Club 80-90 Forums

Hello everyone. I've read as much as I possibly can about this subject on this forum, other forums and the web but I'm still in need of advice please.

I've recently acquired a DoKa with a 3H gearbox and a JR engine. The gearbox needs rebuilding pretty urgently and the engine (of unknown mileage) is pretty smoky, although it's running okay.

I've considered the possibility of obtaining second-hand units, including the attractive AAZ. However, I'm tending towards having both engine and gearbox reconditioned for the following reasons:
1. the history of any second-hand part is at best hazy
2. I'd prefer to keep it stock
3. good second-hand 3H gearboxes aren't exactly plentiful.
4. I can afford it at the moment. Although it's not cheap, I'll be getting what I hope will be some degree of certainty as to the van's mechanics.
5. I don't want to put in second-hand units now, only for one or both to fail next year, say, as I'm cruising down the M5 with family and luggage on board in a freezing gale and pouring rain.
6. I need the van running as soon as possible.

I'm told that the JR originally came from a Mk2 Golf and that it's identical to the JX with the exception of having hydraulic tappets. Can anyone verify this and, more importantly, does anyone know whether this has any implications with regards using this unit in a van, when mated to a 3H gearbox?

Does anyone have any other advice as to which engine to settle on? I'm not especially bothered about speed but this will be our everyday vehicle as well as a long-term investment and, although I need it back on the road yesterday, I also need to be sure I'm doing the right thing.

Also, if it makes any difference, I'm thinking about running it on veg oil.

Thanks for reading

Get the box re-conned, see Aiden on here somewhere, he`s the specialist.
See if you can get an AAZ recon unit in exchange for your JR (they may want a supplement `coz it`s not exchange like-for-like) but it`ll be worth having the 1.9 while you`re doing it. You have most of the parts for the conversion anyway, buy the exchange unit without the AAZ turbo, get a set of JX manifolds and buy a new JX type turbo, it`ll all fit then using standard stuff, standard exhaust etc.

I'm told that the JR originally came from a Mk2 Golf and that it's identical to the JX with the exception of having hydraulic tappets. Can anyone verify this and, more importantly, does anyone know whether this has any implications with regards using this unit in a van, when mated to a 3H gearbox .Well i can confirm the JR engine has hydraulic tappets and should have no problems when mated to a 3H.This hydraulic tappet engine was fitted to my T25&mated to a DK code gearbox fitted by my self .I had no problems but recently i ran it on vegi oil due to its high mileage 160.000 it started making horrible rattle noises.I have the block with the cylinder head on it of which i am going to try and find out what the vegi oil did to the internals on strip down .But i am suspecting the piston rings grooves where cleaned out of carbon by the cleaning effect of vegi oil the rings lost it seal & rattled.

I would go for AAZ everytime, they are the best suited to t25's. JR and JX are almost identical.

3H boxes are probably the most plentiful!
just a standard 5 speed 1.6TD gearbox, nothing special.

Thanks for the advice guys. I've looked up Aidan and will be giving him a call as soon as I reach a decision about the engine.

I gave Vege a call yesterday and they will supply a recon AAZ in exchange for my JR but after the extra surcharge and shipping and VAT, it all comes to just over £2k. I can get my JR recon'd for about half that. On top of that, it'll invalidate the warranty on an AAZ to fit it to a T25 (because it's not the vehicle it was originally destined for).

So I've a few more questions please
1. Is there any way around the warranty issue? Is there anywhere that will provide a warranty under these circumstances?
2. Is it better to find a second-hand AAZ? How much should I expect to pay for one like this?
3. How is my insurance likely to be affected by fitting an AAZ?
4. Is the AAZ really that good?

Thanks again.

DoKa90 wrote:Thanks for the advice guys. I've looked up Aidan and will be giving him a call as soon as I reach a decision about the engine.

I gave Vege a call yesterday and they will supply a recon AAZ in exchange for my JR but after the extra surcharge and shipping and VAT, it all comes to just over £2k. I can get my JR recon'd for about half that. On top of that, it'll invalidate the warranty on an AAZ to fit it to a T25 (because it's not the vehicle it was originally destined for).

So I've a few more questions please
1. Is there any way around the warranty issue? Is there anywhere that will provide a warranty under these circumstances?
2. Is it better to find a second-hand AAZ? How much should I expect to pay for one like this?
3. How is my insurance likely to be affected by fitting an AAZ?
4. Is the AAZ really that good?

Thanks again.

AAZ is the best deisel for a t25, much better than a 1.6td. Secondhand AAZ's i would expext to pay £100-300. Made almost no difference to my insurance.

You can buy an new engine from VW for same money as Vege want.

Got a Mk3 Golf 1.9TD here with the engine still in it. 127k on the clock and its failed the MOT on welding and a few other bits.

Car was running till the garage I bought it from stole the starter for another car last week.

£300 for the car.

Many thanks for the replies, everyone. I've got hold of a used AAZ with 69k on it and am now in dialogue with Aidan about rebuilding the box. Seems that's going to be the tricky part, as I want the 4.57 crown wheel and pinion from an AAP (or a decent AAP suitable for rebuilding).

I get the impression that these aren't freely available currently, so if anyone's got any bright ideas... I need to get the van back on the road, so any help will be greatly appreciated.

DoKa90 wrote:Many thanks for the replies, everyone. I've got hold of a used AAZ with 69k on it and am now in dialogue with Aidan about rebuilding the box. Seems that's going to be the tricky part, as I want the 4.57 crown wheel and pinion from an AAP (or a decent AAP suitable for rebuilding).

I get the impression that these aren't freely available currently, so if anyone's got any bright ideas... I need to get the van back on the road, so any help will be greatly appreciated.

What gearbox have you got?

3H.

DoKa90 wrote:3H.

You would be better just changing 4th and 5th gears, unless your going to modify the engine.

With no mechanical expertise, I don't know what's involved in any of this. I'm just going on what Aidan's told me about what would be the best set-up with an AAZ.

While I do need the van running sooner rather than later, I don't mind waiting a bit longer if it means it'll drive better and last longer.

DoKa90 wrote:With no mechanical expertise, I don't know what's involved in any of this. I'm just going on what Aidan's told me about what would be the best set-up with an AAZ.

While I do need the van running sooner rather than later, I don't mind waiting a bit longer if it means it'll drive better and last longer.

If engine is staying stock keep your existing diff and just change the upper gears. AAZ's don't NEED taller ratios like tdi's but they are nice. If your upping engine change diff and gears.

Well I'm planning on keeping the motor stock, so I'll give that some serious consideration. Thanks Andy.