Some geometries for DQ200 and DQ250 gearbox retrofit, and custom driveshafts are needed:
The reference plane in the center is where the gearbox meets the engine.
The plane at the lateral sides is where the CV joint meets the wheel hub.
DQ200 in Polo 6R:
1 = 50 mm (measured)
2 = 220 mm (measured)
3 = 680 mm (measured)
4 = 400 mm (measured)
5 = 1 + 3 = 730 mm (calculated)
6 = 2 + 4 = 620 mm (calculated)
DQ200 in Golf mk6:
1 = 50 mm (measured in Polo 6R)
2 = 220 mm (measured in Polo 6R)
3 = 725 mm (measured)
4 = 455 mm (measured)
5 = 1 + 3 = 775 mm (calculated)
6 = 2 + 4 = 675 mm (calculated)
DQ250 in Golf mk6:
1 = 60 mm (measured on separate gearbox)
2 = 235 mm (measured on separate gearbox)
3 = 715 mm (measured)
4 = 440 mm (measured)
5 = 1 + 3 = 775 mm (calculated)
6 = 2 + 4 = 675 mm (calculated)
So, by deduction: DQ250 in Polo 6R
1 = 60 mm (from DQ250)
2 = 235 mm (from DQ250)
3 = 5 - 1 = 730 - 60 = 670 mm (calculated)
4 = 6 - 2 = 620 - 235 = 385 mm (calculated)
5 = 730 mm (from DQ200, front axle width does not change)
6 = 620 mm (from DQ200, front axle width does not change)
Now we only know the length of the left and right hand side half shafts, from reference plane to measurement plane.
So we know this:
And the drive shaft company will make this:
I must add manually the CV joints (6R0498099 A/F on the outside and 3C0498103 E/F/Q) on the outside. Do I know the geometry? Yes I do!
Inside CV joint on gearbox side
1 = 85 mm = 2 + 3 + 4
2 = 45 mm
3 = 25 mm
4 = 14 mm
34 splines
Outside CV joint on wheel side
1 = 64 mm = 2 + 3 + 4
2 = 7 mm
3 = 38 mm
4 = 19 mm
27 splines
so if the construction of the axle is defined as:
<---- A ----> <----------------------------------------------------- B ---------------------------------------------------------------> <---- C ---->
A = 23mm for the inside CV joint - gearbox side
B = full length minus (17 + 19 + 22 + 38) --> ±570 mm for right hand side and ±285 mm for the left hand side
C = 38mm for the outside CV joint - wheel side
