All Things Mk5 > How to Guides / Troubleshooting

AWD / Quattrro Conversion

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olethalb:
As prices are coming down and seems to be more popular i thought i'd share my experience with performing FWD to Haldex conversion - if anyonew has any part numbers or something i've forgotton feel free to chime in  :happy2:

First, Parts;

Gearbox with transfer box
transfer box to block mount / bracket with bolts
heat / driveshaft shield that atattches to the above
Drivers (right) driveshaft (passenger shaft is same as fwd)
front quattro ARB
prop shaft complete
prop shaft mounts 1k0 804 332 and 1k0 804 331
prop centre joint heatshield + bolts
complete rear assy - subframe/ diff/ arms / hubs / shaft / haldex / arb + mounting bolts
fuel tank from quattro (saddle) inc tank straps / heatshield / sender unit / quattro pump (ttrs popular option)
abs and esp controller from quattro car
some sheet metal as cutting of the wheel well is required
rivnuts or similar as tank straps land in a different place
exhaust from quattro car or modify existing to snake around diff
there are also wiring mods / additions that need to be done to get it all up and running (don't forget a decent earth strap from haldex to chassis)

Some of the parts together


Box without transfer box fitted


Tank with second sender fitted


Quattro vs fwd rear arb


Rear assembly


Ttrs pump


Rear frame comparison


Tanks


Wheel well trimming


Closing up wheel well


Tank with heatshield / prop and rear assy fitted



Exhaust route modified


Fwd vs quattro right side shaft



Transfer box and bracket fitted


Prop mounts welded in place


Prop fitted with heatshield and exhaust


Esp and abs units used note esp mounts upside down (bracket made)







Now some pics of wiring if i can remember what was what....

Green and white jumper / loop wire added to abs plug




Can wires tapped into airbag plug loom


Ignition live to haldex tapped into cecm plug


Additional sender wire (yellow in pic) added into plug for clocks


I have more loom pics but cannot find them at the mo :(

xjay1337:
Very useful thanks for doing this olly.  :happy2: :happy2:

r5gtt:
That's excellent mate, I'd love to have the balls to do that  :jumping: :happy2: :happy2:

Was it all just bolt on parts?.

Is it all working properly?.

Also how much for the complete conversion please?.

dazza:
Nice one olly. Have you started on your next project yet?

r5gtt have a read of this my favourite build on the forum.

http://www.mk5golfgti.co.uk/forum/index.php/topic,96044.0.html

r5gtt:

--- Quote from: dazza on January 20, 2016, 11:12:20 am ---Nice one olly. Have you started on your next project yet?

r5gtt have a read of this my favourite build on the forum.

http://www.mk5golfgti.co.uk/forum/index.php/topic,96044.0.html

--- End quote ---
Thanks dazza  :happy2:

What a great read and an awesome conversion  :jumping:

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