Club 80-90 Forums

I have installed aaz 1.9 td from passat into my t25 but still have the old 4 speed 1600 d box, I think it is DM serial no. Most of the number has disapeared.
I have purchased a new 5 speed box for which I don't have a serial no. yet. to be delivered Friday.
Do I need to change the gear stick etc? or is it just change over the bell housing(if it is a petrol box) obviously ensuring the correct spigot bearing, and shortening the shaft if required?

yes a gearstick and front part of the gear rod needs changing.
keep the rear part and use your g/box front mount.

Thanks for the advice, basically I just need these parts from any five speed box? or should I try and get the original that went with the box?

When you have the gearboxes alongside one another you should be able to swap the input shaft from the current one to the new one. There is just a circlip and sleeve to draw up before the input shaft will unscrew.

A smattering of instant gasket will normally be sufficient to seal the bellhousing.

Any T25 5 speed box mountings will do.

You might need the back end of the shaft - not sure these are all the same. A complete 5 speed shift mechanism will ensure it works on your van.

The spiggot it in the end of the crank - you shouldn't need to touch that, although you might like to check the clutch thrust bearing for wear.

there are different front mounts,diesel box sits higher in the chassis by a couple of inches,5 speed mount is shorter allowing for 5th gear.
had differnt 4 speed mounts as well moving the engine an inch or 2 forward or back,
best to get complete gear assembly AND matching front mount so the box is correctly positioned for linkage

I take the bit about the front mount back....

I'm not taking the rest back though

Thanks guys, I have the front mount attached to the new box, so will use that. I will have to source the stick and rods. The new box is DW code so hope it will be an improvement on the current one which I think is DM.
Do I swop the input shaft before or after changing the bell housings over?

You can only remove the input shaft once the bellhousings are off the respective gearboxes.