MK2 5 speed in MK1

[Whitetail]

I have a GC trans now and I picked up an AGS 5 speed out of an 86 golf. I was hoping it would be a straight swap but now I see that is not the case.

Although the both physically look the same from what I can gather there are 2 major differences...

GC CV HUB 90MM AGS CV HUB 100MM

GC Clutch 190MM AGS Clutch 210MM

What does this mean? Can I buy 86 golf CV axles and put them on my rabbit? Can I swap the CV hubs?

Does the clutch size matter? Can I leave the 190MM clutch bolted to the engine and put the trans in? Splines the same?

I have also inconclusive research on the linkage, it looks to me that I can use my 4 speed linkage and mounts on the 5 speed but I could be wrong.

Anybody know or done a similar swap?

[TimpanogosSlim]

5 speed linkage is different per bentley diagrams.



.:Sent by pneumatic tubes

[theman53]

I don't think the holes in the trans case line up correctly either. Some trans had both sets of holes, but IIRC the AGS is not it.

[burn_your_money]

Check the diff to make sure it has the studs for the rear motor mount.

You can not use the 4 speed linkage. I think you can get away with only swapping one piece though and it will work.

You can swap the flanges on the transmission, that is probably the easiest way to go. Most MK2 axles are 90mm. All 16v are 100mm and a couple 8v are as well.

For the clutch, you need to match the clutch splines with the input splines on the transmission. I think it's commonly referred to as big spline or small spline but it's been a while...

[TimpanogosSlim]

Per the attached diagram, it looks like you need the 5-speed selector lever for sure, and possibly a 5-speed front selector rod as well. The rod will be cheap from any online parts house. The lever will have to come from a mk1 with a 5-speed.

If you are looking for upgraded linkage, or even just new soft bushings, so far i am very happy with my missinglinkz bits.

[Whitetail]

I wonder if I could modify the GC lever to make it work. I have a 79 with a FF so I can use that as a template.

I also thought MK2 diesels had 90MM CV but I am getting my info from this site http://www.4crawler.com/Diesel/VW_020_transmission.shtml and it says 100MM on the AGS.

I do have a bentley, does it talk about swapping the flanges? It that hard to do? I have never been inside a transmission.

Anyway to find out the splines before taking it apart?

I have a GP (3+E) transmission too, anyone ever driven one? Looking at the ratios I am not sure what it will do to the performance of the car, its the same 1st and higher 2nd,3rd with same 4th as a 5 speed 5th. I do like that it less shifts.

[libbydiesel]

The 5-speed selector lever is approx. 2 inches longer than the 4-speed version.  I modified the selector lever on my rabbit when I installed a 5-speed and it works perfectly.  I cut the 4-speed selector lever and welded in a piece of metal to make it longer. 

Roger Brown (4cralwer.com) sells a bolt-on extension piece if you want to go that route. 

[burn_your_money]

I'm pretty sure that the AGS is 90mm. He has 4S listed twice on his chart, once as 90mm which is correct, and once as 100mm which is not correct.
http://www.scirocco.org/gears/ down at the bottom

Since you have the transmission already, it would take about 10 seconds to measure the actual diameter of the cv flange then you will know for sure since someone could have swapped them around.

You don't need to get into the transmisson to swap the flanges.
http://www.brokevw.com/020flange.html

I prefer a pitman arm puller than what he has rigged up.

[FrankenDiesel]

I wanted to chime this in because I had an axle question when my diesel was in my mk2 vs mk1.

My mk1 was receiving the swap and was an auto with 100mm flanges. The mk2 engine was mated with a manual tranny and 90mm flanges. The knuckle end splines were the same mk2 vs 1 but then again it was an 89 cabrio.

The only issue I had was the rear mk2 tranny mount arm was in the way to install from above (maybe if I lowered the body onto the engine it would have fit). But either way I cut the mk2 arm mount for clearance and then used mk1 mounts.

[Whitetail]

Cool, I am going to measure it tomorrow. It prob is 90, i trust scirocco guys info more that the crawler website.

All the splines pretty much the same for the 020 manuals?

After some research there are some folks that prefer the 3+E with a turbo because the gears are longer, I do plan on adding a VNT 15 or 17 whenever I find one so I am not sure which way I want to go now.

[burn_your_money]

I wouldn't put the GC in the 3+E category. 4A, yes but pretty much any 5 speed will have taller gears than the GC.

[Whitetail]

The gc is what's in the car now. I have an ags and a gp(3+E) with a .71 4 th gear. I was planning in swapping in the ags but am now considering the gp.

[Whitetail]

Good News, despite 2 sites, crawler and brokevw, showing the AGS to have 100mm flanges they are infact 90mm. Also according to this site http://www.a2resource.com/eandt/ratios.html the AGS has the same 22mm input shaft and 16 tooth speedo gear so it looks like it will swap right in.

I see on my 5 speed rabbit the angled and longer lever so I can buy/fabricate that.

Last thing I need to figure out is how to do it LOL. I guess I need to make an engine support thing first. I have steel tube an all that but I know the 1.6 is light, a 4x4 with a long bolt with a hook on the end should work right? Any other tricks?

[theman53]

The AGS was not an MK1 trans. the holes will not line up for the trans bracket

[Whitetail]

The mounts look similar, can I drill new holes in either or to make it work?