my caddy diesel

[Turbo Turtle]

i have an 81 rabbit pickup.
rite no i have the stock 1.6 diesel with a turbo bolted on. runs great

 but over the winter i will be putting in a 1.9 out of a 95 golf
so far i have a Audi 5000 intercooler
a KKK turbo off an mk2
the question is whats the minimal amount of stuff i have to do do be running 20 psi boost. also schould i just use my stock tranny or get the mk3? my cousin has one and it revs so hi on the hwy.

thanks
heres some pics of my truck.

[jaed_43725]

The MK3 tranny requires a lot of work as the shifter is way different, and its all hydraulic clutch and such. I already looked into it, and not worth it. If you get a TDI engine though, then its worth it. As far as the highway RPM's are concerned its not a big deal. I am doing 4Kish at 75mph and I have the good tranny. The IDI engines actually flow better at high RPM's than TDI's and can sustain it much easier.

[8v-of-fury]

If you are running 4k on the highway at 75mph, then you have one of the worst transmissions VW ever offered. haha. The good transmissions (like the one I have ) Put me at 3000 at 75mph. To get the numbers you state, you'd have to running a 3.94 final AND a 0.97 5th gear. That is a close ratio gas transmission.

The 95 golf mk3 tranny is not hydraulic clutched or cable shifted.. Only the TDI powered mk3's (and the corrado's) got the 02A transmissions, the rest were 020.

It is not that the IDI's flow better, its just their injection process is a little better sustained at higher RPM's. If anything the TDI engines outflow the IDI engines because they are next gen and have bigger valves iirc.

[BoostedOne]

Depending on what tire size hes running, no 020 is worth a dang on the highway LOL..(his pics arent loading for me)
I just put a CTN O2A box in my caddy(3.15 ring gear, .75 5th) when I did my engine swap and I am in love..  Engine is a non turbo 1.9..A little more power than a 1.6, but not that much..
I don't know what kind of RPMs I was turning on the highway with the old box(FF) but the fastest I usually drove the truck was about 60..  At 70 the engine was whining too bad.. At 80, it was screaming bloody murder.. 

Tire size I'm rolling on 195-45-14's on the drive wheels.  It's even worse if you are running ATS Classics on the 175-50-13's...
I may find it lugs the motor too much and brings down economy, but I was actually figuring it will help by allowing more time for a more complete burn.  I don't notice that I am lugging it too much.

[wolf_walker]

I've found geography has a lot to do with suitable gear rations for non-turbo VW-D's.

I was pretty happy with my 7A in the midwest with a NA 1.6, but it was iffy anywhere hilly.
Was a good match with any of the turbo motors.  I think the NA 1.9 has an AGS in it, not much
diff than the 7A was but isn't as nice feeling for some reason.

[BoostedOne]

Hmm real good point.  If your interstate has grades a na diesel might not like the high gearing very much.  Worst mine has to deal with are those huge super tall bridges over large bodies of water. 

Sent from my MB865 using Tapatalk 2

[RabbitJockey]

If you are running 4k on the highway at 75mph, then you have one of the worst transmissions VW ever offered. haha. The good transmissions (like the one I have ) Put me at 3000 at 75mph. To get the numbers you state, you'd have to running a 3.94 final AND a 0.97 5th gear. That is a close ratio gas transmission.

The 95 golf mk3 tranny is not hydraulic clutched or cable shifted.. Only the TDI powered mk3's (and the corrado's) got the 02A transmissions, the rest were 020.

It is not that the IDI's flow better, its just their injection process is a little better sustained at higher RPM's. If anything the TDI engines outflow the IDI engines because they are next gen and have bigger valves iirc.

actually idi does flow better because there is no swirl thingy built into the intake port, aaz and tdi have the same sized valves, early aaz did have 8mm valve stems tho.

[wolf_walker]

With the NA 1.9 and my .75 5th I never had to go to forth but once from OK to CA, spent a lot of time on the floor @60-65 but
she held, with two people and a bed full.  That was before I got it re-belted and re-timed and cleaned up too.
I'd take the .71 again in this thing overall, I can run 60 in 4th without it being too upset sounding.

If an 020 with a ton of miles just didn't shift like a bucket of rocks...

[8v-of-fury]

A lot of the gearing is pretty retarded in these 020's.. and IMHO not very well thought out haha.

I have an ACN behind the m-tdi, and I can pull hills in 5th from 1400rpm up (55kmh or 34mph).. but the jump between the 1.03 4th anf the .75 5th is HUGE. It is the difference of 515 rpm between gears! which isn't too bad but I do short shift it to slide in to the next gear at about 1400.. and my dp only k03 is screaming at 1900 lol so it sounds beast to short shift.

This ACN trans apparently came behind the lower powered 8v's.. it would have been an absolute DOG with the 3.67.

[wolf_walker]

Yeah, all of Em I've had I thought were kinda off on the gears.

Sent from my SCH-I535 using Tapatalk 2

[R.O.R-2.0]

A lot of the gearing is pretty retarded in these 020's.. and IMHO not very well thought out haha.

I have an ACN behind the m-tdi, and I can pull hills in 5th from 1400rpm up (55kmh or 34mph).. but the jump between the 1.03 4th anf the .75 5th is HUGE. It is the difference of 515 rpm between gears! which isn't too bad but I do short shift it to slide in to the next gear at about 1400.. and my dp only k03 is screaming at 1900 lol so it sounds beast to short shift.

This ACN trans apparently came behind the lower powered 8v's.. it would have been an absolute DOG with the 3.67.

nah, the ACN isnt too bad behind the low-squeezion GX engine.. mine is modified tho. even my buddies stock 87 jetta GL doesnt do too bad.. you just shift down for hills.

the longer gearing is kinda nice.. you only have to shift one time to get going 60 mph..

[DogDiesel]

What I discuss if for when you put the 1.9TD and intercooler in.

When I built my Caddy upgrade, I found I simply was geared too low with the 020 FF.  I used an ASF with .071 OD, and with 13" rims it revved like an old gasser truck.  I then put 15" tires on.  195/55-15.  I used the 210mm clutch and the only real mod needed was a speedometer converter.  The ASF has 3:67 and while the .71 OD made a minor difference, the tire size brought it around.  I have carried more loads on my caddy, than I am pretty sure anyone on this forum, with no rubbing issues.
  As for power, I recently made a trip with an EMPTY 500 gallon fuel tank in the bed of my caddy. I was running cruise control in VA grades, 10-15% and while my cruise will NEVER droop empty, I was drooping @ 5 mph in 5th.  I have yet to aftercool, and I have my boost limited to 6psi.  This was a 130 mile trip loaded, and is on the well on the outside margins of loads that should be transported in a caddy. 
  I am a farmer, and my little caddy is my commuter daily driver, to a real job, as you can't make a living as a small farmer, and when the opportunity to pick up feed, tools, farm implements arise, if it fits, the caddy is the first choice.  I have owned my little caddy since 1992, and brought it from TX across the US during my miltary career, and took it from its original 1.6 whopping 48-52HP where in flat ground, turning on AC was a jake-brake, and where cruise control was to the floor, and max speed was low 70s, to now, pulling cruise any speed above 35 in 5th, and top speed is registered only by Garmin.  I backed off a 100mph.  I pull 85-90 on interstate on cruise.  Since I routinely run freeways speeds at 70-75, and became tired of my coolant gage laying over to the right, installed a Griffin Schirroco race radiator, double pass radiator, and let me just say she runs cool.
  No problems with the 020, or the clutch.  While I don't rip around like a drag racer, I run hard, and carry some fairly heavy loads.  Wish you luck on your little pickup.
Wayne, south central VA