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Discussion Starter · #1 ·
In August 2007 my car, a '92 VR6 blew the head gasket a few days after turning the boost up a bit. It was really just a matter of time and I fault the stock gasket with 168k miles on it more than the added boost.
I decided to tear it all apart over the winter and rebuild it with a bunch of "while you're in there" go fast and maintenance parts. It's gotten a little out of hand since that day in August. A lot of work has been done over the winter, so I'll do my best to back log most of it and then post updates as I get this thing back on the road by June 7th, 2008.
 

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Discussion Starter · #3 ·
Re: Project VR6 What! (corrado-correr)

Admittedly 2 wheel smoky burn outs are less cool than 4 wheel smokey burn outs - but they are decidedly better than one wheel smoky burn outs and clutch smoke.
Tearing apart the transmission for inspection of gears/syncro's, installation of Peloquin LSD, and tdi 5th.



transmission fluid really is nasty stuff.
 

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Discussion Starter · #4 ·
Re: Project VR6 What! (corrado-correr)

In order to insure the diff was properly shimmed I put everything back to together for a test fit.

Shift forks installed, I had a hell of a time with keeping these suckers in their place until I realized you're supposed to (per the Bently) have the tranny tilted at a 45degree. Presto!

Almost no parts left!

Authentic VW "Sealing Paste"

Almost fully assembled.

The size difference between the TDI 0.75 and the stock 0.83 is surprising noticeable.


At this point the races checked out and were with in spec to the original factory installed shims. I hear this is common when you have a matching case, but its always good to check. I ran into a probable however in that the gears were binding and the trans wouldnt spin freely.
After taking this thing apart 4-5 times I realized the pinion ring was installed on the diff upside down. A quick fix, put it back together again (pretty much an expert at this point) and every thing was right as rain.
A few days of scrubing, some time with a pressure washer, 6 botles of degreaser and I had the case looking like this:
 

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Discussion Starter · #5 ·
Re: Project VR6 What! (corrado-correr)

Some time around this point, after getting the Trans figured out I ran out of momentum and got distracted with a few other projects over the winter. Over the memorial day holiday I got it in my head that I might actually get this thing done in time for the first big show here in MI.
Took apart the head to check for flatness (for lack of a better word), just in case it had warped from the blown head gasket. And did manage to take a few more pictures:




I checked it with a straight edge and a feeler gauge, and couldnt find a single high or low spot. I wasnt too surprised here because the car never had a chance to over heat.
 

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Discussion Starter · #6 ·
Re: Project VR6 What! (corrado-correr)

New Parts, Autotech 13lb flywheel, new clutch and timing chain kit:


The new head gasket/spacer set up will drop compression from 10:1 to 8.5:1. The gasket is comprised of a two piece mk4 metal gasket that is split and then sandwiches the stainless steel spacer. You want to spray the two gaskets (not the spacer with the permatex high temp copper gasket stuff.


New timing chains installed. The head is bolted down using ARP fasteners. Torquing order is same as stock (basically just diagonally from the center out) but the stronger studs can with stand a ton more torque. We stepped it up from 23-49-65-80 ft lbs.


While doing putting the chain covers back on I ran into an issue when installing the upper chain tension. My motor is out of a 96 Jetta, so I have the plastic valve cover and the dual timing chain. This being the first time Ive done the chains on the car, I ordered the new style chain kit-recommended for better durability and ideal for the dual chain setup (also cheaper). The only thing that wasnt back wards compatible with the new timing chain kit was the upper timing chain tensioner bolt. Pictured here is the full chain kit, the tensioner is the large brass bolt in the middle.


The new style upper chain tensioner doesn't thread all the way into the early style upper cover. The problem lies in that the new style cover is threaded all the way through, while the old style (the one i have) isnt threaded all the way. Apparently 92 distributors are some of the only cars to get the "old style" covers - which is what I have to make the new '96 motor work with me obd1 distributor setup.
Not being able to find a 22m x 1.5 Tap locally on the Saturday of memorial day weekend, I oped to port out the back end to get the new style tensioner bolt to thread in all the way. Vortex recommends forcing the new bolt in a 1/4 turn at a time using "lots of oil". I wasnt comfortable with this so I went with the Dremel and never looked back, I only removed (max) a few cubic mills of Al from the back side of the case.
Next up, the valve cover, lightweight flywheel and the clutch assembly.




Modified by corrado-correr at 5:42 PM 5-28-2008
 

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Discussion Starter · #7 ·
Re: Project VR6 What! (corrado-correr)

Monday I was determined to get the transmission in. Here's the transmission lookin' funky fresh on the floor waiting to go back in his home.


Ryan and I struggled with it till it almost landed on my head, then we called around for an engine hoist. Ryan is crazy:


Engine and transmission are in and bolted securely to the motor mounts. The shiny trans looks so out of place in the dirty ass bay.




Oh, and we found a turtle that day... sweet!




Modified by corrado-correr at 5:41 PM 5-28-2008
 

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Discussion Starter · #8 ·
Re: Project VR6 What! (corrado-correr)

Brand new thermostat housing and all new temp sensors. New one on the left, old one on the right.


I took the front cross member off sanded it and hit it with some rustolium. Also painted the front motor mount. Installed the thermo housing and new billet crack pipe.




The obligatory "Fuke you old crack pipe!"
Sensitive content, not recommended for those under 18 Show Content

Lower intake manifold, new gasket, fuel rail, 4.0 bar fuel pressure regulator, and 30# injectors.

installed

Thats it for tonight suckas.
 

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Re: Project VR6 What! (corrado-correr)

Love it, love it, love it.
Amazing how clean that tranny came out... looks like it was painted.
One problem: Where's the beer?
Keep us updated...
 

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Re: Project VR6 What! (corrado-correr)

Any time you feel like headin a couple hours south.... Why don't you just go ahead and take care of my tranny...
There is no way that tranny isn't P-shopped.... how the hell did you get it so damned clean?
 

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Discussion Starter · #15 ·
Re: Project VR6 What! (gunnr0991)

Quote, originally posted by gunnr0991 »
There is no way that tranny isn't P-shopped.... how the hell did you get it so damned clean?

here's an intermediate step (I was orginally going to polish the whole thing untill I realized it was a ton more work that I wanted to do
):

 
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