Author Topic: trans problems- 5th gear swap? (Read 4795 times)

Patrick · « **on:** June 29, 2007, 06:33:39 pm »

Driving a 92 jetta with an AAZ . Car has an AWY trans that I'm pretty sure had a .71 5th gear swapped into it before I got the car,(runs about 2000rpm at 80kph) worked great for the last 100,000 km.
Started to howl in 5th, checked oil and there's lots there. Later that day, started to jump out of 5th.
Checked my stock, I have a 7A on the shelf (worked good but leaked, needs seals +?) as well as an ACH on the shelf that I know nothing about. I also have an AGS still in a car, same deal, never drove it.

Trans is working good other than 5th, pretty sure a 5th gear swap would fix it and save me pulling a tranny and fighting with the older style (big) backup switch. Problem is I can't find the thread I know I saw about doing this job. Anyone got it bookmarked?

QuickTD · « **Reply #1 on:** June 29, 2007, 08:04:35 pm »

There is a decent write up here,

http://www.driversfound.com/scirocco/techtips/5thgearconversion/

burn_your_money · « **Reply #2 on:** June 29, 2007, 08:09:01 pm »

www.brokevw.com also has one

Patrick · « **Reply #3 on:** June 30, 2007, 04:19:15 am »

Thanks guys I'll have a look.

Patrick · « **Reply #4 on:** June 30, 2007, 07:13:26 pm »

Change of plans. the tranny is coming out. Went to town today to pick up a few parts (about 70k round trip) and was having the same problem with third gear, this thing is toasted. Even making noises sitting still with the car running. Current plan is to pull the end of the 7A apart and check the .71 gearset, if it looks good put it in the ACH and install. Otherwise the ACH goes in as is. Only problem will be the backup switch, have to go to the big one and don't think I have a good one of those (not sure yet). Busy tomorrow, so this looks like Monday's project. Wish me luck........

BTW the links on the swap are good, looks like I have (or can make) all the tools.

Patrick · « **Reply #5 on:** July 07, 2007, 04:29:29 am »

Been a busy week. Pulled the .71 5th gear from the 7A, looks good but I'm not sure about the bearing. So, the other tranny is going in with the .75 in it. Should be about 150 rpm difference @ 100 k if the charts are right. Got the tranny bolted to the back of the engine last night, going to finish the rest today and see if it's any good.
Did notice the flywheel/clutch looks completly different. Three groups of three bolts to hold the flywheel on?
Casting# on the flywheel is 027 - 105 273 D
Number on thhclutch disc is 068 141 037G

Is this standard stuff on a 1.9?

BTW, is anyone going to Joe's swapmeet next weekend? (St. Mary's on)
Maybe one of the "experts" can tell me if this .71 gearset is worth keeping/using............

Patrick · « **Reply #6 on:** July 09, 2007, 03:03:27 pm »

Got the car running on saturday, trans seems to be fine. Ran to London and back on sunday (about 200k round trip)
Sold on this box. Has the same high gear (about 120k at 3000 rpm) and better spacing between the gears. Drops from 2500 to about 1700 on the first two shifts, drops to about 1800 on the 3-4 shift, and drops to about 2000 on the last shift.
Clutch feels completely different too, and I never touched it. I would have sworn I had a ceramic clutch before, very grabby. The only thing different is the push rod and throwout bearing. Pushrod was worn off flat (clutch end) in the AWY I took out.
Even got the backup lights working, had a good switch. Funny thing, had to hook red/black to blue/black and blue/black to red/black, wouldn't work red/black to red/black and blue/black to blue/black.....

Still wondering about more gear...........

burn_your_money · « **Reply #7 on:** July 09, 2007, 08:00:29 pm »

Glad to hear you got it all taken care of. VW did switch from a 6 bolt to a 9 bolt flywheel somewhere along the way