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1991 TSi AWD

dwb

Proven Member
238
103
Sep 9, 2021
Broomfield, Colorado
Currently working a full engine rebuild. Timing belt broke so no better time to refresh the whole thing. 270k miles on the virgin bottom end, so it is definitely due. I'll try to keep things updated here!
20220415_171413(25).jpg
 

dwb

Proven Member
238
103
Sep 9, 2021
Broomfield, Colorado
Time to start updating this build. Going way way back, I purchased my stock DSM in 1999 from my brother who bought it in '95. Original Colorado car (still in CO today). About a year after I bought it the harmonic dampener separated while idling in the driveway. This was my first repair but was relatively easy to fix even in the rain. Local dealer hooked me up. Weren't those the days when dealers had parts in stock!

A year or two later I had to install a new clutch. Good ol' vfaq walked me through it and from there I stumbled into the CODSM community. Great club, did some meet-ups, found lots of parts and met some cool people. It got me hooked on DSMs. The club eventually slipped into the Facebook pit so I wandered the desert for while, doing my own thing just to keep it on the road.

Going back to sometime around 2002/03 I blew out 2nd gear syncro and ventured down the rabbit hole of transmission rebuild. Bought another used trans to limp by on and carefully rebuilt my original. Took me about a year to get it done but turned out great. Couple more mishaps like blown turbos, idle issues galore, and many other things too long to list. Nothing overly complicated except a head swap. I kept at it, driving it daily for the most part.

Fast forward to 2021. Blew out 2nd gear syncro AGAIN. I knew I could fix it pretty easily but started to feel the weight of discontinued parts. I found Jacks Transmissions stocked almost everything I needed. That is, until I noticed my output shaft and transfer case coupler splines were completely worn and on the verge of imploding. Jacks hooked me up with a new OEM output shaft but that coupler...not so much. Completely discontinued part. At that point I joined Tuners to see what the community could offer. No bites on my WTB ad so I contacted every DSM transmission shop I could find. To the rescue was @twicks69 who hooked me up with a good used one (Thanks Tim!). Crisis averted (for now).

At around 270k miles on the ODO, the timing belt broke in March 2022, which is where this build picks up. The bottom end of the engine was still virgin and I had a spare virgin head with 220k miles on it. Perfect candidates for rebuild. And so it starts...
 

dwb

Proven Member
238
103
Sep 9, 2021
Broomfield, Colorado
Time for pics! I'll have to start of slowly and show my older stuff first. More to come as time allows!
Transmission output shaft completely wore out! Replaced this with a new OEM.
20210907_213933.jpg


old transfer case coupler, replaced with a good used one.
20210910_105257.jpg


Old leaky transfer case yoke
20211014_140041.jpg
20211014_131952.jpg
 
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