Club 80-90 Forums

hi I just got a 2.1 dj engine in going to run with carb.i was asking what is the best 5 speed box to use with it as I have a 4 speed box at mo thanks.

You don't need a 5 speed box the 4 speed you have should be ok. Changing to 5 speed also means you would have to change the gear stick and linkage parts aswell. Do you know what the code on your 4 speed box is ?

hi no I do not know the code on my 4 speed.

You need to ascertain that first.

Stick with the four. The extra power means fewer downshifts anyway. The 5sp is better suited to lower power vans, as the ratios are closer together.

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The 5 speed box for a DJ has a lower top speed revs so if you do alot of motorway cruising thats the only benefit as far as I can see.


my 2.1 AAP 5 speed box is in theory 3525rpm at 70mph
my 1.9 ABD 4 speed box is in theory 3880rpm at 70mph
I also have a 1.9 ABN 5 speed box which is in theory 3725rpm at 70mph

this is calculated from standard 185 80 14 tyres being 945 revs per minuite x the final drive and 4th/5th ratios
it can also been seen on my rev counters but they are harder to be accurate.

https://web.archive.org/web/20150101225 ... fo/gbx.htm" onclick="window.open(this.href);return false;

itchyfeet wrote:
this is calculated from standard 185 80 14 tyres being 945 revs per minuite

It's rotations per mile

bigherb wrote:

itchyfeet wrote:
this is calculated from standard 185 80 14 tyres being 945 revs per minuite

It's rotations per mile

not according to the tyre calculator I used which says 810 revs per mile
at 70 miles thats 56700 revs
at 70 miles per hour thats 56700 revs per hour or 945 rev per miniute

https://tiresize.com/calculator/" onclick="window.open(this.href);return false;

I am thinking of replacing the 1.9 DG engine with the 2.1 DJ engine (reconditioned) I have in the garage. I also have the AAP 5 speed gearbox that goes with the fuel injected engine. However, I wish to run the engine on the carburettor for reliability reasons, in foreign countries.This will reduce the BHP a bit so has anyone got experience of running the long legged AAP gearbox with this setup? Will it run out of "steam" going up hills on motorways and autobahns etc. especially on the continent?

10 years ago I changed the standard DG 4 speed gearbox for a 5 speed ASM gearbox and it has been brilliant. 4th is super for towns and 5th great on A roads and motorways - less revs and quieter and it seems to tackle motorway inclines better than the 4 speed? Perhaps extra speed lifts the point of highest torque to where it is needed? Will I be better keeping the ASM gearbox, bearing in mind I want this vehicle for long distance camping abroad?

trundletruc wrote:I am thinking of replacing the 1.9 DG engine with the 2.1 DJ engine (reconditioned) I have in the garage. I also have the AAP 5 speed gearbox that goes with the fuel injected engine. However, I wish to run the engine on the carburettor for reliability reasons, in foreign countries.This will reduce the BHP a bit so has anyone got experience of running the long legged AAP gearbox with this setup? Will it run out of "steam" going up hills on motorways and autobahns etc. especially on the continent?

10 years ago I changed the standard DG 4 speed gearbox for a 5 speed ASM gearbox and it has been brilliant. 4th is super for towns and 5th great on A roads and motorways - less revs and quieter and it seems to tackle motorway inclines better than the 4 speed? Perhaps extra speed lifts the point of highest torque to where it is needed? Will I be better keeping the ASM gearbox, bearing in mind I want this vehicle for long distance camping abroad?

I'm going to do the same fitting a DJ with pierburg, by all accounts you won't notice any loss of power, you can up the main jet to help flat out
have a read of this.
https://club8090.co.uk/forum/viewtopic.p ... &start=585" onclick="window.open(this.href);return false;

Switch to 15" wheels and massive (tall) tyres if you want to get the best out of cruising speeds. 195/15/80 - mine is set up like that and it transformed gear changes as well as helping keep the revs down. Speedo accurate too - it wasn't before Waste of time messing with gearbox as any change will be miniscule in comparison to to wheel/tyre change. Cheaper too as 15" tyres are plentiful compared to 14s.

Thanks for your interest Covkid but I don't want to go down that route as I already have nice alloy wheels and the gearbox. You don't say if you are using a 5 speed or 4 speed box?

5 speed but honestly you'll gain nothing by swapping to a 5 speed (if you can find one). Its just got a better crawler gear to be honest and they're expensive to fix/replace if they go wrong. This subject comes up all the time and the answers will be consistent - don't bother.

As I wrote earlier, that has not been my experience as I already have a 5 speed with the DG and it has been great. In fact the "crawler" gear (first) is very useful as I don't think we would have made the ascent of the Col d'Aubisque in the Pyrenees without it. Particularly when a cow stopped us on a very steep bit! I already have the 5 speed box so cost is not relevant.