4 speed to 5 speed mk 2

Hello

I'm fitting a mk 2 8v engine and box in my Mk1 it was an 1.1 C

so trying to get everything sorted like gear linkages etc, but the gearboz is a late one so had bigger in CV's  :cry:

Ive had a check and got a inner cv off a late mk 2 and the splne's are the same as the smaller 4 speed inner CV

so looks like i can just swop over the inner CV's and it will match up to the drive flanges on the MK2 box .

Any body doe this rather than get 100mm shafts ?

are the drive shaftes the same lenght ?

cheers

Gary

why not swap the flanges

will the 4 speed ones fit in the 020 box then ?

thanks

Done some searching and reading, and it turns out that my 4 speed flanges wont fit in the gearbox and the late 90mm flanges that fit are quite rare  

so i think i will just have to machine down the 90mm shafts to make to 100mm inner Cv's fit

anyone done this mod ?



90mm vrs 100mm inner CV



machine down 90 shaft



100mm inner CV on 90mm shaft

I've seen a post on the caddy forum saying DONT use 100mm cv on 90mm shafts !

But cant see where the problem is ? you cant even get the circlip in the groove if you dont machine them down ?

Is there any difference n lenght from the 100mm shaft to the 90mm shaft or is it just the location of the circlip groove ?

Has anyone got any shafts they could measure ?

cheers

Gary

the problem is the shafts arnt the same length, so once you have them fitted they may eat themselves due to the cvs being put under too much stress.

the 90mm flanges you need are found on all mk2 golf 1.6 pretty much, most 1.8 carby mk2 before 1990 and mk3 golf n/a diesel

Have you done this mod before ?

I done some searching and found that the shafts are shorter for 100mm CV's

But there is some many different measurements for them out there.

If you do the mod above the shaft becomes shorter as the face on the CV move's inward to where the 90mm one was and the bit sticking out the end does'nt matter as its sitting in the void in the drive flange anyways.

So no the outer face of the 100mm CV is now in the same place as the 90mm one was, so i cant really see what would'nt work. unless im missing some thing ? it has been know,

hopefully Im gonna borrow some 100mm  and do a bit of measuring to see if it can be done or not

ah no wait, you might be on to something there. the way i have seen it done in the past was to machine the circlip groove on the outside to get them on, hence the problem. your way should be fine as you say the outside face of the cv is in the same spot as the 90mm one

Right I finnaly managed to do a bit of mucking about with the driveshafts,



striped down 90mm shafts



this is the 100mm CV on the 90mm shaft, cant get the clip on



machine the base of the splines down to the core depth and machine the shoulder back until you cant get the circlip on, NOT forgetting the spring washer type thing on the back as this lets the CV have a bit of play.





this is what you end up with the circlip groove now sticking out past the CV



all built up and ready for fitting

A bit off a problem when i went to fit them though, the long shaft fitted on staright away with now prob's and doesn't bind up and works well at all angels  of steering lock and suspension travel.

But the short shaft does'nt fit as its too long

This is because my car was 4 speed and the short shaft it longer ! ( 5 speed box is wider across the Drive flanges )

But i now have a 5 speed short shaft on the way so will machine the groove on that and update this when i have proved it works,

Hope this helps people with driveshaft/CV issue's

bugger yes i didnt spot you had a 1.1! yes the shafts are different lengths to big block sorry! 4./5 speed doesnt matter though, they're the same on all 1.5-1.8 mk1/cab/rocco regardless of the gears. its the gearbox type which has caused your problem

No worries Rubjonny.

It's only when I sat down an had a cup of tea and looked at it for a while that I worked it out,

Haynes Manual stats that they are the same length,

But when I put that Dow and measure them myself if all came clear.

The Haynes manual is now on the shelf out the way !