mk2

I've heard that some people warm up the cog to pull it off with finger force. But with that plastic needle race in there, I don't like it. Yeah, I'll have to mod one of my spare 3 legged pullers. Apparently the trick is to pull from behind without leaving so much as a nick or burr on the cog.

Yeah, completely agree. And good ideas chaps. Thanks. 👍🏻 I don't think the 02J box would fit between the chassis rails on a little lupo SDI? As it is there's only about 10mm clear between the 5th gear cover and the chassis leg. The caddy is wider. I was trying to see if I could get tools in there to get everything off without pulling the box. Tight but do-able! Would still need to lower that end during the work process though. The big question though, to which I can't find the answer without having two gearboxes in front of me is if i get the cogs and synchromesh cone from a 02A or J, would they fit the shafts from a 085. My guess is yes, but I don't want to spend £££ on a box for parts which I'd end up not using. Hmm. Hey, I just thought- maybe that's why they all fail- the bearings are tiny because they had no choice. The shaft centres are too close...

Or me.

Sounds good. You've engineered it properly I just want to try a different gear set for 5th and leave everything else. I can't find cross over part numbers to early polos and mk2 golfs, but I kniw for sure they share the internals with 085 boxes. I don't think 02J has the same gear internals as the 085. Interesting that the 1st gear is 10:1. I bet the clutch wears out faster than most with the TDI...

Ah. Ok, sounds like it needs a good soak in some biological clothes detergent. Will try it next week.

Tried silicone. Nope. No different. But soak the reel of belt material in what? What are we trying to do?

Just about every Lupo I've seen has front seat belt problems. They just don't like retracting. Haven't figured out why just yet, but I guess that this is a very common problem. If you manually feed the belt back up, it reels in no problem. Locking is fine as does the inertia reel lock system. Has anyone had a look at what's going on? Anyone had the same issues and successfully sorted them? What causes it?

Yeah, a lot of work for minimal gains. Don't forget to seriously service the auto box regularly. Trans fluid and filter AND diff oil.

Guessing that you're down south like me. Not a single breakers within 100 miles of Reading has a lupo that I'm aware of. Mad. Most Lupos on here are north of Sheffield.

Yeah, messed up. 0.74 is 100% (original). So 0.64 is actually 15.6% slower. Mmm. I need 25%

Running 185/55/14 = circumference of (185 x 0.55 x 2 + 14 x 25.4) x pi = 1756.5mm so if i swap to a spare set of 14s off a mk2 golf, 175/65/14 I'd get 1991.8mm per rev Gives a ratio of 1991.8 / 1756.5 = 1:1.134 (13%) 80mph compared to 64mph is a change of 1:1.25 or 25%. Wow that much?! 13% slower- Yeah that'd move the max torque to 72.3mph. Speedo 13% error! Getting there. Just realised that the 5th gear from an FLE box still wouldn't be enough as it's only a change of 10% i think. 0.74 to 0.64.... Or have I messed up my maths somewhere?

Yeah. Would need to use my gps phone as a speedo...

Yeah, i was thinking the same. Did over 300 miles yesterday on the m network (85 mpg!) and it dawned on me that the SDI is tuned as stock to be the most economical at exactly 100kph or 64ish mph. Too slow for me. I've gas flowed the inlet path so it definitely 'feels' more torquey than before. A lot. At about 100clicks you can really feel the torque band peak. And hear it now. But. the idea is that you don't even need to pull the gearbox out to change the 5th gear set. Just take the end cover off, remove the sleeves and clips, swap and reassemble. An hour's work I'd guess. And if no good, easy to put back again... Both the regular TDI and 3L have the same gear sets? I might try and get that x reg tdi in bristol for £250 and break it for bits. I have a feeling some mk2 golfs and breadvan polos also used the exact same gears.

I'm looking at changing the 5th gear set on an FFV box (that goes with an SDI). The existing ratio is 1:1.35 or 1:0.74 depending which way you look at it. I'd like to move the RPM from 3000 at 80 to 2400. So I think the gear set from an FLE will be about right. They are 1:0.64 Which cars use the FLE variant? Is it the tdi?

Ebay? Breakers?

I need to investigate a non working leccy window in one of my SDIs. It suddenly started working a few months ago on a day when it was below freezing the whole day. Then ceased again once it warmed up a bit. I have a hunch that the anti fingertrapping 'system' is based on an over-current sensor that measures the excess current before the top stop is reached. And if it is, chances are that by changing a 5p resistor or something could set the current to a different level (to compensate for friction and wear).

Leather lupo seats

Any other symptoms?

Yeah, I'd do both sides to be sure. Loosen off, then pull and push and retighten. You don't even need to take the wheels off ( but you'll need to jack up). Let us know how you get on... Oh, @Samsandwich welcome to CL

Yeah go 1040. A dishwasher cleans it well! or do a egr bypass...

Not always true with VAG stuff... mostly, but not always. Careful...

If the noise goes away when you put your foot on the clutch, but still doing 50/70 whatever and still in gear, the gearbox is still in mesh and spinning- so the noise would either get worse or stay the same if it's the box. Any slop/backlash between the gear teeth caused by bearings about to fail would usually give whine. Could be the diff, but unusual if it is. When the engine is under load, it pulls against the gear selector slightly, or opens up any gaps. I reckon that's what's happening. yeah, check the oil. Take it for a run to warm up then while still hot empty the oil just after you stop to see what comes out with it. Always worth changing box oil anyways...

Need more info

Gear linkage mech or perhaps clutch release bearing? Not gearbox. My bet would be gear mech linkage.

Could be a main power relay. They generate the same problems and fault codes. Yeah, could be a fuse. Fault to ground could mean that the injectors are actually ok, as is the wiring, but the 12v supply isn't there. So the ECU thinks that the supply has been shorted out (to ground). It should say, short to ground or faulty supply...