G60 Mk1 gearbox DEFINITE ANSWER!

Hi guys

My head is really spinning as I have had so much advice regarding gearbox and clutch options for mk1 G60s.

I am at the stage where I really need a box and want an ease of use/good track ratio performance.

Original box seems to last ok if matched with a decent clutch (Sachs Sporting) but ratios are a bit off.

I really dont mind about the top end performance really but am after a simple easy and reliable setup.

cheers. JJ

on mine i think i had a CDA code,i  liked how it worked through the gears,  it pulled very well with mininmal spin and 4th gear seemed to last forever

I opted for the coraddo box but then had to convert to cable change and cable clutch.
I was advised to go for mk3 diesel box but then could not get the correct clutch /spline ratio to suit. so i wasted money going down that route.
I would have liked to go mk2 16v box and retained rod change, but i dont know how long those boxes would of lasted.

I like using my car for 1/4 mile sprints but loose time on gear change due to the set up i use, but overall very happy with general on road use.
 

Thanks guys, anyone got any specific advise on retaining rod setup box ie, original gti box or mk2 16v unit and how they have faired with decent sports clutch?

Also Jim, what fabrication needs doing to fit the mk3 16v box (CDA) surely not a bolt in option? What shafts too?

There's no definite answer because you're invariably using a secondhand 020 box. These tend to be older than 02A boxes, and have a couple of weaknesses which reveal themselves when driven aggressively. If you compared like-for-like, eg new or reconditioned transmissions, then the 020 is only slightly weaker than the 02A and this is outweighed by the ease of fitting (same mounts, same linkage, same clutch setup).

My G60 was running an 16V Mk2 020 box without any problems, standard clutch. The only thing I would say is that the 1st and 2nd ratios are too close and could be longer. I had the box fully stripped and rebuilt as a precaution, the boxes are getting old now.

It is currently undergoing a 16V G60 conversion, for this an 02j box is going to be used complete with an hydraulic clutch, cable shifter and Peloquin limited slip diff !! Not sure on clutch yet, wether to go oem or something more race bred.

I have run mine on the original o2o box with no problems at all only mod was a diff bolt kit fitted it's currently running around 190bhp on a standard vw clutch kit.
Friend of mine runs his on a mk3 TDI o2o box and thats really good through the gears and has a long 5th gear

Thanks guys, all great advice I feel a little happier now, think I may go with the 16v MK2 box and hope for the best. At the end of the day it hasnt cost me much and I have the Corrado G60 box in the shed in case…

Am I correct in thinking that you need to match the friction disc to the input shaft and the clutch/flywheel to the box? Also does the 16v mk2 box bolt straight in without any mods to mounts etc…

yes valver box bolts straight in but you will need bigger shafts i beleive

how much power are you looking at and how much torque?

also no advantge of a 16v box over a 8v in 020, as 16v means 100mm drive shafts, closer ratios but too close for a torqie 8v prob, plus you will need a 16v clutch.

Looking at sunny side of 200bhp eventually but am happy just getting it up and running to begin with. So there is no advantage to the 16v box? Surely it will withstand greater torque, if nothing else it's a bit newer. What's the newest 020 box that will bolt in…?

sorry for all the questions, just one more… if I am using the 16v clutch wont it have a larger friction plate and therefore be better?

So many options to be honest I may just stick with the 8 valve!

with 200bhp I wouldnt even bother with a 020… you will need an LSD as the diff will be under lots of stress and liable to give up, also I ave spoke to a few people running that kind of power and they have all left the 020 due to killing gears etc.

also you will need a 16v pressure plate and race paddle clutch, the paddle clutch isnt cheap and driving around town will be no fun…

the easy option is go 02A cable change, these are good for over 200bhp, and you can use stock clutch and fly wheel, by using a mk3 16v fly wheel and a VR6 friction plate.

the down side to a 02A is the fact you need 100mm drive shafts from a latter cabby, a 02A block from a mk3 gti 16v or raddo 16v etc, plus you need the conversion engine mounts (if if you can weld make your own, to buy they are about ?150 with a new mount pressed in) then you need the shifter from the donor car too.

fitting is not too bad but it does mean you have to find a way to route the shifter cables either under the car or for the motorsport look in the car.

Thanks a lot guys, I think with all the work needed I will simply stick with near stock power for a while just to get the car on the track, then consider upping the power. Thanks for all the advice...

even with near stock power you WILL need a mk2 16v pressure plate (get one from LUK or Sachs as other brands dont always use the correct 16v plate they just use an 8v, where the springs arent as stiff) and fit a good firction plate too, BUT note the 16v friction plate wont fit an 8v box as the centre spline too small compred to the 16v  :wink:

that set up worked VERY well in my 130bhp 8v track car at santa pod taking some very serious stick inc rolling burn outs to warm the tyres and full power starts    not once did it miss a beat or slip!

That sounds like a pretty good setup to go for then thanks.