Project D2 S8 (FL) 01E Conversion.

[71camaro]

Originally Posted by Goran

Audi in the UK were happy to order parts from Germany for LHD cars.
FTF is from a A6 2.5 TDI, although I think A4 TDI used the same box (or similar). I'm not sure if any diesels made it over to the States, I was under the impression they were not popular there.
Your best bet I think is to talk to Tozo or go over and see him, you have the expert over there who has done two of these already. Maybe your cheapest option will be a S4 box, I think Tozo used those in both of his conversions. He may even have advice about the clutch master cylinder, from the pictures I dont think he used a stock one.

If you want I can go to my local Audi dealer and find the prices for all the bits, clutch master cylinder, slave cylinder, over-centre spring, hydraulic hoses etc.
But Tozo may have cheaper solutions than brand new parts.

I've spoken with him in the past, he didn't seem too keen on offering too much information, though I don't know why that would be. If you would be able to find the pricing out, I'd be most appreciative; I have a shipment of parts coming from the UK in September anyway, so these could find their way into the shipping container too.

We got TDi A4s and 6s, though as you said, they weren't terribly popular, and I don't believe manuals were optioned. I'd like to get that 5th and 6th though. Advanced Automotive sells the diesel box here, but for like $2500 USD, which seems very pricey for a unit that isn't new OE. Axles and propshaft are a non-issue.

[ainarssems]

There is always ebay.de

[Goran]

Originally Posted by 71camaro

I've spoken with him in the past, he didn't seem too keen on offering too much information, though I don't know why that would be. If you would be able to find the pricing out, I'd be most appreciative;

Thats a shame. No worries I'll find out the parts costs for you.
Just having a quick look, there are a few DQT's on sale in Germany, maybe you could ask them how much it would cost to ship to USA?
I got my gearbox from German ebay too, never a bad experience yet with Germans, fast shipping and very helpful.

http://www.ebay.de/itm/Audi-A6-II-4B...item3cc60b9dce

This one seems to be from a Passat, but maybe its ok since its a 01E?

http://www.ebay.de/itm/6-GANG-V6-2-5...item2a1c5d425a

http://www.ebay.de/itm/6-GANG-V6-2-5...item2a13fb810c


*another thing to mention is that both DQT and FTF gearboxes are listed in the Word document I attached earlier as having a Drive shaft flange ø of 130mm. I am worried about advising people to get wrong gearboxes, so best to research this before buying. I cant remember off the top of my head what the S8 manual gearbox (usually DGV) flange was, I have a sneaking suspicion it was 108mm.

[Nollywood]

Originally Posted by Goran

Anyway didnt you change your 5th to a TDI 5th?

I did. But that trans is not going into my S8, it's destined for another car, with a hotter than normal AHC motor. This will build massive torque from relatively low rpm.

[Nollywood]

Originally Posted by Goran

I cant remember off the top of my head what the S8 manual gearbox (usually DGV) flange was, I have a sneaking suspicion it was 108mm.

You're correct, it was.

[Goran]

Originally Posted by 71camaro

I've spoken with him in the past, he didn't seem too keen on offering too much information, though I don't know why that would be. If you would be able to find the pricing out, I'd be most appreciative; I have a shipment of parts coming from the UK in September anyway, so these could find their way into the shipping container too.

We got TDi A4s and 6s, though as you said, they weren't terribly popular, and I don't believe manuals were optioned. I'd like to get that 5th and 6th though. Advanced Automotive sells the diesel box here, but for like $2500 USD, which seems very pricey for a unit that isn't new OE. Axles and propshaft are a non-issue.

I went to my local Audi last week, here is what I found out. They no longer make the master cylinder for A8, and there is no stock left in Germany.

Part number-----Description-----VAG stock-----Price £
4D1721401------master cylinder-----0---------£231
811907343B-----clutch pedal sensor--5--------£16.01

They could not find the part number for the clutch pedal, so I'll try to find a different part number. Also I already have a printout for some of the smaller parts, I'll try to find that tonight.

What to do about the master cylinder. I located 2 on German ebay. one is priced ridiculously,
http://www.ebay.de/itm/AUDI-A8-4D2-4...item56489fd091

The other one is very reasonable but no picture,
http://www.ebay.de/itm/Kupplungsgebe...item4cfebf0378

[71camaro]

Hmmmm.... I fear I'll have to make due with other VAG parts bin items. Which is unfortunate as, like I said before, Tozo seems unwilling to be forthright with his knowledge in this regard. Axles and the driveshaft will be non-issues as I have a shop locally that will modify mine. I can extend the shifter as needed. So, pedals are the only holdup it seems. And perhaps a few sensors and the like.

I must say, I'm quite excited to get to working on this; as discussed in another thread, my eventual goal is to add boost and get the car around 550 bhp. I love the lines and interior of my D2, I'd like to have it match the performance of the new car at a greatly discounted price while looking-at least in my opinion-better while doing so.

[Goran]

If I were you I would get all the little parts from Audi, unless you are really good at fabricating I dont think its worth trying to make these.

Here is the picture I was trying to find (its from www.vagcat.com, but that site has been down for days). Here you can see all the parts you already have (for the auto pedals) and the addittional parts you will need.



Attached also is the parts number list as a Word document.

As you suggest you can probably use a different VAG clutch master cylinder, perhaps from a Audi A4, I think they all have 30mm travel. You may need to cut a piece of aluminium sheet to cover the bigger opening for the A8 master cylinder though.

Here are the parts I bought from the diagram above to give you an idea of pricing.

Part no-----------description---------------------------------------price £
4D1721465M------metal hose from master cylinder to slave cylinder---71.50
857721453--------rubber hose supply to master cylinder-------------10.96
4D1721485--------slave cylinder to gearbox bracket-----------------11.24

I bought a slave cylinder also but cant find the price. I think it was around £100.

[Goran]

I was not convinced that machining the pedal box casting to fit the master cylinder, and needing a custom over centre spring was the best solution so I thought of an alternative.

I simply rotated the entire master cylinder assembly out of the pedal box casting so it would sit on top, and re-shaped the clutch pedal design to fit.
Inspiration is mainly from Audi A3 / Golf clutch pedal assembly, I bought one of these for £20 off ebay, and it came with a over-centre spring too.

In up position the clevis meets the pedal at 85 degrees, this seems to be how the stock LHD clutch pedal is set up. Master cylinder moves through 30mm, and is 75mm from clutch pedal mounting centre, so I made the over-centre spring arm 75mm too. This is how the A3 pedal was set up too, master cylinder mounting point was 58mm from pedal pivot point, and that was more or less the lenght of the lever arm going to the over-centre spring.

New list of requirements: custom clutch pedal (with polybush bushing), custom aluminium mounting bracket for master cylinder and over-centre spring (welded or bolted to pedal box), move brake pedal spring mounting to right side of well, custom mirror image brake pedal spring, ebay M8 clevis.

A few potential issues:
1) over centre spring is just underneath the master cylinder, may need to machine the pedal box casting a little so it can move freely.

2) over centre spring is 30mm wide, it will fit between the brake booster piston boot but with only a couple of mm clearance.

3) the re-designed clutch pedal reaches up 11mm above the height of the sensor bracket. I have had a look in the car without removing the trim and it seems like there is enough space up there, but not much.

Here are some pictures of a wooden test pedal, A3 over-centre spring and S8 stock clutch master cylinder.

[Dezzy]

nice work goran but 71camaro wouldn't need to manufature / modify a pedal box just get hold of a pedal box and assoiciated bits from a left hooker eh? as he won't have the starter motor bulge to get over.

It's easy for the guys already sat over on that side, like a 20 min job or something