Club 80-90 Forums

https://lh6.googleusercontent.com/-b5bI ... 80115.JPG]

original gear box (no 3rd or 4th)


https://lh5.googleusercontent.com/-O7mN ... 180121.JPG

replacement g/box


https://lh5.googleusercontent.com/-9Zga ... 180118.JPG

Exhisting g/change

I sent the links to the photos before I had written about the problem!

I have already asked for advice concerning adjustment of g/change, could not locate all gears. Eventually realised the gearbox was duff(no 3rd or 4th) located another 4speed 1.6l D box.(all gears working!) fitted it & discovered its front mounting was 3/4cm short.

Botched that ok but now I am completely lost on the gear change. Cant find any serial no's on either g/box & have no idea how to locate the correct gear change linkage? Can anyone throw any light on my confusion?

1. original gear box (no 3rd or 4th)

https://lh6.googleusercontent.com/-b5bI ... 180115.JPG


2. Exhisting g/change

https://lh5.googleusercontent.com/-9Zga ... 180118.JPG


3. close up of exhisting g/change

https://lh3.googleusercontent.com/-kzkh ... 180119.JPG


4. Replacement g/box in place

https://lh3.googleusercontent.com/-cxPz ... 180120.JPG


5. close up of original g/box

https://lh4.googleusercontent.com/-JCj_ ... 180116.JPG


6. replacement g/box

https://lh5.googleusercontent.com/-O7mN ... 180121.JPG


7. replacement box cobbled up (3/4cm shorter) !?

https://lh4.googleusercontent.com/-zN5X ... 180122.JPG

you've fitted an early Aircooled gearbox into a later watercooled van, the linkages are different, the mounts are different and to be accurate the driveshafts were different, but if the engine has stayed put and the mount for the front of the gearbox has been modded then the driveshafts stay original and are right

Aiden,thankyou for yr rapid reply. I have no probs with the instalation having fabricated/modded the front mounting. drive shafts etc all OK,I think.
Am I right in thinking that I must now locate an early petrol g/change linkage to activate the gear change?
I am in N.Wales in spring 2014 (for a couple of rounds of the BTRDA British production car trials championship) & will make the effort to visit you& drop
off the origial g/box for yr inspection + subsequent repair.

yep you'll need the rear linkage parts to suit the Aircooled gearbox and you may have to mod the shaft length to get it all to work but if the van was 4 speed originally then the gearstick and front half of the linkage are fine I think though I have never done this installation

you will nee the rear shift rod from the Aircooled van along with the bolt pin that goes into the hole in the gearbox near the selector and supports the rod.

make sure the bolt has the nylon washer on the front as they are usually missing. also the bolt should be straight , usually there bent.

I am not sure if the diesel / petrol early shafts are different like the water cooled ones.

you will then need to cut the rear diesel and petrol rear rods and weld them together so you can join the late front to ther early rear

i will almost certainly have an early petrol linkage and possibly rod if you get stuck!

in you picture your selector rod looks a lot more bent than it should be! hopefully this was not the initial problem!

thank again Aidan & thanks to billy739
for yr info the the linkage shown is that of the original 1.6D,had a good look at it & its pretty heavy stuff so I guess thats its original shape.
I'm in france(last 25yrs for my sins)& most transporters are diesel,so I may take up yr offer of a petrol rear linkage.
Anybody got an idea what that early petrol g/box ratios are like versus the 1.6D box originally fitted?
have looked at ratio/type.list //rjes.com/html/gearbox_types.html
but not sure whats what!?

there's an exellent page of info about the c.og boxes in the brickyard info site.
Home page/info/t3/ gearbox codes

here you are..
http://www.brick-yard.co.uk/VehicleSpec ... fo/gbx.htm" onclick="window.open(this.href);return false;

The plot thickens! after much scrubbing the codes on the broken g box is DY(10.82-84 ) 1.6D
& the code on the 'new'fitted g/box is DM (78-82) 1.6D
Yes,a diesel g/box!? there is a DN Aircooled(78-80) so can only imagine the same g/box was used
for both?
I also presume that the same early gear change fits both?

RSVP

early gear change is completely different under the van front/ rear.

but you can cobble the early rear rod end onto the later rear rod end so they work. many do this when using the 2.0 Aircooled petrol box

your original box is just an early later box hence the different linkage set ups.

basically the early box is a bay window 60-70's box with modified shifter / front case. just like the Aircooled engines

when vw went watercooled they changed the boxes also

these photos show the old gearlinkage that arrived with the 'old model' working g/box that I have now fitted. It also shows the gearbox end bits that are missing!