02B Gearbox how to do 5th Gear Upgrade

With reference to the size of final drive and casing size to suit, do the diff carriers carry the same part number with the casing increased just to house an extra large final drive?

 

Not sure if the diff carrier is the same as an 02A/J. The casing will be larger I would assume to fit the 4.9 ratio. This means there are a lot of teeth on the crown wheel, this requires a larger circumference to fit them all in. The limiting factor being the size of the pinion on the output shaft. You cannot just have one tooth on output shaft and 4.9 on the crownwheel and make a 4.9 : 1 diff, and expect it to work!

I would take pics of the box but it is buried under a few bmx bikes and engines. I am sure Brookster could put a pic up from the T4 forum though. That would help show the differences in engine angle and casing size.

 

Crack on then! Dew, lazy or what lol
Looking at the 4.6 I had here a while back it looked like the pinion gear was getting to the point that everything else needed to be bigger. You could see where the machining of the teeth was just eating into the bearing diameter. There's no way it could have gone to the next size on that pitch.
So anyway. chop chop, getting shifting the bmx's

 

Here you go Monsier Hotgolf.
Now get some pics of suitable poontang up in a "pimp out your sister or mum stylee"!

 

Hmmm, I see. That's not going to fit a Golf engine and still be in the engine bay!

Cut the bellhousing off turn it and re-weld, to give an instant, equal length driveshaft, touring car spec box, with the abilty for high driveshafts and ultra low ride height.

But the diff might run dry

 

Equal length drive shafts

Put the box back together tonight , less 5th gear drives ok with no nasty noises .

So i'm on the look out for a new box , will fit a 5th gear from a 02A if anybody has one spare and see how it goes, also need a new selector fork set - up as the old one is abit worn from me wedging it in 5th all the way back from Berg Cup with my left knee

And the new 0.681 5th Gear will be going in the repalcement box.

The T4 Engine sit on a 45deg angle facing forward but the gearbox sit flat like a Golf so if it were mounted on a golf engine you know the score (Touring car style)

2.4D C/W Turbo conversion

 

Does it not need the 5th gear fitted and the large bolt tightened up to stop the input shaft floating?

 

The gear has been refitted to the input shaft to stop it floating, but it has no teeth left on it , and i've left the selector fork out

How much for the Box Danster ? it shall shame to see it sat there doing nothing.

 

Think I have a 34/44 here if you're stuck.
Input shaft is on tapers on these so shouldn't float at all

 

If only the van was running you could horse up the road to Scotland, wire up my extension, then leave with the box!

This box was out a 4 pot. I do not know if they are the same as the 5 pot ones. I listed the code above though.

 

The 1.9D & 2.4D are the same box Code

Only the 2.5TDI ACV Engine that was a different box.

 

2.4D 02B Ratio's

1st - 3.778 : 1
2nd - 2.063 : 1
3rd - 1.345 : 1
4th - 0.971 : 1
5th - 0.756 : 1

Final Drive - 4.941 : 1

looks like they are very similar to the 02A/02J Ratio's posted apart from Final Drive.

 

So is your box trash Brooky?

 

Brooky, offer Monsieur Danstere 1000 Francs - more than reasonable

 

Well 5TH Gear has arrived c/w selector fork etc.

33/47 - 0.70 Ratio too so things are looking good.

The Old box is staying in , went to Santa Pod and back towing the MK1 on the trailer and it ran fine ! 4th gear all the way there and back 230miles .

 

o thought you were joking when you said you towed all the way there with no 5th gear your a complete loon lol

 

Well its been a long night but i've just got the 02A TDI 0.70 5th Gear fitted in the T4.

Makes a big difference and on the motorway at 70mph drops the revs with the lower gear very well for better MPG and cruising at 3500rpm , rather than 4500rpm.

i'll post pix tomorrow.

Cheers to Benny for the Gear Set.

 

Small 33 tooth gear fitted



Large 47 tooth gear fitted


Syncro Fitted


Gear Selector fork fitted




Box filled with 2.5litres Castrol 75/90 Gear oil and 125ml of Activ 8

All finished the whole job takes abut 2 hours, it took me abit longed in the dark with hardly any light a job well worth doing on a T4 Transporter.

 

Good job.
It sounds a worthwhile job too if the rpm reduction helps fuel economy.
Yours is the larger 5 cylinder engine though, I wonder if the smaller 4 cylinder would be able to pull the taller 5th.

 

only 77bhp my 2.4D but will get getting a KKK K14 Fitted over winter (140bhp)