gearbox swop for aaz conversion

Post by **strat1** » 12 Jul 2006, 20:18

I have installed aaz 1.9 td from passat into my t25 but still have the old 4 speed 1600 d box, I think it is DM serial no. Most of the number has disapeared.
I have purchased a new 5 speed box for which I don't have a serial no. yet. to be delivered Friday.
Do I need to change the gear stick etc? or is it just change over the bell housing(if it is a petrol box) obviously ensuring the correct spigot bearing, and shortening the shaft if required?

Post by **billy739** » 13 Jul 2006, 21:28

yes a gearstick and front part of the gear rod needs changing.
keep the rear part and use your g/box front mount.

Post by **strat1** » 14 Jul 2006, 08:12

Thanks for the advice, basically I just need these parts from any five speed box? or should I try and get the original that went with the box?

Post by **Diamond Hell** » 14 Jul 2006, 08:24

When you have the gearboxes alongside one another you should be able to swap the input shaft from the current one to the new one. There is just a circlip and sleeve to draw up before the input shaft will unscrew.

A smattering of instant gasket will normally be sufficient to seal the bellhousing.

Any T25 5 speed box mountings will do.

You might need the back end of the shaft - not sure these are all the same. A complete 5 speed shift mechanism will ensure it works on your van.

The spiggot it in the end of the crank - you shouldn't need to touch that, although you might like to check the clutch thrust bearing for wear.

Post by **billy739** » 14 Jul 2006, 08:28

there are different front mounts,diesel box sits higher in the chassis by a couple of inches,5 speed mount is shorter allowing for 5th gear.
had differnt 4 speed mounts as well moving the engine an inch or 2 forward or back,
best to get complete gear assembly AND matching front mount so the box is correctly positioned for linkage

Post by **Diamond Hell** » 14 Jul 2006, 08:54

I take the bit about the front mount back....

I'm not taking the rest back though

Post by **strat1** » 14 Jul 2006, 21:16

Thanks guys, I have the front mount attached to the new box, so will use that. I will have to source the stick and rods. The new box is DW code so hope it will be an improvement on the current one which I think is DM.
Do I swop the input shaft before or after changing the bell housings over?

Post by **Diamond Hell** » 14 Jul 2006, 22:00

You can only remove the input shaft once the bellhousings are off the respective gearboxes.