mk2

From looking at the failure mode on them, the gears and shafts are fine. The housing also can take the torque. It's the bearings that give up as they're just teeny weeny little things. Usually caused by yellow metal in the oil getting trapped in the bearing rollers, causing pitting, then failure. Or leaky input selector shaft seal, low oil level, causing needle roller bearing cage inside gear 5 melting (made of plastic). Or syncros being forced as clutch not being fully disengaged- caused by broken pedal box (the most common reason). Lots of metal in the oil leading to bearing failure. Again. The 085 box is based on tried and tested old mk1/mk2 golf design. Only thing that changed is the oil, to bring down the friction. So they used thinner oil. Not good. Good for economy, but not endurance.

Be cheaper to swap the entire engine after bearings and headgasket etc...

Pics i took in here... https://forums.clublupo.co.uk/index.php?/topic/63534-mending-cleaning-lupo-indicator-stalk-lever/

Don't drive it... at all. get it sorted now or it'll cost a lot more later... Might just be the synchro clutch cones have become glazed. You still need to strip and rebuild it though. Worth it if you plan on keeping the car.

Dunno if you noticed, but on the back of the block is marked 1.9... Our little 1.7 AKU SDI is in fact a 1.9 ready to go- just on a short throw crank. Pull engine out and directly transplant the 1.9 ASV turbo in. It fits like it's made for it. Afternoon job when properly planned. Then just the wiring and you're away... You can chip the ASV to 133hp. yes the box is weak, but if rebuilt for £100 every 30k, not a problem. CV joints will also go sooner, but they're only £35 a pair. I've been mulling over the exact same project. Time is lacking sadly.

Do the EGR delete and sump fume diversion too. If you want more power and efficiency, you can also gas flow the inlet trumpets. It's on here somewhere...

Fully synth ep75w90 is what i use from these guys. 3.1L https://www.westwayoils.co.uk/ but we have the opie oil rep on here who might be able to give a club discount. They have some good lube. i'd personally get a new back door fix the arches and swap the fuel lid. The car would instantly be worth a sh!t load more. what's the inside like? I'm just doing up another SDI right now. Sourced a new drivers seat cover from Germany (passenger side over there). You'd love a Lupo 3L steering wheel. Ok, so i would, but they're rocking horse poo over here and stupid money in Germany. oh, and I was out today cruising at 80- rev counter reads exactly 3000 at that speed, so you can do gearbox ratio tests.

Yeah, deffo the pinion bearing by your description... hopefully the outer race of the bearing is still tight in the casing allowing you to replace it. Once the casing has gone, it's too late to salvage. Be a shame to rat it. I've never seen an SDI in that colour. Might be rare (worth more). Just noticed- Lupo in Durham. What is it with Lupos in Durham? There must be thousands running the streets up there!

ETF has different ratios to FFV, so the engine will rev higher... Did the old box whine in all gears or just one particular one? If all, it's the pinion shaft bearing that runs into the the diff crown gear. They do go, but that bearing is easy to press out and replace. But if too far gone, the outer bearing starts chattering after which it cant be fixed, as it just sits loose in the casing. Can't be pressed in- loose fit. Don't dump the old box... and take care stripping it (if you're brave). Rebuilt, it's worth decent cash. Personally I always take my boxes to a local guy who knows this stuff in his sleep. An expert will tell you straight away if it's worth fixing. The seal and bearing kit is about £90 on line (for a total rebuild). love the colour!

Welcome. yeah, don't drive it if it whines. At all. It may just need a £2 part to fix it.... usually the needle roller bearing inside gear 5. Before getting a new box, have it stripped and checked. Strip down takes just 15mins. May still be salvageable at minimum cost (about £150 incl parts and labour), and you'll have a box that is like new. FFV code boxes are hard to find (for SDIs)....

Hey hey! Welcome to CL! show us a couple pics. Check gearbox oil, egr and cam belt. The rest is basic/regular maintenance stuff. May we ask what you paid/how many miles/what condition...

Looking good! You've done a fair bit already. Not much left to do now by the looks of things. Maybe a day or a weekend of time needed. Get any used bumper/front setup and have a local place spray it. Do the prep work yourself to save a handful of cash. keep us updated with progress

Ray doesn't get paid for his time... completely voluntary I believe? All for the good of maintaining the high level of moral fibre on the forum. And for the enjoyment of Lupo enthusiasts

Do diagnostics still say the same? As in injectors open circuit...? Electrical problem. On the engine loom, is there a plug with lots of wires connecting the engine to the car? It may have been moved/loosened when the EGR was looked at.

I think Angry is the wrong word. Jealous. It's gorgeous. The car that is....

Yeah, look here... http://www.oemepc.com/vw/main_group/markt/RDW/modell/LU/year/2005/drive_standart/441/hauptgruppen/1234567890/lang/e

It's looking good... keep going. Adjust it at the hinge and the corner stops. Loosen everything then keep tweaking till it sits right. You may need to adjust the centre catch on the slam panel too (you can't do it till the catch is in). Yeah any Lupo dash will do. Shame it wasn't the driver's side airbag. Much easier, as it's in the steering. just bumper, lights, alternator, grill and grille surround and you're back in business!

Nice mk1 in the background...

Ah yes. Ghosts in the machine...

There is a fault which is causing the problem. The light is there to let you know it is serious enough, so if you don't get it checked you might get stranded somewhere.

Yeah, I have been having similar thoughts. But I need at least one economical/cheap car with 4 doors that I can use on long journeys and park in supermarket car parks. A red GTi would be nice. I presently have another leak in my mk4. Another.... and can't find it. I wonder if there's a list of mk4 leak locations. Will have to go on the mk4 forum. Boring lot.

Aha!

Good stuff. May I request mine without the pins or clips. Do you want payment up front? Let us know the transaction process...

I know, but thought it'd be an interesting read.... kinda related. Everyone knows that the key to more power is more airflow in an NA engine. So the way vdub get the extra 25Hp is mainly inlet in this case. Personally, I'd just transplant as suggested, complete with loom and ECU. Certainly the easiest solution. And as mentioned, cheap too. But all that effort for just 20 odd hp?! Too much bother for me.

Read... http://forums.clublupo.co.uk/index.php?/topic/52765-can-i-convert-my-14-75hp-to-101hp/