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talk to me about replacing my gear box...

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So my 1.6 petrol 4-speed box decided it doesn't want to work in anything other than reverse, so it needs taking out and replacing.

I've no idea about the process, though me and a couple of mates are gonna have a crack at it.

Should i replace like for like?

Or, how easy is it to drop a different one in? ie a 5 speed box

how easy is it to identify which box i currently have, and how do i know if a replacement one will fit properly?

i've also thought about replacing the whole engine, but if i were to do that, i'd want something i could pretty much just drop straight in without having to worry about new engine mounts, wiring looms etc. the 1.6 has enough poke for me to handle anyway, so i'm not really looking to go any faster!

If anyone has anything suitable near bristol, feel free to lemme know!

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Dropping a tranny isn't hard.

Needs Good Jack Stands.
Engine Support
Racheting Cargo Straps.
8mm Triple Square wrench
assorted spanners, Sockets, ratchets and extensions.

Loosen the Wheel Lug bolts.
Jack the car as high as you can get it and support the Frame.
Remove the Wheels.

Support the engine
Remove the Axles and use a Bungie to hold them as high as you can…I usually hang the bungies on the springs.

Remove the starter.
Remove the speedo cable
Remove the clutch cable
Remove the transmission to frame ground off the transmission.
Support the tranny with a racheting cargo strap.
Remove the Front, rear and Side mounts.
Remove the 3-4 remaining bolts that hold the transmission to the engine.

Slightly pry the engine off the tranny, and it helps a bit to lower the rear of the transmission.

Use the racheting strap and lower the transmission.

Swapping over to a 4 speed will require new shift linkages, and forks.

The Tranny type or style is stamped on the Bellhousing.

Here is my engine support.


Setting your tools out helps when you start looking for one or more of them


the stamped type on a automatic.


List of tranny numbers and specs.
Transmission Ratios

I would replace the clutch when going back if you don't know how old yours is.

To hold the PP steady to break it loose.
From a friend on how to hold it.


8mmts


I would drain the oil on the new to you tranny and make sure you fill it with proper amount.




What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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blimey, thanks mate - much appreciated! I'll fire this to my buddy who's gonna help me - we'll be back with Qs!

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I've got a 4 speed box in Oxfordshire if you need one. 

It's from a 1093 tho. Ratios would differ I'd imagine?

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Everything you ever wanted to know about VW gearboxes.

Welcome to BrokeVW.com

1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.

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A little more info though.

I have changed my transmission from a four to a five speed box on my 1.5 big block engine. This was an option available at the time of sale, similar to the 1.6. I used a code 4T, which is a 4 +E gearbox.

Cruising at 70 my engine does about 3000 rpm in 5th instead of 4000rpm in 4th with the old 4 spd gearbox.

As  Briano1234 mentions, the transmission chart is excellent in your selection of a gearbox you want to fit and takes into account the ratio, drive shaft size and speed drive gear colour/number of teeth required.

You will also have to change some gear linkage components (rods and levers) and the gate, many parts are common to both 4 & 5 gear installations. Also the passenger side gearbox mounting bracket has to be replaced.

I do have a close ratio 5 speed box code FM spare. I believe it was fitted to the 1.6 GTI.  The ratio might be OK for your 1.6, it depends on your current gearbox code and ratio. See my project blog for pictures on page 6.

https://vwgolfmk1.org.uk/forum/index.php?page=topicview&type=misc&id=projects%2Fyour-mk1-golfs_2%2Fgarythegolf&start=100
 
I purchased it from ebay, but did not use it. I have had it stored since 2011.

Have a look. As with all second hand gearboxes, you might want to have it checked / overhauled before installed. which is what I did.






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thanks again guys for the posts - this'll require a bit of reading over the weekend i think!

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Close up of the engine support.



1 1/2 inch steel bar stock.
2 Blocks of wood that at the top is notched for hte barstock and drilled below it to accept some 3 inch fence u-bolts to hold the bar stock to wood.  The Bar stock is drilled to accept the u-bolts.

The blocks of wood are notched at the bottom to accommodate the lip of the fenders as well as the fender bolts.

I use a Toggle bolt and muffler clamps to hold the engine to the barstock.  I can lower or raise the back end of the engine about 4 inches.
I use a ratcheting gargo strap with another muffler clamp to raise the tranny off the ground and to hold it.

I have different sized widths of boards 1X 12's and 2X12" 2X10's  so I can get any angle I want.

I do take care with the 1X12's as they aren't as beefy as the 2X's When done I can totally make it flat and store it easier.

Harborfreight over here sells one that is similar.



Others after seeing my have reported that a 3X3 paddded on the fenders works too.  But I don't like the idea of using the fenders as they aren't as supportive and may bend.  The inside fender lip is stronger, and has the inner fender lip so it is doubly strong.


 

What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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so, after trying to measure the flange diameter while the box was still in the car, and failing to do it accurately (no ramps), i finally managed to remove the box.

Initial measuring while still bolted in the car suggested it was gonna be the less common 100mm flange diameter, but if I'm measuring it correct, it's a 90mm one.

so, am I measuring the right bit?!

20171210_125944.jpg

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Yeah that's a 90mm cup, actually measure inside to inside of the cup as its the d/shaft that is 90 or 100mm.

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thanks mate - that makes life a lot easier - already know of one for sale!

cheers

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talk to me about replacing my gear box...

 So I found a new box and got rid of the old one. Nearly done fitting the new one but any left with the below and can't work out where it goes!
Any ideas?

Sent from my SM-G935F using Tapatalk

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Easy that is probably the front mount on the Grille side lower frame valance to the tranny/engine/starter.  

2 of the transmissions bolts are used to hold it and the starter on a Cabriolet or my 81 Diesel.

It sits in a cup on the front Valance. one bolt is Threaded into the bracket, and the other is nutted to the bolt.

Look at the ETKA to see it exploded,
your pic is 16, but you can have 17

Screen Shot 2018-02-04 at 10.19.56 AM.png

What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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Re:

Briano1234 said

Easy that is probably the front mount on the Grille side lower frame valance to the tranny/engine/starter.  

2 of the transmissions bolts are used to hold it and the starter on a Cabriolet or my 81 Diesel.

It sits in a cup on the front Valance. one bolt is Threaded into the bracket, and the other is nutted to the bolt.

Look at the ETKA to see it exploded,
your pic is 16, but you can have 17

Screen Shot 2018-02-04 at 10.19.56 AM.png
Thanks mate - I'll have a dig around!

Sent from my SM-G935F using Tapatalk

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