Flywheel & clutch for 2.5 TDI/T3

Post by **Pat Dolan** » 01 Jul 2008, 13:49

Those with a very good memory may recall that we bought some of the bits to do this swap a couple of years ago, but business, medical and family committments have left it sitting in a corner most of the time.

To update: we had to hire a full time mechanic, since this, and a bunch of other projects plus farm work were not getting done. He got well into a bunch of stuff, and his shoulder joint blew out, so we were at full stop for another year.

Fast Forward to now (sorry David, I couldn't resist): It is taking up hoist space in the projects shop, so it wil now creep forward. The gearbox is out to Glen Cook in Burnaby BC for Weddle top gears, full rebuild, factory decoupler (keeping VC) and Peloquin diff. Pump is at Giles Gallie (performance diesel in Toronto) to get converted to m-tdi. It took the original 2.5TDI, a 2.4 pump casting and 2.0 guts to make one 2.5 m-tdi, but well and truly worth the trouble. If I had found a complete 2.4 NA pump, that's all it would have taken. Both will be back in a week or so.

We have the RSA bellhousing, mounts (hydraulic) and will be trying our best to keep the whole thing under the decklid.

I may have asked this before, so please forgive me, but it has been so long: What about flywheel and clutch? The 2.5 should be a torque monster, so even the 228 is questionable. I was hoping for 240mm. What vehicle(s) have this for inline 5s? My hard parts supplier tells me he has a 240 mm flywheel, but from the same page, the clutch disc for a T4 Eurovan NA sold in Canada ('96) is 228. What gives? Was there a 228 clutch on a 240mm surface??? HHHEELLLPPP!?!?! Also, is there a better clutch cover and disc at any size? I have heard that a 944/968 setup will fit, but really don't have a clue.

Pat

Post by **moonshine** » 01 Jul 2008, 21:39

Pat,I've just looked it up on vagcat and the AEL/AATs have a 240mm clutch.

http://www.vagcat.com/epc/cat/au/A6/199 ... 9/1698998/

Post by **Pat Dolan** » 02 Jul 2008, 14:02

Moonshine:

Many thanks for the answers/links. I have never encountered vagcat, but you can be assured it will live on my screen for many more reasons.

If you look carefully at the page, both 228 AND 240 clutch parts are listed. Unfortunately, only the AUDI flywheels are listed, and, since no 2.4 or 2.5 Audi diesels were ever sold in NA, we have no such listings for the 046 parts. However, we DID get the 074 (2.4NA in T4) and that is the one I can get a flywheel to fit (074 105 269E). What I have to determine is if that flywheel has enough room for the 240mm parts (as is suggested by the vagcat page for the Audis).

Pat

Post by **moonshine** » 02 Jul 2008, 17:42

Pat Dolan wrote:s.

If you look carefully at the page, both 228 AND 240 clutch parts are listed.

Pat

yes,but only the AAT and AEL are diesels and they are def 240mm

Post by **Pat Dolan** » 03 Jul 2008, 00:54

moonshine wrote:
Pat Dolan wrote:s.

If you look carefully at the page, both 228 AND 240 clutch parts are listed.

Pat

yes,but only the AAT and AEL are diesels and they are def 240mm

I ordered the only easily available flywheel today, and a 228 clutch kit. However, if there is any way I can squeeze a 240 in there, I will. The only 240 they had at my supplier did not, though.