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Here's some 1.9TD data I've collated comparing the performance of the "economy" Caravelle gearbox with the close ratio "van" gearbox (which happens to be what I'm running)...

1.9TD Caravelle and Transporter from August 1992 to 2003 with manual transmission (to keep things "simple" I've only used the gear sets that run with the 4.611 final drive for the comparison)

* max. power output 50kw (68bhp) @ 3700rpm
* peak torque band 140Nm @ 2000-3000rpm
* power to weight ratio 34kw/tonne \ 33kw/tonne
* unladen weight 1490kg (T4a Caravelle) /1505kg (T4b Transporter)
* av. fuel consumption 8.3l/100km (34.8mpg) - typical
* range per 80 litre tankful 1176km
* CO2 emissions 224g/km Tax Band K
* taxable weights 2380kg (800 Special) / 2575kg (1000)
* top speed 132km/h (82mph)
* 0-80km/h (50mph) 16.8 seconds
* 0-100km/h (62mph) 24 seconds
* ¼ mile 28.5 seconds 24.1 seconds

* 5th gear ratios (02B) 0.756: \ 0.837:
* final drive ratios 4.611: \ 4.611:
* overall 5th gear ratio 3.486: \ 3.859:
* Pulling Power 488Nm: \ 540Nm: @ 2000-3000rpm

mph @ engine revs

* @ 4000rpm 88/92: \ 80/83:
* @ 3500rpm 77/80: \ 70/73:
* @ 3000rpm 66/69: \ 60/62:
* @ 2500rpm 55/57: \ 50/52:
* @ 2000rpm 44/46: \ 40/41:

These road speeds are for wheels and tyres that are new and have 26" and 27" overall diameters...

http://www.vwt4forum.co.uk/showthread.php?t=42056

taken from the above article..

Crucially, all of the tyre sizes listed fall within the overall diameter limits (between 648mm / 25.5 inches and 687mm / 27 inches - with only one or two exceptions) so gearing and speedometer readings remain easily within accepted tolerances (i.e. within 10% inaccuracy) - the larger overall diameters give your van longer legs, aiding fuel economy and lowering CO2 emissions.

Many folks choose to fit 16" VW / Audi or Mercedes wheels and retain the 205/55x16 car tyres. When compared with the standard 195/70x15 T4 tyre, these tyres undergear the T4 by about minus 3% in every gear, whereas the 150bhp red I 225/60x16 option tyre has an overdrive effect of plus 3% in every gear.

Below are the performance figures for the different fifth gears - go too high and it all quickly becomes counter productive compared to the blue I, which I have assumed to have similar outputs to a tuned 1.9TD pp...

1.9TD based project power theorectical road speed at 2500rpm (3000rpm) - 4.611 x ...

* 0.837 = 50 (60) mph (standard Transporter). Tractive Effort (pulling power) = 540Nm (std van TD) / 691Nm (TDI)
* 0.769 = 54 (65) mph. TE = 496Nm / 635Nm (TDI)
* 0.756 = 55 (66) mph (standard Caravelle TD). TE = 488Nm / 624Nm (TDI)
* 0.744 = 57 (68) mph. TE = 480Nm (1.9D na = 474Nm) / 614Nm (standard van TDI)
* 0.717 = 58 (70) mph. TE = 463Nm / 592Nm (TDI)
* 0.700 = 60 (72) mph. TE = 452Nm / 578Nm (standard Caravelle TDI)
* 0.681 = 62 (74) mph. TE = 440Nm / 562Nm (TDI)
* 0.658 = 64 (76) mph. TE = 425Nm / 543Nm (TDI)
* 0.622 = 68 (81) mph. TE = 402Nm / 513Nm (TDI)

note that the road speeds remain the same for all engines. Greater tractive effort equates to quicker acceleration in fifth gear - but choosing a gear that's too high becomes counte productive - the 0.658 T5 fifth gear in a blue I will result in fifth gear performance on a par with a 1.9TD panel van!

These are the ratios for the 1.9TD Caravelle gearbox...

(from the T4a CCY, CHS, CRN and T4b DJZ, DQL, EVY gearboxes)

1st gear 3.778:1
* 2nd 2.118
* 3rd 1.360
* 4th 0.971
* 5th 0.756 (34:45)
* Final Drive 4.611
* Overall Ratio in 5th Gear 3.486:1 = Theoretical Road Speed @ 3,000rpm 66mph (106km/h)

note the overdrive 4th gear, and the 66mph road speed with 26" OD wheels and tyres...

Compared to the gear set of the 1.9TD van, below...

(from the T4a CCW, CHP, CRL and T4b DKA, DQM, EVZ gearboxes)

1st gear 3.778:1
* 2nd 2.118
* 3rd 1.458
* 4th 1.029
* 5th 0.837 (36:43)
* Final Drive 4.611
* Overall Ratio in 5th Gear 3.859:1 = Theoretical Road Speed @ 3,000rpm 60mph (97km/h)
 

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what a brilliant guide T: . I've been toying with the idea of going for the 0.622 5th for my van but i think it might be to much of a jump from 4th .. i'll probably go for the 0.658 just to be on the safe side when funds allow

anyone fancy doing a group buy I:
 

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A very interesting read! Thanks for sharing. I just wonder, does anybody get 1176 km to a full tank of fuel?! Thats 730 miles!! I got 565 miles in mine and thought that was quite good going, although I didnt dare to run it too low.
 

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Discussion Starter #4
A very interesting read! Thanks for sharing. I just wonder, does anybody get 1176 km to a full tank of fuel?! Thats 730 miles!! I got 565 miles in mine and thought that was quite good going, although I didnt dare to run it too low.
That info was gleaned from some German brochures I have...

I'd take it with a pinch of salt - I'm lucky to get 500 miles the way I drive...
 

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A very interesting read! Thanks for sharing. I just wonder, does anybody get 1176 km to a full tank of fuel?! Thats 730 miles!! I got 565 miles in mine and thought that was quite good going, although I didnt dare to run it too low.
I'm not sure about the 730 miles but i guess it will be possible . i filled my van on the 30th july (£87.45 had some in already ) ive covered 610 miles and still have a good 1/4 left and thats 50/50 town/urban driving T: well pleased with that

with a longer 5th and on a steady m/way run i could easy get 700 miles per tank
 

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Hi, I have found this post from the search option. I am new to the t4's and have a question about the RPM. I have a x reg 1000 1.9TD and i think its reving alittle high? at 70mph on the moterway its at 3400rpm, gets to 75mph (just) and its at about 3800 (redlines at 4200) Is this high? by reading this it seems it isnt, just wondering if anyone can put my mind at rest. I'm taking one step at a time, and will look to maybe getting engine tuned? like it seems some people have done. I'm a long way off yet, as concentrating on conversion, but looking at options for furture. Thanks in advance for any comments. gem xx
 

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That sounds about right. My 1999 TD does about 60mph at 3000 rpm. So far it's not tuned at all and I quit efancy changing to the 0.756 5th gear from a velle. I know it's only a bit of improvement to the rpm but I am concerned about getting too big a gap between 4th and 5th.

Has anyone done the 5th gear mod on a standard TD (mines a camper with a high top so I guess a bit more wind resistance than normal vans)?
By the way I get about 550 miles to a tank if I drive no more than 56-70mph. Go much over that and consumption goes up wildly. Once I only did 33o miles, but that was a high speed dash along the A303.
 
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