ABL engine in mk1 Caddy with 020 gearbox

Hi,

I need to replace my clutch and gearbox. the engine is a 1.9 ABL by looks of it and the gearbox has the code 020 301 107 H 3, the problem is the current gearbox has obviously been modified for a performance clutch as the shaft is much smaller than the replacement I have brought and the clutch assembly must have also been changed so it will not house the correct clutch. I just want to get this back to standard, whats the best way to do this?

It seems the easiest way would be to send off my new gearbox to have the shaft replaced to fit my current system. But currently the clutch pedal is so stiff and cracking i'm concerned the pedal itself my snap as it now twists when you push it. I do not race the caddy so don't need this as i assume its for quickly changing gear.

So ideally i would like to replace it to how the 020 should be originally.

Thanks.

Firstly welcome along from me (the Cornish Host!)

The gearbox swap is relatively easy, just a few wires and bolts to undo.

020 boxes can be found in the scrap yards, they were also on some mk2 and mk3 golfs I believe.

Has the shaft from the engine been modified in any way? If not it should be a straight swap. Just check the size of the driveshaft couplings. Should be 100mm.
Also the easiest way to remove the driveshaft bolts is with a rattle gun, we've found.
It's tricky getting the new box aligned onto the shaft with the engine in the bay, loosen the engine mounts a bit and support the engine on a jack, this helps with a bit of wriggle room as the distance from the end of the gear box to the chassis rail is quite tight and is only just enough for the gearbox to come off. By dropping the engine a bit the gearbox will go on  under the chasis leg.

Have a friend to help to!

If you get stuck give me a yell and I might be able to help. (I'm in Camborne)

Cheers

Ian

Ideal, i didnt realise there where some many down in cornwall! Afraid ive just moved up country mind.

it is only the shaft within the gearbox that appears to have been modified, so the gearbox should be easy enough. It’s the set they’ve had before for this performance clutch that seems to be the problem. I can get a mk3 clutch rep set which includes the correct baring and house and all so its only the flywheel as far as i can see then i should be back to standard. Thats the plan anyways. Thanks for all the tips will hopefully help the job go smoothly once ive got my hands on the flywheel.

Cheers

Tom

 is your engine tuned up at all as the problem with the 020 clutches is they cant take the torque of a modified 1.9 td so the performance clutch was probably needed to stop it slipping under boost. I did a few on an aaz and they would only last a week before slipping up hills. in the end I turned the boost down and it was ok  

Do you mean the clutch plate does not fit the splines on the gearbox.? The mk1 020 box has different size splines to the mk2 16v box and the mk3 8v box, both of which are 020 boxes. Think they have a larger clutch as well. The mk3 box has taller gearing as well which may be more suitable.

sporttrucker said

 is your engine tuned up at all as the problem with the 020 clutches is they cant take the torque of a modified 1.9 td so the performance clutch was probably needed to stop it slipping under boost. I did a few on an aaz and they would only last a week before slipping up hills. in the end I turned the boost down and it was ok  

The engine has been tuned previously but I have already done similar to you and turned it down as I dont need it to that extent for my daily use. So hopefully it will manage on the standard clutch

abfmk1 said

Do you mean the clutch plate does not fit the splines on the gearbox.? The mk1 020 box has different size splines to the mk2 16v box and the mk3 8v box, both of which are 020 boxes. Think they have a larger clutch as well. The mk3 box has taller gearing as well which may be more suitable.

I see, do you know if the full code is identical on all the 020 boxes then, surely they must have had diffent codes? The box I am replacing and the one I have brought both have the 020 301 107 H 3 so i just assumed that they were the same and the shaft had been altered on the old one to accommodate the stage 2 clutch set up?  

 the gearbox code is stamped in on a flat section on the bottom or if from a mk3 on the top near the mount. the cast 020 code on the inside is for the casing not the gears.

its worth checking what ratios the new box has as really need a long ratio box for a td also the drive shaft flanges can be 100mm or 90mm so check they match before fitting  

sporttrucker said

 the gearbox code is stamped in on a flat section on the bottom or if from a mk3 on the top near the mount. the cast 020 code on the inside is for the casing not the gears.

its worth checking what ratios the new box has as really need a long ratio box for a td also the drive shaft flanges can be 100mm or 90mm so check they match before fitting  

Perfect, Will check tomorrow as the boxes are at work. I know its a separate post but have you managed to post the flywheel yet? Once i have that I should be ready to get it back on the road.

yes posted the other day, it is a mk3 210mm flywheel so need to use mk3 pressure plate with with 1 locating pin, mk1 and 2 flywheels have 2 pins

Gearbox code info on here, about 1/2 way down is a picture of the gearbox and a yellow square show you where the code is.

020 GEAR RATIOS

Great website with everything you ever wanted to know about the 020 gearbox.