Gearbox is toast

Post by **robthechemist** » 12 Oct 2009, 08:06

Hi folks,

I have a T25 with a 2l Aircooled CJ engine, that is in the garage as the DK gearbox fitted is knackered. There are a few 4 speed gearboxes for sale at the minute, from £120 - 250 depending on the source. Should I get my old one fixed, or buy one of these in replacement? Also, does it really matter which gearbox is put in? Would any 4 speed box fit?

Ta. Rob

Post by **Fritz** » 12 Oct 2009, 12:52

If you are a gambling man then the cheapest option of a 2nd hand box should do the job (if you are lucky) BUT if you can afford it,have yours looked at and then decide.

If yours is a 4 speed box stick with what you have otherwise the linkage will have to be changed to suit a 5 speed//////

Regards

Fritz,,,,,,,,

Post by **robthechemist** » 12 Oct 2009, 14:25

Cheers for that Fritz,

I'm going to go with the cheapest option for now, seems even if I get the box reconditioned, if an old gear goes, I won't be covered. Bought one from a 1.6 Aircooled and getting it fitted on Thurs. Chatted to the guy that's selling and he seems knowledgeable and fair. Fingers crossed.

Post by **camper** » 12 Oct 2009, 16:39

robthechemist wrote:Cheers for that Fritz,

I'm going to go with the cheapest option for now, seems even if I get the box reconditioned, if an old gear goes, I won't be covered. Bought one from a 1.6 Aircooled and getting it fitted on Thurs. Chatted to the guy that's selling and he seems knowledgeable and fair. Fingers crossed.

Did he tell you it will rev its nuts off.

Post by **toomanytoys** » 12 Oct 2009, 16:44

Is your clutch hydraulic?? (IIRC 2L left the factory with hydraulic clutch actuation) the 1.6 aircoled box is cable operated and changing the arms over may not go well as they never seem to want to come apart..... (You dont want to try and change your van to cable.. waste of time..)
Also the overall ratios on the 1.6 box will be lower. so it will accelerate well but will be reving at 60... (4k rpm IIRC)

The watercooled boxes are different, the change rod is different too..

Aidan doesnt do the Aircooled boxes, but I think he says try "Bear motorsport" (IIRC)

Post by **robthechemist** » 12 Oct 2009, 16:58

I was checking out the gear ratio's on the brickyard http://www.brick-yard.co.uk/VehicleSpec ... fo/gbx.htm and it shows that the replacement box has the same ratio. If this is so, why would the revs be higher at the same speed?

Post by **camper** » 12 Oct 2009, 17:48

Final drive 1.6 Aircooled 5,43
5,428
2ltr Aircooled final drive 4,571
Thats why it will rev higher at the same speed.

Post by **Cafnod** » 12 Oct 2009, 18:12

camper wrote:Final drive 1.6 Aircooled 5,43
5,428
2ltr Aircooled final drive 4,571
Thats why it will rev higher at the same speed.

What camper is saying here is that the differential ratio, the bit that takes the drive from the gearbox to the driveshafts is of a lower ratio on the box you intend fitting.
Dont know if it is viable to change the differential or even if it fits.

Post by **toomanytoys** » 12 Oct 2009, 18:24

Should have made what I said clearer.... Appologies...

Box is essensially the same, but its not just a case of swaping the crown wheel.. there are setup measurements and the pinion and ring gear are matched sets.. thats if they havent been eaten by whatever has caused the demise of the box...

in a simplified way (and not exactly correct coz of the gear ratio's

) the engine turns 5.43 times to make the wheel turn once on the 1.6 box and only 4.57 times on the 2L box...

OK.. here are the 3000 to 4000 rpm in each gear.. (if I have done my calcs right..) (unless you are really lucky to fnd a rare early 1.6 ABW, same as 2L)
usual 1.6 DH box. 2L DK box...
3000 11.1 20.4 33.4 49.4 3000 13.2 24.3 39.7 60.7
3250 12.1 22.1 36.2 53.5 3250 14.3 26.3 43.0 65.8
3500 13.0 23.8 38.9 57.6 3500 15.4 28.3 46.3 70.8
3750 13.9 25.5 41.7 61.7 3750 16.5 30.3 49.6 75.9
4000 14.8 27.2 44.5 65.8 4000 17.6 32.3 52.9 81.0

Fancy telling us what code the box you have found is??

Post by **Cafnod** » 12 Oct 2009, 18:53

Obviously it isnt viable

Post by **robthechemist** » 12 Oct 2009, 22:41

It's a DH box or so I'm led to believe. I'm getting it shipped to the garage from the seller on thurs. It would seem I may have a gearbox for sale later. bugger. That'll teach me to be too hasty.

Post by **billy739** » 13 Oct 2009, 08:44

hope you didnt pay much more than £50 for the 1.6 box!

it will do to keep you going , but remember 55mph is the max you want to be doing in 4th now!

Post by **billy739** » 13 Oct 2009, 08:56

also the 2.0 and 1.6 boxes are different in apperance.

check the ribs on the top when you see the 2 boxes , the 2.0 box has deep casings almost like heat vanes and can be known as the 6 rib box, whilst the 1.6 casing isant deep, and the cast ribs are just off the height of the box
1.6 box

http://cgi.ebay.co.uk/VW-Camper-gearbox ... 286.c0.m14

Post by **camper** » 14 Oct 2009, 06:42

ddf maybe the shipping cost of sending a good used box from the UK would be cheaper?

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