Gearbox Advice / Experience Please

[psychonaut]

Good afternoon all, this is the first of a couple of techie questions from me this afternoon.

My van is an '81 diesel, originally fitted with the 1600 diesel but now fitted with a 1y block that came from a '98 Seat Ibiza. It is fitted with a DM box with a 5.43 final drive with a 0.85 top gear, giving a final gear of 4.61. I run Empi wheels with 185R14C tyres.

I went to get a new ABD box from Aidan Talbot, our resident gearbox man, but because my van is an early diesel, it's fitted with an air-cooled type of box and the ABD wont fit.

So, Aidan thinks he can fit a new crown and pinion into a DK box, with a 4.83 final drive with a 0.82 top gear, giving a final gear of 4.11. My question is therefore this - has anyone run a 1Y with this gearbox set-up and whell / tyre combination and give me some real-life feedback of it? Failing that, opinions on the viability of it would be useful, not just for me but for Aidan too.

Many thanks for any help anyone can offer

[camper]

You say your van was fitted with a early 1600 deisel engine and with a DM code gearbox.Which means then it has the early rod change linkage so then a DK gearbox would be a easy fit.I have a 1Y engine in my van with a DK gearbox but the van was late so i had to fit in early linkage.Regarding Adain fitting a new crown and pinion into the DK box was you meaning a standard ratio and not a custom one to give a 4.83 final drive with a 0.82 top gear? .My own van fitted with the 1Y engine and the DK gearbox fitted drives a treat i carnt give you rev figures but in top the revs seem low at 70mph.

[psychonaut]

Thanks for the quick reply Camper

Yes, my van has the early linkage, so I wouldn't need to change that. Aidan was looking at custom ratios in the box, but reading your post it sounds like you have put a DK box into your van without changing any ratios. Are you running standard wheels and tyres with it, and do you find with your 1Y that you have enough power and torque across the rev range and gears for all types of driving - hilly roads to motorways, etc?

Thanks again

[camper]

Running 14" wheels the 1y engine fitted with DK gearbox copes well with hills and motorway driving included pulling a trailer.Only thing i would say is if you fit the 1Y inlet&exhaust manifold it makes a big diffrence in performance&mpg..I was told that Adain dont work on DM or CU gearboxes due to special tooling needed has this changed?.

[psychonaut]

Aidan was originally going to do my box before we realised I had the DM I'm not sure he'll work on the DK one for me, but I'm hoping, obviously, as he knows his onions.

I've had a custom exhaust put on my van, and kept the 1Y exhaust manifold. I have a 1Y inlet manifold fitted, which came from Ringo All of those seem to give me just a wee bit more power, which is no bad thing lolol

[camper]

Regarding the 1Y inlet manifold did you bash out the side panel for clearance or an other method.Ive not fitted the 1Y inlet untill i decide how to get the clearance i proberly will notch the chassis rail and bash the side panel.Longlife exhaust made a custom stainless down pipe to fit from the 1Y exhaust manifold to the 1.6td silencer on the van.

[billy739]

wouldnt it be easy to fit late gear linkage set up from a late van for the late box?

or personally i would try the standard dk box and see how it performs. afrter all vw set the gears to the cu Aircooled engine!

[psychonaut]

Regarding the 1Y inlet manifold did you bash out the side panel for clearance or an other method.Ive not fitted the 1Y inlet untill i decide how to get the clearance i proberly will notch the chassis rail and bash the side panel.Longlife exhaust made a custom stainless down pipe to fit from the 1Y exhaust manifold to the 1.6td silencer on the van.

Sorry Camper, i sold you a dud in my post earlier. I re-used a 1600 inlet manifold so that no modifications to the engine bay are needed. If you use the 1Y manifold, you either have to bash out the side a bit, or put up with a lot of vibration. Neither option is desirable!! Pro-Speed exhausts in cardiff made me a complete exhaust to my specs for £10 less than a new system from VW Heritage / JK would have cost me. It sounds awesome, frees up a few BHP, but makes conversation inside the van at anything over 50 a bit awkward. But at least I don't hear the kids arguing....

wouldnt it be easy to fit late gear linkage set up from a late van for the late box?

or personally i would try the standard dk box and see how it performs. afrter all vw set the gears to the cu Aircooled engine!

Thanks Billy. Changing the linkage was one option, but I wanted to see if anyone had any experience with the setup and take advice that way. I think I may take the route of the standard DK box judging by what you and Camper have said. I forgot your dash pod btw, when I was up north a fortnight ago. Although to be fair, Aidan forgot it too, so I'm only taking 50% of the blame for it!! I'll bring it down next time I'm up north

[billy739]

no prob!
one day we will be uninted!

no rush tho

[psychonaut]

Cheers Billy