How much power are you / do you plan to be making?
Right now I have an APR K04, S3 Injectors, APR HPFP, and that's it for hardware. So stock engine cover, dp, etc. I've made a de-tuned K04 file in Maestro that seems to work. Never had it on a dyno, but if I had to guess, I'd say around 290-300. And then torque is probably about the same, 290-300. I had more power with a P-Flo and AWE DP which were nice, but the P-flo was too loud for me with the turbo-muffler-deleted APR K04, and the extra torque wore out the engine mounts which in turn broke the downpipe flex joint so I went back to OEM.
In an effort to preserve the clutch I'm toying with the idea of writing a tune which limits torque to around 270, keeping it flat from hopefully ~3200-6000 or so. That would drive very nicely IMO and hopefully still keep top end power the same, but it's of course easier said than done.
I'm surprised you went with a stock clutch. I went through 2 stock clutches on just a non-HPFP APR stage 2 tune boosting at most 18psi. The second clutch only lasted 1 year / 12,000 miles. Both clutches started slipping only when ambient temps were <40F, so be especially careful loading up the engine in high gears in those conditions.
I wish I would have read your thread sooner, I would have tried to convince you to spend a little extra and get a Sachs RE clutch/pp for the stock flywheel. Mine has been taking 23psi from a K04 with no hint of slip.
g60_corrado_91 said:My stock clutch would slip in 5/6 at 20k with APR Stg 2. However I made it last to 120k before it started slipping in 3-6 with the KO4. But the key is to downshift on highways, when passing, etc. That's what automatics do. Definitely use your gears with the stock clutch and KO4. Not sure how long it'll last. I made 255wtq on a mustang dyno on the stock turbo. Made 270wtq on the KO4 (Unitronic) on a mustang dyno spinning all 4 (AWD dyno day) and it was 95 and humid out. On the stock to the turbo s3 ic, it was heatsoaking bad. I put my estimates around 285whp and similar torque in ideal temps.
Nice progress...looks like you have it fairly under control.
Also, I always get the new guy with the starter bolt, they never believe it's there. And that back bellhousing bolt is difficult for sure, try an 09g 2.5, that's super tight.
Another question--I'm in no rush to get rid of them, but I'm going to have a DSG and a boat load of DSG parts after this..currently sitting in a bin. Any ideas what i should do with it?
Was thinking about putting it in my GF's jetta...but gave up on that since her tiptronic has 92k vs 137k on the DSG.
Could also sell the transmission complete, but not sure what the market is for high mileage transmissions?
I'm thinking maybe the best thing is to part it out...I could see where someone would want a mechatronic, a gear, a housing, an axle, etc., something that's maybe not as mileage dependent or is unique to the '06 02E. Then just scrap whatever people don't need.
Orrr maybe I could find a GTI/GLI with a blown DSG to fix up cheaply. Dunno. Lots of options, and I bet the golfmkv community has ideas!