1.6 GTI Gearbox, replace / rebuild?

I can understand where you're coming from there, but 1.6-1.8 GTI box wont be as awfull as that  
I had a 4+e in my 1.6 driver and it suited the car down to the ground, I loved it. wouldnt have a 4+e in either of my GTIs though it would be completly wrong! Though I keep thinking about getting an E gear and fitting it to my FD box, I think that would give me the best of both 8)

So i found a FF box not very far from here.

The owner does not know anything about its condition.
I think i can get it for ~30?.
Maybe i should take it home and with the help of brokevw pull it apart?

My car is still very driveable even though it crushes a little when i change quick from 1st to 2nd and.

I think the choice for me is to buy the FF box. Pull it apart and change the syncromes to be sure that it doesn't do when i put it on.

Then big question is if i should go to the Junkyard and find a 4+E box and pull the E?

As i am rolling on 14" with lowprofiles the FF brings me to ~160 in 4th and that is all enough for the bit of streetracing i am doing.

Which box should i pull the E gear from?

As I understand things, its about ?120 for the specialist tools required to take apart and put back together a gearbox. Its also about ?120 for a gearbox specialist to take the case off and inspect a gearbox's internals (if any parts needed replacing this would cost more in time and labour). So you need to weigh up which is better for you, the investment in the tools and you're happy to suss it all out; or to leave it to the specialist.

It depends how far you go with the strip down/rebuild.  I managed to completly strip mine into component parts using nothing more than a socket set, a hammer, spanners and a pair of good circlip pliers (important!!)

I used a succession of spanners from small to large either side of various gears to slowly lever them off! There was no damage to anythign that I could see, but dont tell broke prob have a fit

If you just strip the gears off the shafts and plan to swap in new syncros you dont need anything special, a good set of deep reach pullers would be a 'nicer' way to get gears off though.

The specialist tools come in only if you decide to take out the diff/output shaft races and replace them, then properly set/measure shimming and preload.  You could decide leave these alone if there isnt any damage to the diff races/bearings and hope that the play/preload is ok. Its a risk, but you might get away with it.  Alternatively if nothing is wrong with the old box but crunchy 2nd, you could strip this one and replace the syncro and build it back up, providing nothing else nasty rears its head.

rubjonny said

I've tried both a MK1 GTI and MK2 GTI box on my KR engine, MK1 box is deffo quicker accelleration thanks to the short ratios, but then you're stuck with a short 5th which makes cruising not as comfortable.  Not a massive amount in it but it does make a difference. MK2 GTI box is still quick thru the gears and nicer in 5th.  If you can find a good MK1 box the 5th gear can be swapped for a taller one easily enough to give you the best of both, though if you go toooo tall you might find going from 4th to 5th a bit of a jump.  
I had a 4+e in my driver and I loved it for economy, but basically 5th was a cruise gear and thats all, I didnt have the torque to pull at all, could go quicker in 4th!  Though this was a 1.6 driver, something beefier might manage better.

handy ratio calc here:
Gear Up!

also note that MK1 & 2 GTI boxes have a different final drive, whihc means different speedo gear is required.

I agree. I got a MK2  box on my 1600 GTI at the mo.

Lovely round town with the longer ratios but the original box is much quicker through the gears and the MK2 box has pretty much nothing to give in 5th.

Mines just rebuilt (not by me!) waiting to go back on.

Al

The specialist tool is no problem as i have family at a autorized VW Dealership. They started in 1963 so they have all the nice old special tools that they aren't using anymore  :mrgreen: