll update this section at some point with pics and info on all the upgrades already installed to the car before the 4motion swap.

4motion AWD Swap
Ahh, here is the real meat and potatoes of this build, the true reason you clicked on this thread (I don't mind at all, it's my favorite part of this whole build)

But first, a quick preface on why we went AWD (other than the reasoning of: why not?): As many of you might know, New German Performance been in the performance tuning business for quite some time now, and we have had a history filled with many a big horsepower VW/Audi project car. Aside from the VR6T Rallye Golfs that we built awhile ago, our VW project cars have always been FWD. Now as much as we love a great FWD car (ask me sometime how much I drool over building a mk5 Rabbit track car), at the end of the day, putting down over 450 angry ponies to the ground through only the front wheels is a bit daunting to say the least. This 4motion conversion lets us reliably put down the power that the forthcoming turbo kit will produce, with a minor hit in weight (about 210 lbs) Also donuts, donuts are another good reason to do an AWD swap... :D

The parts list. If you've been waiting on doing your own AWD swap, this list will contain every part that we used in the process converting to 4motion. This list will be completed as I have time, so please be patient. Please note that we are not responsible in any way for the usage of this information. If you are going to complete this swap on your own, make sure you know what you are getting into first!

Rear components
0BS525010A/B - Final drive assembly (the glorious haldex rear differential assembly that makes 4motion possible)
You can also use a Tiguan unit as well since the rear subframe is the same on a Tiguan as it is on the B6 Passat/CC.
5N0505235L - Rear AWD subframe assembly
B6 Passat/CC/Tiguan only! I found out the hard way and bought an Audi RS3 rear subframe that installed, but sat two inches to far back to install the prop shaft.
3C0201055AE - Passat/CC 3.6 4motion fuel tank
3C0919673B - Transfer pump/second fuel level sender
1J0919133B - Seal for transfer pump/sender
1K0201375 - Locking nut for transfer pump/sender
3C0201653C - Fuel tank strap #1
3C0201654B - Fuel tank strap #2
3C0201307B - AWD fuel tank heat shield
3C0505433G - Left rear AWD spindle assembly
3C0505434G - Right rear AWD spindle assembly
1K0501203F - Left rear axle
1K0501204F - Right rear axle
3C0498621 x2 - Rear hub/bearing assembly (you'll need two, they're the same as the fronts)
3C0521101AJ - Passat/CC Prop shaft assembly
3C0971166B - Haldex wiring harness
WHT003857 - Left rear ABS sensor
WHT003856 - Right rear ABS sensor
3C0971166B - Haldex wiring harness. Please note that this is only the part of the harness that connects to the Haldex control module on the rear differential.
It comes with the 8 pin connector on one end, the grommet for sealing it to the body of the car, about two feet of wiring, and the 6 pin connector on the other end.
The rest of the harness is part of the main chassis harness and is not available unless you want to purchase a $1400 factory harness and re-wire about 1/4 of your car.
You will need to make a five wire harness that will reach to the front end of the car. I'll post up the connection location information as soon as I've wired my own up.

Rear sway bar - Due to the location of the rear differential assembly, the FWD sway bar will not fit. This is a good opportunity to upgrade to a better aftermarket rear sway bar.
I went with a SuperPro 26mm solid adjustable sway bar, but there are many aftermarket options available. Just make sure it's for an AWD application before purchasing it!

Exhaust system
You will not be able to use your existing FWD exhaust system with the AWD components installed. This is due to the routing of the exhaust pipe on FWD models.
The FWD exhaust goes between the chassis and the rear control arm assembly. However, you will have a drive axle in that area when the car is AWD.
The solution is to either source a 3.6 4motion exhaust system or to make your own.

Front components
This information is 6 speed MT only! Please do not ask me questions about DSG as my research has been entirely manual transmission based.

Now there are two ways you can go about this, either buy a whole 6spd AWD transmission, or make your own.
I went with the latter path and found that most manual transmission CCs with build dates up to mid 2011 have the needed mounting points on the transmission case to attach the AWD transfer case.

Building your own:
0AV409053S - Angle drive transfer case from a Mk2 TT, Golf R, A3, etc. Do not get one from a 3.6 4motion car! The 3.6 4motion transfer case uses a completely different automatic transmission.
N90990202 x4 - Hardware to attach transfer case to transmission.
02M409905AQ - Transfer case support bracket. This attaches and braces the transfer case assembly to the back of the engine. If buying used parts, please note that 02M409905AH is designed for use on an FSI engine and will not work on the TSI.
N91000002 x3, N91002702 x2, N10425302 x1 - Hardware to attach support bracket to transfer case and engine.
02J409359* - Bolt that secures the transfer case and differential together.
The ekta listing for this part is incorrect however (silly VW listing incorrect part numbers), I've simply posted this for a placeholder until I can find the correct number since the transfer case I pulled had the correct bolt already.
AWD differential - You could use a stock one, but I decided on using a Peloquins VW/Audi high torque limited slip differential since this thing will be hitting the track.
02Q409021T - Standard 4motion/Quattro open differential if you are not installing a limited slip.
06F145735F - TT/A3 oil return line (I'm still trying to track down the exact part number for this one. I pulled one off of an Audi TT with a TSI engine, but it doesn't have a part number on it)
You will need the different oil return line to clear the transfer case. On a side note, it uses a stainless braided line and is much nicer than the FWD rubber unit.
1K0407720A/B - Axle heat shield. Attaches to transfer case. You can also use the unit from other 4motion/Quattro cars, but you will need to modify it to fit.
3C0407272BD/HX - Passenger side front driveshaft/axle. This is the same unit as used on the Golf R, Audi TT, etc. The unit used on the 3.6 4motion Passat/CC will not work since it's for an automatic and has a different flange.

Front sway bar - Once again, you will not be able to use the FWD sway bar due to fitment issues with the new front transfer case.
I used a SuperPro 24mm solid adjustable sway bar, but once again, there are many AWD aftermarket options available.

All in one unit:
02Q300011CE - 6MT AWD transmission (Golf R/TTS/S3) - If you just want to purchase the whole thing pre-assembled from the factory. Please note that this is only the transmission and transfer case only!
You will still need several of the components from the building your own section above.

Optional components used in this build
3C8807521A - 4motion dual outlet valance
Since we were already going to need to make a new exhaust, I decided to just make a dual outlet one seeing as it fits the 4motion theme of the overall car.

...

Installation So Far:

Old subframe/suspension assembly removed


What we're left with after the stock fuel tank and subframe have been removed.


4motion fuel tank installed




New Heatshield installed


View from the back


New OE 4motion dual outlet exhaust valence being installed


Golf R Haldex rear differential and suspension installed


Different angle


Figuring out exhaust tip fitment




More custom exhaust fitment


More pics to come soon!

With everything going on with the car right now I more than likely forgot something, so don't be surprised if I update this post with new info in the future.
 

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Discussion Starter · #4 ·
Subscribed, naturally. :)
Thanks guys. :thumbup::thumbup:

I've been slowly getting pics resized and hosted, so bear with me.
I should also have the parts list updated a bit more later today.

Here's what we started with. All the rear end parts (and a few front parts too):

Ignore the large heatshield, I wasn't sure if I'd need it so I ordered it from a 3.6 CC. Turns out you don't need it.

Dis-assembly of the old rear suspension


Removing the stock rubber bushings from rear trailing arms


We ended up removing all the the weak puny stock rubber bushings so we could install these beautiful things from SuperPro:
 

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Discussion Starter · #10 · (Edited)
Awesome stuff Chuck, keep it flowin! :beer::thumbup:
Thanks dude! Your CC is one of my inspirations for this project!

More content coming tonight!

Bitchin :thumbup:
The PERFECT project :thumbup:
Thanks guys!

I should have more updates to the parts list soon for those looking to do their own conversion. :beer:

Shout out to TyrolSport for their support of this project! These guys know their stuff and you'll be seeing quite a few of their great products going onto the CC R.

Since we had to install the new AWD rear subframe, we installed a set of TyrolSport's great rear deadset subframe collar kits.
For those of you unfamiliar with this kit, the collars make everything sit completely flush and tight instead of having a gap between the hardware and subframe assembly.
Removal of the unneeded shifting of the rear subframe allows for significantly better response from the rear suspension.


Installation is very simple, (especially so if you already have the rear subframe off of the car).

Speaking of, this is the AWD rear subframe that you'll need if you're doing this swap.


You simply need to remove the 4 bolts holding the rear subframe to the car.
There are a few methods to do this, but I highly reccomend having access to a lift and proper supports to do it safely and efficiently.
Once you have the bolts removed, simply insert the TyrolSport brass collars and use the included new OEM hardware. Re-install subframe, align rear suspension and you're done.
I've got some pics of them installed on my work computer, but sadly I'm out of the office at the moment. I'll have them posted up here tonight.

Exhaust update
The downpipe section is complete and the catback portion is about 90% done.

42 Draft Designs crafted this extremely nice AWD downpipe with a V-band fitting at the bottom so I quickly install my test pipe for track days.


42 Draft Designs also supplied us with a pair of their 4" brushed stainless steel tips. These should be installed very soon.


Rear ABS sensors
Last night we installed the new rear ABS sensors. The FWD ones will not install into the new rear spindle assemblies.
We also extended the sensor wiring as the stock wiring would have been stretched a bit too tight and could possibly break.
So far no ABS faults, but then again there shouldn't be any yet since we still have to wire up the factory Haldex harness.

More SuperPro Bushings

We've got all of the SuperPro rear suspension bushings installed at this point. I do not suggest these as a DIY job at home.
Some of the bushings are a very tight fit and require specific tools to press in properly.

That said, these are some of the best made pieces of polyurethane that I've ever handled. The guys at SuperPro definitely know their stuff.
I can't wait to get this thing back on the road so I can test them out. :thumbup:
 

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Discussion Starter · #12 ·
So.... what the plan for the ECU?
Here's the thing. Pre-facelifted CCs (FWD and AWD) all use the same overall ABS system, which is very very good if you're doing this swap.
From looking at other people's swaps, I'll probably have to have the ECU coded to say it's AWD to avoid getting any pesky codes.
That's the least of my worries though, I can have someone here to re-program my ECU the same day if need be.
If this were a DSG AWD swap, there may be a few more caveats as far as the ECU, but Jason would be better to ask that question than myself since he's done one.
 

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Here's the thing. Pre-facelifted CCs (FWD and AWD) all use the same overall ABS system, which is very very good if you're doing this swap.
I like the way that sounds! I've always had this on my list of things to do, but I've never spent any real time researching it. In the past its been low on the list. It seems to be creeping up now.

Keep posting updates... I am taking notes :)
 

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My roommate and I were talking about all of this yesterday. I said, the CC would probably be a much sicker car if it came AWD in the 2.0T. I mean I already love it, handles great, sexy design, and people see it all the time and ask about it and give me compliments lol. But we were talking about how much it would cost to convert to AWD and I mentioned to him about this build. So rough estimate what would you say it would cost to do this build when everything is said and done? I'm just curious.
 

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Here's the thing. Pre-facelifted CCs (FWD and AWD) all use the same overall ABS system, which is very very good if you're doing this swap.
From looking at other people's swaps, I'll probably have to have the ECU coded to say it's AWD to avoid getting any pesky codes.
That's the least of my worries though, I can have someone here to re-program my ECU the same day if need be.
If this were a DSG AWD swap, there may be a few more caveats as far as the ECU, but Jason would be better to ask that question than myself since he's done one.
Was going to actually ask about what if I wanted to do this swap with the DSG Transmission. I did read most of Jason's build and saw the issues that came from it. However was wondering with the pre facelift I would assume I would still use the same DSG Transmission Jason used correct.
 

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I have no idea how much this would cost. We should start a pool and guess.. like guessing how many jellybeans are in a glass jar. :D

Then again... it would probably just muck up the thread. Scratch that jellybean idea!

Transmission is what would run my cost up... probably would opt for the Golf R tranny...
 

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Discussion Starter · #19 ·
I like the way that sounds! I've always had this on my list of things to do, but I've never spent any real time researching it. In the past its been low on the list. It seems to be creeping up now.

Keep posting updates... I am taking notes :)
Don't worry, I plan on updating this thread as much as possible.

My roommate and I were talking about all of this yesterday. I said, the CC would probably be a much sicker car if it came AWD in the 2.0T. I mean I already love it, handles great, sexy design, and people see it all the time and ask about it and give me compliments lol. But we were talking about how much it would cost to convert to AWD and I mentioned to him about this build. So rough estimate what would you say it would cost to do this build when everything is said and done? I'm just curious.
Cost is pretty much whatever you can get all the parts for. I am fortunate enough to work for a shop where I get very good deals on the many parts needed to do this.
For the average individual without access to such supplies or tools, I'd estimate the cost to be around $5-6k in parts and maybe around $4-5k in installation cost at our shop
hourly rate for a custom build like this. Keep in mind that I've been installing a few extra aftermarket parts that aren't necessary for the swap.
Depending on how you had the rear exhaust section made, you could possibly save some money there as well.

So far it seems like one of those "if you have to ask..." projects lol.
Sent from my iPhone using Tapatalk
Kinda sorta. I don't mind giving out quotes at all. It's more like people don't like hearing realistic prices for this kind of stuff.

Was going to actually ask about what if I wanted to do this swap with the DSG Transmission. I did read most of Jason's build and saw the issues that came from it. However was wondering with the pre facelift I would assume I would still use the same DSG Transmission Jason used correct.
I'm honestly not as sharp on DSG info as I should be. There have been several different versions of the DSG released between 2008 and now so I couldn't tell you for certain.

oh hell yes. I've wanted an AWD manual CC for so long. whats the running cost of all of this?
It's honestly how the R Line models should have come from the factory. At least that's how I feel about them.

I have no idea how much this would cost. We should start a pool and guess.. like guessing how many jellybeans are in a glass jar. :D

Then again... it would probably just muck up the thread. Scratch that jellybean idea!

Transmission is what would run my cost up... probably would opt for the Golf R tranny...
I'll try to get some relative pricing for people when everything is all said and done.
 

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So that dif in the pic is the peloquin? Curious about the aftermarket dif and its inclusion into the OEM 4mo. I am running the wavetrac so, this might cut my costs a little.

Sorry for the spamming of questions, but this is a modification that I think... well, it really needs to be done. Done on my car.

My wife is going to be so jacked when she finds out that the major modifying isn't done on the CC yet!
 
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