1.9 dg box to 1.6 diesel

Post by **magic bus** » 01 Feb 2007, 20:13

ive got my eye on a 5 speed gear box with all the bits through to the gearstick,its on a 1.9 dg van.I was wondering if i could fit it to my 1.6 diesel bus,and if it would be worth the effort in terms if extra top end ect..thanks for any advice(checked the wiki,couldn't see anything)

Post by **HarryMann** » 02 Feb 2007, 00:29

NA Diesel?

Post by **Mocki** » 02 Feb 2007, 07:59

you will need to change both the input shaft and the bellhousing, and the nose mount.

then you will find you cant ever get into top gear unless its downhill or backwind coz the derv aint got enough power to manage tall gears imo.....

Post by **camper** » 02 Feb 2007, 15:16

Sorry i have to disagree with the top gear down hill bit.I had a 1.6n engine was in good condition and fitted a 1.9 dg four speed box .I had no problems with it .It used to cruise on motor ways with no problems.I am running a 1.6td at present fitted with a DK gearbox this is came out of a 2ltr cu aircool .As you said you need to change the bell housing and input shaft .The 1.6n gearbox fitted as standard to it reminded me of a delivery van okay for short local runs with lots of gradients.When i had the 1.6n it was fitted with a tow bar and i used to pull a raclet trailer tent from surrey to cornwall.There was this long up hill gradient from motorway towards plymouth.The 1.6n with the 1.9dg gearbox fitted pulled that raclet in second gear the same as when it had the standard box fitted.I would agree the engine is underpowered but that van was a delight to drive with the 1.9dg box.Present 1.6td fitted with the DK gearbox drives even better .

Post by **Mocki** » 02 Feb 2007, 15:22

did the man not say a 5 speeder?

Post by **camper** » 02 Feb 2007, 15:49

Yes i no the man said a 5 speeder example . 70/82 petrol code AAP 5 gears 5th gear 0,816 final drive 4.57. 2ltr cu Aircooled code DK gearbox 4 gears 4th gear 0,823 final drive 4.571.Oh and both vehicles running on same tyre size 185 R 14

Post by **HarryMann** » 02 Feb 2007, 18:02

Yes i no the man said a 5 speeder example . 70/82 petrol code AAP 5 gears 5th gear 0,816 final drive 4.57. 2ltr cu Aircooled code DK gearbox 4 gears 4th gear 0,823 final drive 4.571.Oh and both vehicles running on same tyre size 185 R 14

Any chance you can format that so its readable and makes sense, it helps readers comprehension of what is what and what isn't what...

That is, Box 1 in comparison, where from and what are the ratios?
[New line]
Box 2, where from and what are the ratios?

Then we can all join in and pontificate

-Many thanks!

P.S. I got the bit about being on same tyres

Post by **magic bus** » 02 Feb 2007, 18:20

thanks for the advice,its all starting to sound a bit complicated for a novice 1st van man.what about the bigger wheels that sounds easy,do you have to fit them all round or just the back,would that gain me any thing?.it is 1.6n/a...thanks.

Post by **HarryMann** » 02 Feb 2007, 18:31

The first question you must ask yourself is, will it pull that gear ratioin other than ideal conditions, that is picture this...

Very slight (unnoticaeble) incline
20 mph steady headw or corsswind (both as bad as one another ina T25, dragwise)
Full tank, full of family, gear etc ?

Would that make you drop down to 3rd for miles and miles at a time, because although an undergeared vehciel is buzzing away and a bit nosiy and not a lot of fun, trust me, a seriously overgeared one is twice as bad, never really able to pull top unless it has everything going for it, nowind, no incline, and low load and engine in peak tune..

hink about it, but cheapest is definitely to pop up 5-8% in TR Circumference and see. Maybe even borrow a set of wheels and tyres that will give you that 5%

10% on TRC or overall gear ratio is usually too much without seriously upping power of engine...

Post by **camper** » 02 Feb 2007, 18:41

http://www.brick-yard.co.uk .The information i was providing was to compare the ratios as an example between a AAP gearbox code five speed and the DK code 4 speed gearbox which is fitted to my 1.6td .As can be seen the link with the gearbox codes and ratios will give further and complete information kindly provided by the brick-yard.iMy 1.6td fitted with a DK gearbox with the ratio of 0,823 in 4th gear and a final drive of 4.571 drives without a struggle. My point is if you compare the ratios as an example of a 5 speed gearbox code AAP you will see there very close to the DK 4 speed gearbox

Post by **camper** » 02 Feb 2007, 18:53

Very slight (unnoticaeble) incline
20 mph steady headw or corsswind (both as bad as one another ina T25, dragwise)
Full tank, full of family, gear etc ?.And yes with 4 kids and camping gear with 50,000 miles running on that 1.9 petrol gearbox all over great britain.

Post by **magic bus** » 02 Feb 2007, 19:53

thanks,always have a good load on the bus 3 kids,dog and the wife.think ill gether the knowledge and go for a bigger diesel unit in the bus,interesting to see how much knowledge is out there though.nice one.

Post by **HarryMann** » 02 Feb 2007, 21:28

Magic bus,

Now we're sure of those figures from Camper, thanks, seems the difference is a shade less than 1%.. so although you will get 5 gears, top will be as good as indistiguishable (5.554 DK Vs 5.607 AAP).