Author Topic: PD gearbox (Read 3189 times)

oldskool rich · « **on:** May 04, 2008, 06:07:21 pm »

ive just bort a 2.0 6 speed gt tdi gear box to go on my AAZ mk1 caddy.

has anyone done this before?

anyone know how i can make the shafts fit? and the engine mounts?

any advice wud be good :oops:

cal · « **Reply #1 on:** May 05, 2008, 01:49:46 am »

shorter drive shafts are needed (the ned to be custom made) as for mounts check the caddy forum. then you'd need a seat cable shift setup (can't remrmber the exact model but it's the onewith the shortest cables you need) also a seat hydro actuator to run a cable clutch.

it's a lot of hassle and money tbh!

numbnuts · « **Reply #2 on:** May 05, 2008, 03:41:28 am »

hi rich, whats the gearbox code? I think some of those boxes are based on the 02m boxes. Infact i think all of them are. I think it was the 1.9 tdi box that was based on the 02a. I put this 6 speed into my mk1 16vg60 as it is alot smaller than the 02m 6 speed. The side gearbox mount will be alot different and will be a hang it in there and fab up a mount job and should sit ontop of the chassis leg, would be wise to weld in some supports to this leg too. The rear can be fabbed up using the mk1 mount. Not sure on the front :? Its not impossible though as i am sure u have the skill, we put this box and engine into my mates bay window camper, will put up some pics if u want, although not much of a comparison :lol:
Also there are some gearbox mount pics in my build thread.........
http://www.dubforce.net/forums/index.php?s=44816382ba182bc8b923598b7e934e99&showtopic=9163
Cheers Joel

oldskool rich · « **Reply #3 on:** May 05, 2008, 05:36:35 pm »

i looked at ur build tread, very helpfull, although your box is quite different to mine, my box is much chunkyer, still dont know the code, ive looked all over it and cant find anything. its off a mk5 golf 2.0 PD if thats any help. i see you know dubshack, its a small world.

btw your engine is amazing.

also clutch cant be changed to cable as the seat thing wont fit

, im gona have to use sum kind of master cylinder, any ideas?

cal · « **Reply #4 on:** May 06, 2008, 03:13:09 am »

if you can't use the seat clutch thingy, you'll need to change the pedal box (which a you probabl know is a big job)

snakemaster · « **Reply #5 on:** May 06, 2008, 04:30:58 am »

Hey rich i like the sound of the 6 speed trany i may get one for my mk2 yet
this bit may help you out http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&rd=1&item=320232113676&ssPageName=STRK:MEWA:IT&ih=011

numbnuts · « **Reply #6 on:** May 06, 2008, 07:42:50 am »

Quote from: "oldskool rich"

i looked at ur build tread, very helpfull, although your box is quite different to mine, my box is much chunkyer, still dont know the code, ive looked all over it and cant find anything. its off a mk5 golf 2.0 PD if thats any help. i see you know dubshack, its a small world.

btw your engine is amazing.

also clutch cant be changed to cable as the seat thing wont fit , im gona have to use sum kind of master cylinder, any ideas?

Yeh i know daz and the guys at dubshack, also used to work at cov uni in the engineering dept. Small world.
To get the hydraulic clutch to work, get hold of a corrado master cylinder, make a plate for it to bolt onto and weld under the dash nesxt to the steering column. On the mk1 pedal assembly there is a take off that fits the rod perfectly, you will see it when u get under there. Then just plumb it in :wink:

oldskool rich · « **Reply #7 on:** May 06, 2008, 05:16:48 pm »

Quote from: "snakemaster"

Hey rich i like the sound of the 6 speed trany i may get one for my mk2 yet
this bit may help you out http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&rd=1&item=320232113676&ssPageName=STRK:MEWA:IT&ih=011

this wont work, already cheacked this out, my box is totaly different but thanx anyway

Quote from: "numbnuts"

Quote from: "oldskool rich"
i looked at ur build tread, very helpfull, although your box is quite different to mine, my box is much chunkyer, still dont know the code, ive looked all over it and cant find anything. its off a mk5 golf 2.0 PD if thats any help. i see you know dubshack, its a small world.

btw your engine is amazing.

also clutch cant be changed to cable as the seat thing wont fit , im gona have to use sum kind of master cylinder, any ideas?

Yeh i know daz and the guys at dubshack, also used to work at cov uni in the engineering dept. Small world.
To get the hydraulic clutch to work, get hold of a corrado master cylinder, make a plate for it to bolt onto and weld under the dash nesxt to the steering column. On the mk1 pedal assembly there is a take off that fits the rod perfectly, you will see it when u get under there. Then just plumb it in :wink:

got my linkage today and got sum idea how to bodge up sum mounts, found out that custom shafts mean 2 shafts stuck together, so i might as well do it myself than pay sumone hundreds
sanburns are helping me out big time, gona sort me out a pedal + mastercylinder.
im good mates with daz hes a ***ing hero.
pretty sure i saw a pic of your engine in golf+ this month congrats, im in there too

my next project is mounting a supercharger, do you mind if i pm you with a few questions as it unfolds :oops: you realy seem to know your ***

numbnuts · « **Reply #8 on:** May 07, 2008, 04:25:36 am »

haha, yeh it was in the golf+ this month, it was a nice compliment i thought

Ask away, but i tend to make it up as i go along

jtanguay · « **Reply #9 on:** May 07, 2008, 12:49:59 pm »

as for the master cylinder, thats not really that hard. just mount the master cylinder to the firewall and fab up a linkage system to it (make sure that the shaft isn't pushing on an angle to the master cyl or it will wear out fast. you want to be as dead center as possible (so making a linkage will most likely be necessary)

as for the mount, check out vw_mike's mk3 with a pd150 & 6 speed box. he bought a bracket that fit in quite nicely. you could probably fab up something no prob.

as for the driveshafts, i think there is a way to keep the end that connects to the flange on the transmission, and splice it onto your original shafts. if you decide to just cut and weld them up make sure its a good weld.

sounds like you are on the road of speed. that box should propel you quite fast with relatively low rpm's for added economy :wink:

numbnuts · « **Reply #10 on:** May 07, 2008, 01:07:40 pm »

as for the driveshafts, i think there is a way to keep the end that connects to the flange on the transmission, and splice it onto your original shafts. if you decide to just cut and weld them up make sure its a good weld.

yep i was thinking i would get some tube with the ID interferance fit over the OD of the driveshafts. Cut the diveshafts to the correct length, knock the into the tube and weld it up, job done