Tweet
(VERY) Long story short, I am now running 222bhp with 390ft/lbs, which has been lovely for a while.
But the friction plate on the stock ACV (DXG) is slipping. It just can't cope with the power.
http://www.t4-wiki.de/wiki/Getriebekennbuchstabe
ACV/DXZ = Overall Ratio in 5th gear (final drive x 5th gear) 2.847:1 = Theoretical Road Speed @ 3,000rpm 81mph (130km/h)
AXG/DQR = Overall Ratio in 5th gear (final drive x 5th gear) 2.737:1 = Theoretical Road Speed @ 3,000rpm 85mph (137km/h)
The DXZ can only house a 220mm clutch, a paddle clutch that size may handle the power but it would be too aggressive.
With a larger bell housing, the DQR box has ability to house a 240mm clutch. So we can put a less aggressive (organic) clutch in but it can hold more power.
2cm seems like nothing but in real terms there is 289.03cm² extra surface area. Which is a lot.
Not been able to find anyone else who has done this but it is all T4, so it should all be a direct fit, right?
Managed to source a DQR gearbox from Auto Parts 24 which was shipped from Denmark of all places.
Not cheap by any stretch of the imagination... but when it turned up, it looked mint!
After this rather large purchase, it look me a few months to save up to afford to have a go at putting it in.
(I was also having a ProjektZwo body kit put on, that put a rather large hole in my pocket. Watch for a blog on this soon)
This is the much larger friction plate and clutch.
-------------------
This week, the Supermen at MV Engineering stepped up to the job, an unknown, and began work.
Problems arose very quickly.
Turned out that the drive shafts were NOT compatible. Neither is the intermediate shaft... or the starter motor.
For an extra 50bhp, VW went bat-shit crazy oversized, making everything HUGE. Who ever heard of 130mm driveshafts, on a van!!!!!
Tried removing the ends to see if we could do some kind of mix and match Lego setup but it just wouldn't go together.
Look at the difference!!!
Luckily, MV Engineering currently has a 151 AXG Autosleeper in the shop right now, so they were able to measure up and get the part numbers for everything we needed. As apparently, there is about 6 different types.
Come to far to turn back now.
The good, if somewhat expensive, news from all this... The new AXG setup will have the ability to take "much" more power.
So, long term, if I decide I want to push on further (not something I am planning right now) then there will be plenty of scope for the drive train to take more.
Going to have to sell my old ACV(DXZ) gearbox and drive shafts for well over £2k to get my money back on this...
Seriously, the drive shafts and gearbox will be for sale at some point. Would be a perfect kit for converting an auto to a manual box.
Anyway, we now have parts on back order.... Shall continue with the blog when they arrive....
Good news.. with a sprinkle of bad, of course....
Parts arrived from VW:
Complete genuine VW AXG driveshafts - Check
Driveshaft bolts - Check
Bolt spacers - Check
Speedo drive plug and connectors - Check
Driveshaft output seals - Check (May as well replace these while it's all being done)
Starter motor - Check (ACV doesn't fit!)
BUT....
Intermediate shaft bearing - Back order
Intermediate shaft - Back order
On asking how long I'd have to wait for the intermediate bits... VW said "17th... of March!"
Mario being the superstar he is, managed to track down a second hand one from Germany, which should be here by Tuesday(26th).
Starting to get close, as the van is going to be on the stand at CamperMart, Telford (31st)
Getting close...
--14th January 2016--
-----------------------------------
Few snaps of the bits that have arrived.
New vs Old ... The AXG drive shafts are 21mm bigger!
Even the bolts are much bigger....
Hoping that the 2nd hand intermediate shaft arrives from Germany today...
--25th January 2016--
-----------------------------------
IT'S IN!!!
So, the good news is, everything has gone together and Bongo Fury is now fitted with full AXG running gear.
The only slight downside is, that the new 240mm clutch is slipping quite badly.
Which was kind of the whole reason we upgraded in the first place!!!
But on the flip side of that, the clutch is VERY light, so we are going to upgrade the springs in the pressure plate.
Giving a stiffer clutch pedal but hopefully meaning no more slippage.
--31/01/2016--
-----------------------------------
Eddy sorted out the gearbox connection for the speedo today.
Big thing as I need the speedo but more (well as) important that that... the fuel gauge uses the speedo.
It only checks the level if the speed is the same for X amount of time, so the fuel isn't sloshing about.
When you accelerate or brake or go round a corner, the van thinks you are still doing 0mph, so it checks the fuel and goes BEEEEEEP to say you are running low/out of fuel.
Bloody annoying!
--10/02/2016--
-----------------------------------
Friction plate news!
Mario did a bit of research and there is GOOD NEWS!!
Now we are running the AXG 240mm clutch, there are LOTS more options for use by way of pressure plates.
The one we are going for is a Sachs SF, also put onto SEAT Leon FR's
OEM AXG vs the Sachs SF. Spot the difference:
OEM AXG: £70
Sachs ZF:£240
Not only are the springs much thicker and therefore stiffer but also the plate itself has a different friction surface for better transmittable torque.
Originally posted by Sachs Website
Hoping this will solve the issue, as the clutch slipping is VERY annoying. Having all the power & not being able to use it. Bordering on painful.
--11/02/2016--
I haven't translated it yet, but there does seem to be an awful lot of interesting info on there.
Can't wait to see what happens next.
TURK
I know this is an old thread, but I'm doing the same conversion and I'm beginning to be desperate because for some reason the drive shaft on the left side won't fit and it's too long. I have a 2001 ACV and the donor is 2001 AXG. I looked up the parts and cannot find a difference in the subframe, lower or upper wishbones. I'm changing the gearbox, intermediate shafts, drive shafts, bearing knuckles and brakes from the donor vehicle.
I'd appreciate any hints, thanks!