93 cabby project

[scottyc]

Yes!!! I can start my conversation.
I have just found a manual box, steering rack, selector rods, drive shafts, fly wheel, starter and cables which i will pick up next week.

Just a few questions before i do it.
Will a earlier steering rack fit a later model, just concerned with the U-joint matching up?
Will I be able to just fit a clutch pedal to my existing pedal box as its a later model or will I need to replace.

Thats it for now, but I'm sure ill be asking more questions once I'm in the thick of it all. Cheers

[The One]

Wonder if this will give you some help mate?

Question Auto to manual

Re: Auto to manual
I'm currently in the middle of said swap on my MKI, and have already completed this swap on my MKII Jetta.

1st of all, as far as I know, there is no such thing as a MKI with a hydraulic clutch.

Here's a list of parts you will need:

1. Transmission: to make this swap worth it, find a 5-spd transmission. An 020 out of a MKII will work also.
2. Engine Mounts: You need the Front, Rear, and Transmission mount. Make sure they are for whatever transmission you are using. 4-spd and 5-spd mounts are different.
3. Pedal box: There are 2 kinds of pedal boxes, one with a brake light switch, one without. Some MKI's have the brake light switch mounted on the master cylinder.
4. Shifter Rod and box
5. Shift linkage and relay rods: Again, make sure that you get the parts that pertain to either 4-spd or 5-spd. Almost all parts are different. IIRC, 4-spd relay rods have white ends, 5-spd have black ends.
6. Clutch, Flywheel and pressure plate
7. Steering Rack (YES, you need this): The MT steering rack has the mount for the shift linkage to bolt to. The AT rack does not have this.
8. Clutch Cable: Much easier to adjust a new clutch cable than an old, rusty one.
9. Throttle Cable: The automatic uses a really strange 2-cable setup, you will not be able to use these cables after you do the swap. What type of cable you need will depend on if it's Carb, CIS Mechanical FI, DigiII EFI (MKI Cabrio), or Diesel. If it's DigiII or CIS, you will probably have to change the throttle body as well, since the arm on the TB might be different from the Auto TB, and they are not interchangable. (I remember this from the MKII swap, MKI may be different.)

Also, make sure you determine if your new tranny has the same size axle flanges. There are 90mm and 100mm flanges, and the inner CV Joint must be the same size. This is not so much of an issue on the MKI as it is on the MKII.

Things you should consider renewing before you install the parts.

1. ALL Shifter Bushings
2. Shifter Relay Ball
3. Relay Rods
4. Clutch assembly
5. Axle Flange Seals
6. Input Shaft Seal
7. Engine Rear Main Seal (since you have the trans out anyway.
8. Starter Bushing

[scottyc]

Hi guys, Well its been a while since the last update. The parts I went to look at many months ago were no good. The guy had all these spares in his shed but failed to tell me that the shed has been flooded twice. two hour drive to find theses parts are rusty, seized.
After months of looking for parts I found a complete car for a donor vehicle and its a manual. 163ks on it and some other trims etc..... thats also needed for my sons golf. Paid $350 for the hole car

The same day I found this car I also found a right off mk1 cabby with a brand new convertible roof that was fitted not long ago. I got the complete roof and frame for $180.
Once all these good part are on my sons car, Its going to look mint.

[sports racer]

Two steps forward and one back, typical progress with a MK1 but it's good to hear you're getting the parts you need and at a good price.

Time to build up another MK1 for yourself?

Cheers

Paul

[scottyc]

Oh yes mate its been a head banger trying to find parts or a donor car. Well at last were on the right track now. Both gearboxes are out and steering racks have been swapped. I hope to get the manual box in in my sons car tonight. Then is just clutch pedal, cables and starter wiring. I hope the drive shafts fit to, that would make it easier..

[nightphotographer]

Hey mate - I've got loads of Cabriolet parts if you need any - including manual pedal box etc

Also you'll be happy to know both auto and manual drive shafts are identical as far as I can tell - I've got both and have the shafts side by side and they're identical in terms of length, diameter - haven't compared flange ends at the box though.

[sports racer]

Here's some incentive. Never seen this bodykit before but it suits the Cabby.



Cheers

Paul

[sports racer]

And another one

[scottyc]

Manual box is in and working,
Driveshafts was the same. couldnt believe the revers light plug was already there tucked up at the way, so that saved some time.
Could anyone tell me what colour wires to bridge for the auto selector switch?. for now I still have the auto shifter connected to the wiring with the selector in park so the car starts.


I also picked up a new roof this weekend. $180 for the complete roof. I will remove the roof cover from it to fit to my sons car.

Im looking to find a rear window frame if anyone has one for sale? out of the three roof I now have there all rotten

[scottyc]

Hey mate - I've got loads of Cabriolet parts if you need any - including manual pedal box etc

Also you'll be happy to know both auto and manual drive shafts are identical as far as I can tell - I've got both and have the shafts side by side and they're identical in terms of length, diameter - haven't compared flange ends at the box though.

Hey bud, shafts were the same so it went straight in

I had a radiator from you a while back, Thanks again for that. Im now looking for a rear window frame thats thats not rotten, haha

[sports racer]

Could anyone tell me what colour wires to bridge for the auto selector switch?. for now I still have the auto shifter connected to the wiring with the selector in park so the car starts.

I don't know what colour the wires are but find out which wires the selector affects, disconnect the selector and wire in an on/off switch to duplicate the action of the selector. Hide the switch somewhere and you've got an additional antitheft system.

Cheers

Paul

[scottyc]

Hide the switch somewhere and you've got an additional antitheft system.

Cheers

Paul[/QUOTE]


Thats a great idea sports racer, Ill do that.
Still can't find a rear window frame thats not over priced

[nightphotographer]

Hide the switch somewhere and you've got an additional antitheft system.

Cheers

Paul


Thats a great idea sports racer, Ill do that.
Still can't find a rear window frame thats not over priced

I have a rear window frame - how much are you looking at paying?

[scottyc]

I have a rear window frame - how much are you looking at paying?

hey mate,
would interested bud, the less its going to cost me the better, hahaha. Its for my son so its for a good cause, hehe
if you throw a price out there were go from there. I have to consider postage to.
Go on hit me with a price!!!!