Club 80-90 Forums

Hello,

Apologies for posting this here, too - I posted it in the "alternative engines" forum, but looking at it, it doesn't seem to be visited that often...

The engine/gearbox in my 1.9 Caravelle have blown up and I've got hold of a 1.9TD (not TDi) from a '94 Golf to replace the engine. I've been told I need the gearbox from a 1.6TD T25 (plus adaptor plate etc) to replace my dead box.

Having spoken to most of the VW gearbox specialists in the area, they all seem to have a different opinion of which box I should actually go for. Can anybody tell me how much of this is right and what's the best way for me to go next, please?

1. I need a diesel gearbox as I need the diesel bell-housing to fit my 1.9TD

2. The non-TD diesel box is too low ratio for the 1.9TD engine

3. The TD box is still too short-geared for the 1.9TD, but 16" wheels might help.

4. The 1.9 petrol box has the same ratio's as the 1.6TD box (how does the bell-housing work, then?)

5. The four-speed box is stronger than the five-speed box

Any help will be much appreciated,

Thanks,

Paul

1.No you just need a diesel bellhousing and input shaft
2.Probably
3.Should be OK
4.Could have depending on your current gearbox code. A diesel bellhousing and input shaft will fit on a petrol box.
5.Yes

You can check the ratio's here

http://www.brick-yard.co.uk/VehicleSpec ... fo/gbx.htm

Hey, that's pretty damn helpful, thanks for that

I didn't realise the bellhousing was seperate to the gearbox - shows how much I know

Are the diesel gearboxes stronger built to cope with the low down torque than the petrol gearboxes, or is there no difference really?

Thanks again,

Paul

cant see there is a definate 'stronger box' as the 2.1 and only some south african boxes have the stronger 4 pinion diff!

the 1st gear on a 5 speed does suffer from wear but theve all done lots of miles, and the 2.0l Aircooled box is a baywindow box?
start racing a van with any box and it wont last.
you just need to make sure you have a good box to start!

So the 2lt box is the same as the bay what about the nose cone is that the same or will it need to be swapped obviously the bell housing is right...

Are the diesel gearboxes stronger built to cope with the low down torque than the petrol gearboxes, or is there no difference really

Nope..

Unless you overfuel, up the boost and improve the intercooling and oil-cooling, a std TD JX box will do, provided you go up in tyre rolling circumference 7~10%. Remember, they do rev a bit better than Tdis even without governor mods.


Transaxle ratios

Speeds, tyres and axle ratios

Thanks for all of this.

Just so's I know what you mean, though; what are "overfueling" and "governor mod's"?

The 1.9TD doesn't have an intercooler as standard (not in my Golf, anyway) - can you plumb in the 1.6TD intercooler - is there any benefit?

A 10% increase in rolling circumference on the standard wheels would mean going up to about 15.5" diameter - is 16" too big? I've been offered a set of 16" Merc alloys drilled out to fit my studs for 100.00...seems like a bargain, but will they strain whatever gearbox I fit to death?

Thanks for your help,

Paul

nose cone and selector rods need changing , the gear internals are the same so no stronger than the old bay , i think its just the fact that t25's are worked more that the boxes ware,also theres more of them!

you can go to 16/17 or 18's , you just need to change the tyre profile to suit , i have 45 series tyres on 18 inch rims , these are the same diameter as standard van tyres!

cheers fella thought as much