gearbox removal and replacement.

[skint-van-man]

Evening all.

The new plan for the money eating van is to replace the gearbox (4 speed) with one with a higher cruising speed for better motorway economy and speed.
But... i dont really fancy doing it myself as ive had enough of farting around under it for a while!

Any ideas of how much a garage would charge to remove and replace gearbox, wheel bearings and drive shaft bearings (the whole lot)...

Or.. if im going to man up and do it myself how long it will take me and how much it will test my patience..?

Ta v much!

[Plasticman]

Do all that and you'll live up to your name

If its all working ok the n dont make work and spend money, fit some bigger tyres it will up your gearing a fair bit, that said what size rubber you running at the moment and what engine
mike

[Fritz]

Dear Sir, may I point out that the final drive ratios of the 4 and 5 speed gearboxes fitted to these vehicles as standard are almost identical so replacing a gear box other than because it is shagged will be of no benefit what so ever.

The simplest way to get a few more miles for your money is either put bigger tyres on the back or buy something a lot more ecconomical like a T4....


Regards


Fritz,,,,,,,,,,,

[Ian Hulley]

You seem to think a T25 will cruise at a high speed ? Why ? Our 2.1 5sp camper will happily cruise at 70 all day, but there's a world of difference ... a 1.9 will not be happy or last long if you try the same too often.

i dont really fancy doing it myself as ive had enough of farting around under it for a while!

If you are a 'skint van man' then you need to get down and dirty and learn how to work on your own van, professional mechanics need to earn a living and pay their rent and bills, good luck to them.

Sadly if you've bought a pup or have unrealistic expectations it'll be a long while laid in the rain before you can bask in the sun.

[nrxx]

Hi, I''ve just changed gearboxes due to failure, 2-3 hours under the van or c£100 if you have mechanic used to them. I'm pleased to say that the replacement box gives me the same motorway cruising speed. I't'll happily cruise at 70+.
Nick

[nrxx]

...and I should have said '87 1.9 DG!

[billy739]

standard 5 speed 1.9 gerabox (ABN code ) 3000rpm @ 58.75mph / 3500 rpm @ 68.54mph / 4000rpm @78.34 rpm

standard 4 speed 1.9 (ABD code) 3000rpm @ 56.4mph / 3500 @ 65.80rpm / 4000rpm @ 75.20

2.1 5 speed box (AAP code ) 3000rpm @ 62.09rpm / 3500rpm @ 72.44rpm /4000rpm 82.79rpm

from my experience on the AAP box if you fit 195 80 15 wheels/tyres over standard you drop about 200rpm or about the difference between 1.9 5 speed and 2.1 5 speed(above boxes)


as stated above you need to know the code from the box , not the sticker in the van as you may not have the correct box fitted.
also some engines sound like they are working harder than they are!
get the code from the box and i will tell you what speed your doing as opposed to engine revs.

[Plasticman]

Sadly if you've bought a pup or have unrealistic expectations it'll be a long while laid in the rain before you can bask in the sun.

Thats a classic
mike

[skint-van-man]

i understand the 'if it aint broke dont fix it' rule but im toying with the idea of a trip down to spain in the van. THats the only reason i am thinking about it as i dont want it going half way round france! The engine destroyed a main bearing when i told it it was going to cornwall!
I have spent plent of weekends and evenings getting 'down and dirty' thanks working on my van doing the braking system, new engine, re-paint, new interior and partial re-wire just now the missis only recognises my feet sticking out under the van as thats all she see's so thats why i asked about a garage.

Il have a ganders under it when i can and see what gearbox No is. Currently running in a re-con 1.9 DG WBX.

ta all

[Ian Hulley]

Currently running in a re-con 1.9 DG WBX.

Treat it gently but do plenty of miles not far from home ... if it can be trusted then leave it be, service it well and gently bimble round the beautifull countryside of France and see how far ya get.

TBH forget the 'cruise at 80' bit ... trust me, we've seen 'em come and we've seen 'em go (usually much the poorer)

Ian

[Aidan]

I'd advise sticking to the correct gearbox for the engine, they are only small differences between the 1.9 and 2.1 boxes but they are there for a reason, if VW could have fitted the same box in all vans they would have,
the five speed is only really better for towing or hilly terrain in a petrol van otherwise the four speed is fine
the syncros have to make do with the four speed ratios and they are fine, get a rev counter so you know what revs you are pulling, 3 and a half thousand sounds harsh but is perfectly ok and you can rev them over 4k for short periods, but 3-3.3k seems to give best combination of speed and economy, 5% faster =10% more fuel
far more important is to change the oil on the gearbox if you don't know when it was last done and do it regularly, every 3 years 20k miles minimum, if you can do it every year (£20 for the oil) then so much the better, most of these vans are running 20 year old grinding paste by now

[CovKid]

Thats the best description I've heard for old gearbox oil

[Titus A Duxass]

I had the gearbox oil changed last year after 270,000 kms.
The yooff asked why did I want to change it when it is filled for life by VW!

They then proceeded to put only 3 litres in and not 4!

They had no concept of filling it up until it just starts to come out of the fill port.