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Engine Specific Info and Questions => IDI Engine => Topic started by: g-spec on March 03, 2007, 10:52:37 am

Title: 5th gear swap questions!!
Post by: g-spec on March 03, 2007, 10:52:37 am: I can get a .75 5th gear from a TDI 020....Just wanted to know whether or not it will fit into my 95 1.9 IDI???
thanks...I know this has been beat to death already!!!
Cheers, Michal
Title: 5th gear swap questions!!
Post by: 935racer on March 03, 2007, 06:37:47 pm: Tdi's never had o2o transmissions, they either have o2a, o2m, o2j, o1m... And none of those gears will fit an o2o gearbox.
Title: 5th gear swap questions!!
Post by: g-spec on March 03, 2007, 07:23:37 pm: So what are the options I have? where can I get a longer 5th???
Title: 5th gear swap questions!!
Post by: 935racer on March 03, 2007, 10:54:07 pm: Get a 3.67 R&P and a .71 5th.
Title: 5th gear swap questions!!
Post by: g-spec on March 04, 2007, 12:34:16 am: I am very new at transmisions.....can you expand on that!!! and is it something I would be able to do without taking the tranny out???? I just want to lower the rpms on the highway!!!
Thanks
Michal
Title: 5th gear swap questions!!
Post by: Op-Ivy on March 04, 2007, 09:52:02 am: Quote from: g-spec
I am very new at transmisions.....can you expand on that!!! and is it something I would be able to do without taking the tranny out???? I just want to lower the rpms on the highway!!!
Thanks
Michal

From what I've heard you do need to take the transmission out to do something like that. You also need a special tool once you are inside.
Title: 5th gear swap questions!!
Post by: QuickTD on March 04, 2007, 10:42:33 am: The 020 transmission used in the 1.9TD alrerady has the tallest regular production final drive available @3.67. The fifth gear ratio is already 0.75. There is one ratio available that is taller than stock. The gears are from a 81 up FF/FN/FH or 7A tranny, they are 0.71. The difference is negligable, about 5%. I did the swap because the bulk of my driving is highway and it makes the engine sound a little more relaxed, particularly above 120km/h. It has no effect on fuel economy that I can tell.

The swap can be performed with the tranny in the car. A few special tools are required, a 12mm triple square and a special wrench to release the 5th gear fork. the special wrench can be made pretty easily from a piece of tubing. Instructions and pictures are available at http://www.driversfound.com/scirocco/techtips/5thgearconversion/, I would highly recommend reading them before attempting the swap.
Title: 5th gear swap questions!!
Post by: g-spec on March 04, 2007, 01:33:26 pm: So I found a FF 5th gear swap from a 83 rabbit...From what you said QuickTD that should work no problem???
thanks, Michal
Title: 5th gear swap questions!!
Post by: QuickTD on March 04, 2007, 08:50:48 pm: Quote from: "g-spec"
So I found a FF 5th gear swap from a 83 rabbit...From what you said QuickTD that should work no problem???
thanks, Michal

Any 8 valve gearset will fit. Be sure to count the teeth and do the math though, some early FF's had a 0.75 in them, an '83 should be 0.71 though.
Title: 5th gear swap questions!!
Post by: g-spec on March 05, 2007, 05:00:06 am: Is there any longer hear that I would be able to use....Something under 0.7....I do a fair bit of highway driving and I wanted to be able to cruise at 120...with the roms under 3K!!!
Title: 5th gear swap questions!!
Post by: QuickTD on March 05, 2007, 05:46:55 am: Quote from: "g-spec"
Is there any longer hear that I would be able to use....Something under 0.7....I do a fair bit of highway driving and I wanted to be able to cruise at 120...with the roms under 3K!!!

Not really.

There is a 4 speed 020 gearbox used in the early 80's dodge omni that has a taller final drive, but these gears cannot be used in a 5 speed because the pinion shaft has no extension to hold 5th gear. VW motorsport also used to offer a "landspeed" final drive, somewhere around 2.9:1. Not sure if this is still available, it costs thousands of dollars. There is also the 02A (TDI) tranny option, but you'll need all the hydraulic clutch parts and cable shifter parts as well as the flywheel and clutch from the TDI, but it's probably your cheapest option in the end...
Title: 5th gear swap questions!!
Post by: burn_your_money on March 05, 2007, 05:54:53 am: I sit at about 3000 rpm at 120kmh. I have my small winter tires on though so that throws my speed off by 10 kmh (higher) and my rpm is higher as well.
I have a stock 4S transmission
A 4A transmission from a rabbit has even taller gears but it is a 4 speed. I'm still debating putting one into my mk2 Jetta. It would require custom mounts.
check www.brokevw.com and the manual transmission FAQ on vortex. It's in the technical section.
I was looking around at different transmissions and there is one that will put me at 2500 at 120. I think that might be too tall though
Title: 5th gear swap questions!!
Post by: g-spec on March 05, 2007, 05:58:24 am: Thanks guys for the help....I think I'll stick with the 0.71 5th for now.....it will be better than anything else!!!
cheers, Michal
Title: 5th gear swap
Post by: mvptrukin on March 05, 2007, 10:53:35 am: You might want to call the folks at www.longenterprises.com although they have mostly air cooled Xmission parts they carry many watercooled
parts and tools. Alot of the stuff they have isn't on the website.
Title: 5th gear swap questions!!
Post by: jtanguay on March 05, 2007, 11:00:13 am: hmmm i wonder how much 5th gear would cost to buy from them.. that 0.71 ratio seems nice!
Title: 5th gear swap questions!!
Post by: Mark(The Miser)UK on March 05, 2007, 11:48:53 am: Quote from: jtanguay
hmmm i wonder how much 5th gear would cost to buy from them.. that 0.71 ratio seems nice!

There is a .53 that comes from the 5 ganger inlines but I'm not sure if the drive holes are at all similar. Would be nice to fit it to the Q TD. I've not had the oportunity to check this; since I sold my last 5 ganger 8 years ago...