Author Topic: Best 5spd gearbox for a PD150 engine (Read 5353 times)

Amit · « **on:** January 30, 2008, 07:08:43 am »

Hi guys,

I am doing a PD150 conversion into a mk1 caddy.

I want to use a 5spd gearbox to make the conversion easier and save some weight up front.

What would be the best gearbox to use? I was thinking a DEA code 02J box from a mk4 110 TDi.

The other issue I am not sure about is.. how will 15" rims with 195/45/15s effect the gearing..

also.. if anyone wants to swap a 5spd box for a 6spd, give me a shout

aidan · « **Reply #1 on:** January 30, 2008, 01:03:38 pm »

o2a would possibly be easiest and cheapest, off the mk3 tdi, you can use the stock smf and a vr6 clutch. Only thing is every o2a car i've driven has a *** gearchange, i had a dieselgeek short shift on my vr6 and it improved it, but still not great.
02j is a much nicer change but has the dmf, or rattles apparently with a smf

Amit · « **Reply #2 on:** January 30, 2008, 01:16:55 pm »

hi, thanks for the info. Why would the dmf be a bad thing/ cause issues?

Amit

aidan · « **Reply #3 on:** January 30, 2008, 02:02:13 pm »

it may well be fine, but they are much more prone to failure than the single mass and very expensive. You will 100% need an upgraded clutch maybe even on standard power, and they are expensive too. A vr6 clutch may well be fine and they are only about £100, and you can use any 02a flywheel, i.e tdi, 2.0 16v, G60 and you can get them for nothing. I think they are a bit lighter too.

I don't know if this applies to VW, but on the fords with dmf's, its much easier to stall as they cut the power at idle to prevent damaging the dmf. if this is the case, you can up the fuelling at idle and it'll drive like a 1z/ahu, much much better in traffic and hill-starts etc

Amit · « **Reply #4 on:** January 30, 2008, 05:15:30 pm »

to keep the cost down, do you know if the 02A or 02J box will work with the 02M flywheel and dmf clutch? I can replace when it brakes.

Amit

Tintin · « **Reply #5 on:** January 30, 2008, 05:17:46 pm »

A PD150 in a MK1 waow..!!! that goes burn the tires in fifth gear... héhéhé!!

If you plan to chip your engine, the VR6 clutch will not support all these HP/LBFT, in the past I burn in one week a VR6 clutch with only a M-TDI set-up at 164HP.

I have this PD150 set-up at 28PSI (vnt20) and max tuning fuel... etc.. and It's a real monster, I have a 240mm ceramic disc and it tend to slip a little some time when the clutch is cold.

aidan · « **Reply #6 on:** January 30, 2008, 07:06:32 pm »

6 speed has 240mm flywheel as tintin has mentioned, o2a has 228mm and i think, but not sure, o2j is slightly smaller? 225mm possibly.
Is it not possible to use the 6 speed box? It has the best shift of the lot in my opinion and would be worth the extra weight, surely someone has put one in a mk1

Amit · « **Reply #7 on:** January 31, 2008, 04:03:57 am »

Yes it is possible to use the 6spd box but its tight.. and will need custom shortened driveshaft.. (big bucks!)

The 02A/02J drop straight in

Amit

Tintin · « **Reply #8 on:** January 31, 2008, 11:08:42 am »

custom shortened driveshaft, go to a machine shop in your area, if the guy is honnest, that cost around 60 + - 80$ each.

vwmike · « **Reply #9 on:** January 31, 2008, 01:42:46 pm »

Quote from: "Amit"

Yes it is possible to use the 6spd box but its tight.. and will need custom shortened driveshaft.. (big bucks!)

The 02A/02J drop straight in

Amit

The 02M is still a tight fit in the MK3 even. It took a little more effort that normal to get the engine/trans into my car even after the mounts were all sorted out. I think the biggest issue might be the differential clearance to the steering rack. Mine didn't clear very well and that is why I had to run the automatic mount brackets which push everything forward about 16mm.

MikkiJayne · « **Reply #10 on:** February 01, 2008, 05:59:55 pm »

I have an 02A 5-speed from a mk3 that I'll swap for your 02M if you're serious! I'll throw in TDI SMF flywheel too

The code is CTN which I believe is an 02A box with 02J diff, although whether that makes much difference I don't know. I'm running a short shift on it and the shift is pretty good, but I've never driven an 02J to compare it to.

I'm running it on 195 45 15 on my Corrado, and even with only a TDI90 attached to it its pretty quick :wink: It will be absolutely bonkers on a PD150 in a mk1 :shock:

Top speed is about 120 @ 4200rpm.

Mikki x

Amit · « **Reply #11 on:** February 02, 2008, 07:44:40 am »

I really need a mk4 box with mounts because I am welding the mk4 mounts into the mk1.

Amit

MikkiJayne · « **Reply #12 on:** February 02, 2008, 12:58:34 pm »

02A and 02J casings are the same - it's only the alloy bracket that makes it fit the mk4. I can find a bracket for you....?

Amit · « **Reply #13 on:** February 03, 2008, 05:29:08 am »

OK it sounds like an interesting propostion..

You being in devon, how do you propose we do the swap?

What are other peoples opinion on the 02A box? Will it take the power/torque?

Amit

Tintin · « **Reply #14 on:** February 03, 2008, 10:56:24 am »

02A/02J are good transmission, and I believe that it will handle the PD150, If not, you have no other choice than the 6spd.