1991 MF 1.6TD --> 1981 Jetta Bastid'

[8v-of-fury]

So I picked this up the other day because it has a newly rebuilt 1.6TD, I also am getting the 1984 1.6 N/a and 4spd 4A trans (out of this rabbit) in front of the rabbit in the second picture.




And I was thinking this would make a good reliable, minimal power mods engine for my 84, in place of its guzzling 1.7 CIS gasser..



Real Ontarian highway driving (Shift light tells me to shift up in 5th.. its stoop-id) Sad thing is there was still people passing me at this point 




So what I was thinking, was that I can take the 1.6TD and the clutch that it has on it (as it felt pretty solid on the test drive) and just bolt the 4spd 4A up to it. The reason I am not just going to keep the 5spd is because it has some bad grinds to it, that i don't need failing on me in the middle of BFI. The combination will be a real torque monster I think, the 4A has incredibly tall gearing. With a 3.94fd and .70 4th it will cruise 100km/h @ 2400 on 175/80/13's.

From my understanding any 020 transmission will work with any 020 clutch, its keeping the clutch parts matched (190, 200, 210 and so on..) that is the major concern. Will there be any issue in just popping off the 5spd and mating up the 4spd? Just a couple bolts?

[R.O.R-2.0]

your gonna want a 5 speed buddy, i know this from experience, i too own a 4A trans, and they have RIDICULOUS long gear spilts.. and you kinda gotta have quite a bit of power to make it worth while.. my car would have been so much nicer to drive if it had a 5 speed, rather than the stupid long geared 4A..

its a good trans, none the less, but you wont like it very well once you get used to it and the newness wears off.

honestly, its in your best interests to just do yourself a favor and find a nice ACN or something like that. ACN trannies ROCK!
(equally tall 5th gear, but slightly closer 1-4, its a really fun trans (ACN)

[8v-of-fury]

I do agree with you that the gears are way crazy spaced.. but I have driven said rabbit when it had the 4A 4spd, behind the 1.6 N/a. I think a %25 power increase over that will be completely livable.. if I don't like it? how hard is it to swap out a tranny? the 5spd on it has a nasty sounding reverse.. or i'd use it no questions asked.

[8v-of-fury]

ok, so what should I do here? Got a question about ordering a clutch kit..



This picture to me, shows a PP, Disc, TO bearing, and an alignment tool?? the small gray round thing is what the bearing pushes on, and the clip is for what? So in ordering this. I could order a 210mm clutch kit and bolt it in one of my 020's? most are 24 spline?

dammmn i dunno what i'm doing here

Drove the car back in to town (35kms) to a buddies where were going to do the swap, and the car has a weird chugging sound to it.. hard to describe.. might just be an exhaust leak?? drove it pretty hard and by the end of my drive it was running superbly.

What do i do for a transmission here boys? I'm thinking I might have to just settle for putting it behind the 4K.. I mean the highest RPM it would ever need to see is only 4000.. and that gets me 130km/h I'm sure this little engine will have no problem with 4000rpm for the minimal times its on the highway.

[theman53]

You have to get the small 24 spline setup. 8V scirocco I think had it in 210mm.

[8v-of-fury]

i have found a 24 spline 210mm, just.. what 020's are 24 spline and what are 22 spline I have no idea sadly

[theman53]

IIRC the 020 before 93 were the small 24 spline except some 16V. Passats maybe too??? All of the diesel boxes were definately small splined.

[8v-of-fury]

well that makes life easier thank-you good sir.

I fear what people say about the 4A being too far spaced.. and it being a real dog.. shiii

[8v-of-fury]

WHAT ABOUT!!

Putting the TD against my 81 FF/FN, and buying a 210mm clutch kit for the 4spd and putting it behind my TDI until I get the 02A sorted out, eh eh eh?!

[maxfax]

The TDI in front of a 4A may be better but...     I had a GP or something like that in the green Rabbit..  Around town and flat terrain on the highway it was fine.  I kinda got used to the thing and knew where to shift for it to run half decently..  However the 2 times I remember the thing sucking the most was on hills, and trying to pass on 2 lane roads..  It was either screaming with no speed, or bogged down and lugging with no speed...

[sprstu]

When you go to the 210mm clutch and PP you also need a 210mm flywheel. That little ring thing in your picture is the clip that holds the grey disk in place on the PP.
Im not sure if it will screw you up going to a 4spd from a 5spd, i cant imagine it would be seem less, but you will also need the shifter linkage, shift relay lever and maybe even the shifter box (its the piece that is bolted to the car, the all metal bit with the reverse lock-out) Maybe going to a 4spd is easier that going to a 5spd, i dont know.

[R.O.R-2.0]

IIRC the 020 before 93 were the small 24 spline except some 16V. Passats maybe too??? All of the diesel boxes were definately small splined.

any 16v 020, or post 93 020, will have the 24mm shaft,
any other 020, will have a 22mm shaft..

a 16v clutch disk (24mm hub) will NOT work on an 8v (22mm hub) transmission.

[R.O.R-2.0]

I do agree with you that the gears are way crazy spaced.. but I have driven said rabbit when it had the 4A 4spd, behind the 1.6 N/a. I think a %25 power increase over that will be completely livable.. if I don't like it? how hard is it to swap out a tranny? the 5spd on it has a nasty sounding reverse.. or i'd use it no questions asked.

split the case and replace the reverse idler. you can use one out of a 4spd or 5 spd.. i learned that one a while back when i blew up reverse in my 9A

and jermo, i had a rabbit with a VNT, 22 psi, and an open downpipe. 3rd gear is too short for climbin hills, and 4th was almost too long with 22 psi.. thats the only reason im warning you about it..

it was WAY TALL.. my car would have been quite a bit quicker/faster with a good 5 speed..

i didnt have an intercooler, so i got really bad heat soak problems in the top of 4th.. 1-3 pull like a mofo, then 4th is just sooooo damn tall..

[R.O.R-2.0]

The TDI in front of a 4A may be better but...     I had a GP or something like that in the green Rabbit..  Around town and flat terrain on the highway it was fine.  I kinda got used to the thing and knew where to shift for it to run half decently..  However the 2 times I remember the thing sucking the most was on hills, and trying to pass on 2 lane roads..  It was either screaming with no speed, or bogged down and lugging with no speed...

GP 3+E trans from a pickup? basically the same layout as the 4A.. you gotta have lots of boost to make the 4A any fun. when i first got my car, i hated the trans, cause it was a stock n/a..

[theman53]

That is what is in my car right now. I have an 86 AGS  020

Make sure when mixing and matching the flywheels you have the pressure plate centered with the pins. MKIII flywheels I think have only 1 pin instead of 2 like the MKII, just what I have heard.