CJ's Stage 3 RS4+ Blueberry Build Thread

[CJ_]

So I've been doing some research and since I have the diff out right now, would it be worthwhile to do the 4:1 center diff washer mod? Anyone have experience doing that mod?

[erykv1]

So I've been doing some research and since I have the diff out right now, would it be worthwhile to do the 4:1 center diff washer mod? Anyone have experience doing that mod?

the diff mod is easy to do even with the car back together (obviously easier now). depending on the revision of diff you have its either a simple mod, or could be a complicated one. later year diffs require a different thickness stack to keep the diff happy. the earlier style diffs utilized the same thickness washer/shims.

[christianb5s4]

Is there a way to differentiate which diff is on the car?

[erykv1]

Is there a way to differentiate which diff is on the car?

on the car? no, but once its out you can tell based on how the windows are cut on the diff itself.

[CJ_]

Does anyone know if this is supposed to be happening? During my trans rebuild, after mating my front diff housing and the middle gear housing, when I would turn the 3rd-4th gear shaft, it would not spin freely, and made a grinding/ticking noise. After taking it back apart and inspecting everything, this was the only thing I could find that did not seem right. When the shift collar engages the gears, the synchros get stuck halfway up. Is this only going to happen when the shaft is out of the car? Is this anything to worry about?

In short:
-Mated front dif housing and gear housing
-Shafts did not spin freely
-Took back apart
-Inspected everything
-Noticed 3rd-4th synchros not snapping back
-Is this a problem?

Video:

[Blake2423]

Are the synchro springs in there correctly? it almost seams like they could be in backwards. If not then it may just be lack of lube

[armageddon-]

I would say that's normal when comparing to this: https://www.youtube.com/watch?v=etE85I8aKSs

[JayCar]

I think the syncros actually function when the gears are in motion. They actually use the momentum of the spinning of the gears for operation as I understand it. Don't quote me on that. :-)

[CJ_]

So my harness is cracking everywhere and I have a few broken connectors.

Now I went to the junk yard the other day and they had a 6speed allroad with a 2.7 BEL and I cut the harness for the injectors/coilpacks. Would it be possible to just solder where I cut the allroad harness into mine? then wouldnt I be upgrading to the 4pin coil packs at the same time and fixing all my existing connectors/wires? Anyone done anything like this?








Here are the sections I cut off:



And the 4 pin coil connectors:

[CJ_]

Knocked a ton of things off the list last night and today
-Coated manifolds in VHT header paint and cured
-Installed DS Turbo and inlets
-Bought some BKR7e's and installed them
-Installed my ev14s in the fuel rails
-Installed IM and throttle body

I brought out the big boy camera and took some pics today

manifold on and turbo test fitted, Turbo fit way better than I was expecting, I clocked the cold side about a degree. I didnt mess with the wastegate because I figured I didn't change anything enough to worry about it. Let me know if Im wrong





Used stock wastage line as I didn't see any problems with it



IM installed with new vacuum lines and n249 delete.. Will most likely be deleting the n80 when I get more hose/caps



BKR7Es



And how I ended the day

[Corradovolksb]

Dude looks like some great progress. Keep it up I want to see video of it running . Did you pressure test the wastegates to check cracking pressure? If not you should before you install the downpipes just to make sure they are both adjusted correctly.

[CJ_]

Dude looks like some great progress. Keep it up I want to see video of it running . Did you pressure test the wastegates to check cracking pressure? If not you should before you install the downpipes just to make sure they are both adjusted correctly.

Thanks! I can't wait! I have not checked the wastegate pressure because I don't know how. Do I need any special equipment/tools?

[Pelican Parts]

Awesome thread. Great progress so far.

[Corradovolksb]

Thanks! I can't wait! I have not checked the wastegate pressure because I don't know how. Do I need any special equipment/tools?

You need a vac/pressure hand pump. Set it to pressure and apply pressure to each WG until the WG flap moves and that will be your cracking pressure. Keep applying pressure until the flap is open and that will let you know how much boost you need to fully open the WG

[axnjaksn]

diggin the build

[02nms4]

looking good man

[CJ_]

You need a vac/pressure hand pump. Set it to pressure and apply pressure to each WG until the WG flap moves and that will be your cracking pressure. Keep applying pressure until the flap is open and that will let you know how much boost you need to fully open the WG

Sweet, I will definitely get that tested before the dps go on.

looking good man

diggin the build

Awesome thread. Great progress so far.

Thanks guys!

[CJ_]

So I'm working on the pass side turbo today and I'm curious how you guys with aftermarket old feed lines route them.. Does this look right?

[erykv1]

The passenger side oil feed line should run over the coolant crossover pipe and into the distro block.

like this

[cinimod25461]

^^^ Yup, just run it up and around everything.

[CJ_]

^^^ Yup, just run it up and around everything.

Sweet, thanks. BTW props for tightening those oil line fittings with the motor in the car. They were kinda a pain to do even with the motor out lol.

Few updates:
Glad to say that the turbos are on! There were minimal fitment issues. The biggest problem was that the pass side inlets didn't really line up. After some tweaking the lower tabs, I got them to fit pretty well, but the upper inlet pipe tab doesn't line up at all.

My roommate had some extra DEI Reflect a Gold tape laying around, so I wrapped the lower inlet pipes in it.







Also got my clutch in, Southbend stage 3 endurance with stock resurfaced dmfw (Thanks zilla!) and some IE Billet fuel rails. Oh and some more Audi 'specialty' tools

[JaredB5s4]

So I'm working on the pass side turbo today and I'm curious how you guys with aftermarket old feed lines route them.. Does this look right?

Clean af🏽


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[Corradovolksb]

Looking great bro keep it up

[aysix]

Those lines are going to tear with those clamps. Get different ones and run new hose. Trust me I been there more than once.

[CJ_]

Wait which lines/clamps are you talking about? Are you talking about the band clamps on the inlets?

[aysix]

Wait which lines/clamps are you talking about? Are you talking about the band clamps on the inlets?

Wastegate lines

[CJ_]

Ahh.. Are you not supposed to use clamps at all on wastegate lines? Any reccomendations for the correct hose?

[aysix]

Ahh.. Are you not supposed to use clamps at all on wastegate lines? Any reccomendations for the correct hose?

Use oetiker or fuel hose clamps on those unless you're using something with a steel braided shielding.

[CJ_]

If I were to do braided steel lines, would I use -4an fuel line or...?

[nefkntym]

Very nice!!! Looks great, I was thinking about K24s as well since they are so close in price to F21s.

Subscribed for more.

[JaredB5s4]

Are you going to keep stock coils or upgrade them?


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[CJ_]

Very nice!!! Looks great, I was thinking about K24s as well since they are so close in price to F21s.

Subscribed for more.

Thanks! I originally ordered the k04s from SRM but ended up with the k24s at no extra cost because they were heavily backordered on k04s. Needless to say, I'm pretty happy how it worked out lol.

Are you going to keep stock coils or upgrade them?


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Im going to keep them stock for now, if they give me any trouble, that will be the first thing I swap once the motors in

[JaredB5s4]

Okay good idea I was just wondering because I'm doing a stage 3 right now too


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[CJ_]

3-bar map sensor vs old one. Anyone ever install one like this? Obviously the new one won't clamp into the tbb like the stock one did. Am I missing something here?

[erykv1]

4-bar map sensor vs old one. Anyone ever install one like this? Obviously the new one won't clamp into the tbb like the stock one did. Am I missing something here?

you need to find some hose to make up the extra diameter missing, i cannot remember off the top of my head what size it was, but thats the solution to this problem.

[jaychen]

Whoever the company is in the uk make a spacer. I ended up cutting the old bit off the map sensor and jb welding it to the new one to make it perfect. The first time round doing the hose method gave me leaks

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[CJ_]

Sweet, I had some hose sitting around that fit snug around the o-ring and inside the tbb, so I think I'm going to try that method first, If that doesn't work, i'll go about the jb weld method.

Does anyone know if this is supposed to be happening? During my trans rebuild, after mating my front diff housing and the middle gear housing, when I would turn the 3rd-4th gear shaft, it would not spin freely, and made a grinding/ticking noise. After taking it back apart and inspecting everything, this was the only thing I could find that did not seem right. When the shift collar engages the gears, the synchros get stuck halfway up. Is this only going to happen when the shaft is out of the car? Is this anything to worry about?

In short:
-Mated front dif housing and gear housing
-Shafts did not spin freely
-Took back apart
-Inspected everything
-Noticed 1st-2nd synchros not snapping back
-Is this a problem?

Update on this:
Found out there was something wrong with the synchro that JHM sent me that was causing it to stick.. Got in contact with them and they sent me a new one to try, works perfect now! Still not sure what was wrong with the old one but my guess would be maybe it wasn't perfectly round or something, there was nothing visible that would keep it from working properly.
Anyways, got both shafts assembled, should have the transmission done by tomorrow or the next day!

[erykv1]

I bet it was some casting boo boo on JHM's end. OEM synchros are forged I believe. Either way, glad you got it sorted!

[CJ_]

Finally finished up the transmission! Was really easy once I got the new synchro in and didn't run into any more problems. Really happy to get this done because it was one of the main motivations for this build.

All thats left is just to throw the differential in and button that up, but I'm debating just sending it in to JHM for a 4:1 diff before putting it all back. We'll see..

Sorry for not really taking any pics of the process, but here she is all back together. What a good sight it is opposed to the big pile of transmission parts its been the past few weeks.

[oppositelock]

Why are you deleting N249 and N80? Search for julex's "N249 delete: why you should not do it".