Tranny & clutch

[Maarten]

The next thing on my list is a gearbox/clutch upgrade, I've got a 020 4S GTD gearbox with a slipping clutch and 90mm driveshafts behind my 1.9TD AAZ. the clutch can't hold 244NM/180ftlbs and I already broke one inner CV joint.

I already have a complete cableshifted CEX code 02A 5S gearbox with 100mm driveshafts from a passat around (been given to me as a 1.9TD passat box). Got 3 questions about the gearbox, does anyone know where I can find the gear&finaldrive ratios and is it comparably strong as a gearbox from say a Mk3/Mk4 TDI? (capable of 300+Nm)

Last question is, does it fit my AAZ? I've read that there are 2 different mainshafts with different teethcount. How many teeth has the stock gearbox? Mine has 28 splines (correct english?)

I want to upgrade to a sportclutch with some tuningroom left (possible 300Nm) and should be reasonably streetable, when the CEX fits but brakes down ealier than I expected can I still upgrade to a TDI gearbox and keep my clutch setup? I've read the old clutchthreads so I conclude that a Sachs sportclutch is a good option, maybe combined with a lighter flywheel.

[Maarten]

I found great site for comparing different clutches:

http://webcat.zf-trading.com/index.asp?SPR=1 (change language below, sprache:)

I found that the clutch on my 1.9 should be a 210mm with 24 teeth, my tranny has 28 teeth so I need a new clutch to make it fit. I'm going to call the Sachsdealer to info what options they have.

1.6GTD: 24 teeth/210mm
1.9TD: 28 teeth/215mm
1.9TDI mk3: 28 teeth/228mm
1.9TDI mk4: 28 teeth/220mm

Does any flywheel from a mk3/mk4 TDI fit my AAZ?

[vwmike]

You have much more in the way of engine/transmission choices over there, but I can tell you the way it works here in the US.

02A - G60 Corrado, Passat TDI/16v, and the MK3 Jetta TDI should conclude the list of 4 cylinder incarnations of this transmission. It was also used on the Passat/Corrado/Golf/Jetta VR6 engines with a different bell housing.

02J - MK4 Golf/Jetta - All. TDI's had the 100mm CV's, otherwise they were bigger and you need the outdrive flanges off of the 02J TDI trans to make it work in anything but a MK4. They also used this trans in the Audi TT 5 speed cars

02M - 6 speed - New Beetle S, GTI 337 (180hp 1.8T - US edition of the 25th anniversary GTI), Audi TT 6 speed and Quattro. Also I beleive this would be what was used in the R32.

02A cars used a 228mm clutch with the exception of the TDI which was smaller - something like 220 or 225mm. 02J cars used a dual mass 215mm clutch setup which sucks. It lasts something like 20k miles. All of the upgrades we use are to use a VR6 clutch (228mm) on a G60/Passat 16v flywheel. The splines between the O2A and O2J are the same as far as I've heard. In 2001 they revised the syncros in the O2J (not sure if this was just in the 1.8t, or across the board) so it should be a bit stronger than the earlier 02A's. The shift tower on the O2A will fit on the O2J and features limits on the gears so you can't 'over-throw' a gear. The mount on the end cap is slightly different between them, but either can be made to work.

[Maarten]

I don't want a dual mass flywheel... I want a light flywheel (but still drivable) with a strong clutch/pressureplate.

All of the upgrades we use are to use a VR6 clutch (228mm) on a G60/Passat 16v flywheel.

On a Diesel? Isn't the flywheel of a gasser too light compared to the dieselflywheel?

[vwmike]

I don't want a dual mass flywheel... I want a light flywheel (but still drivable) with a strong clutch/pressureplate.

All of the upgrades we use are to use a VR6 clutch (228mm) on a G60/Passat 16v flywheel.

On a Diesel? Isn't the flywheel of a gasser too light compared to the dieselflywheel?

That G60 flywheel is quite heavy....the only time you might run into an issue is if you use an aluminum flywheel. Even lightened, the G60 flywheel is still heavier than the stock 1.6td flywheel.

[Maarten]

I just searched for a G60 flywheel and found one for €25,- (still waiting for the price to have it lightened/balanced) and got a price for the Sachs sportclutch for streetuse, €363 incl VAT and discount (normal price €470,- ex VAT)

Do you know what the 1.6TD and G60 flywheel weigths? On my 1.9 AAZ should be a 1.6GTD flywheel cause the gearbox is from that car. And what is the limit for sporty streetdriving?

[DVST8R]

I don't know what the stock wieght of either though as I am writing this I am recalling 12-15 for the 020 depending on the variant 190-210mm and about 22lbs for the g60. I currently run a 6lbs flywheel on my 020 and love it for street driving, the acceleration is great, doesnt lug in traffic as well but still better then any honda I have owned.  :lol:

[BlackTieTD]

02Os are cable clutch, 02As are hydraulic clutch. i didn't see any mention of this.. but that is a consideration. i much prefer the feel and simplicity of the cable clutch system.

100mm flanges and a bolt kit can be installed on your 02O to beef it up if you want to go that route...

[Maarten]

DVST8R> I'm going to weigh it a soon as I get my hands on it and shop around for some more info about a lighter flywheel on a diesel. 6lbs seems a bit light to me.

BlacktieTD>

I've got a complete tranny with cableshifter, cables and pedalbox with hydraulics. My larger downpipe is fabricated on a 1.6TD so I ran into a small shift problem when I installed it, I couldn't shift to 2 and 4 anymore because the C-clamp was blocking the rod. I modded the lever a bit so it sits about 2cm higher. the mechanism needed overhaul anyway so I'm better off with cables maybve I'm going for a mechanical clutch but I don't know yet.

[Maarten]

02As are hydraulic clutch.

Some types of VW transporter T4, Seat Toledo and Seat Ibiza have a mechanical clutch on a 02A box.

The dude which has a 1.9 single mass TDI flywheel for me weighed it at 20.9lb (9.5kg), so thats needs some serious shaving  :shock: When I pull my flywheel I'm going to weigh that too, if it is about 5.5kg/12lb I'll shave the new flywheel to 4.5kg/9.9lb to start with

[Maarten]

I just recieved my TDI singlemass flywheel with pressureplate and clutch, I weighted the stuff:

On my AAZ now:
Complete: 10.6kg / 23.37 pounds
Flywheel only: 5.7kg / 12.57 pounds

TDI:
Complete: 15.6kg / 34.39 pounds
Flywheel only: 9.6kg / 21.16 pounds

I don't want to go heavier with the new flywheel/clutch combination so I want to shave some 6-7kg / 13-15.5pounds off the TDI flywheel to get to a total overall weight of 1-2kgs / 2.2-4.4 pounds less then my setup now . Is it possible to shave off that much weight without weakening the flywheel too much?

[djteam]

Hi,

Of course, you can weight it to the 10kg, no Problem.

I took a CYP of an TDI on my AAZ IDI.

Switched to cable clutch to.


I think you will have no fun with this Tranny, it´s way to short!

1.)3.77
2.)2.117
3.)1.344
4.)0.971
5.)0.755

Final:3.944


christian

[DA-BRT]

02As are hydraulic clutch.

The dude which has a 1.9 single mass TDI flywheel for me weighed it at 20.9lb (9.5kg)

Yeah... I'm the dude.... hihi

Member: Caddy on this forum has found a topic on a French forum (Goolf)which explains what is needed for mounting a mechanical clutch on a 02A.

Hope to get started on the gearbox studs for mounting the 02A in the MK1 body next week.

[hillfolk'r]

im building a mech. tdi,,and imusing the old 020 trans,,ive got a light flywheel,6 pounds,,i had the guys at work turn the weight off at work,,what a rip like 150$ for a lightened fw,,,then i also removed the crankpulley,,its way too heavy,just got the stock rabbit belt setup,,musta eliminated 20 pounds ,,,,that stock tdi fw is heaavy!!im runnin a centerforce d/f clutch,,iwas quite happy with it on my 1.6 td,,it would chirp3rd no problem,,,,its sweet,,the center sprung hub has the springs doubled up,,really eliminates alot of drivetrain lash,,,,the friction material is very grippy too,,,,,

[DA-BRT]

@hillfolk'r: Correct me if I'm wrong.

You took the fuelpump pulley from a 1600 and also the camshaft and krank pulley from the 1600?

What I noticed placing my modificated 1900TD pump on my AHU engine is that I defenitly need a 1900TD fuelpump pulley. This because the offset of the 1600(T)D fuelpump pulley is not correct and not lining Up with the other pulley's.

What kind of tension pulley did you used than? I can imagine that the TDI one hasn't got the right offset either?