Can I just pull for example a low mile gearbox from a 1999 2.5TDI

A low mileage (say, 30-60K) 2.5TDI T4 might be worth £6k; taking that into account + the incredible scarcity of these 'boxes, I suspect you've got 2 hopes: Bob & No. :ILU:

 

02B Reconditioned gearboxes are available from about £450 however, reconditioned may mean "steam cleaned and sprayed silver"

Only the AJT engined 2.5 88bhp box will be suitable for your van unless you plan on changing other parts too.

Having your own box repaired or finding a donor may be the best option

 

You can physically fit gearbox's off other models but the ratios will be slightly different,I have a 2.0 petrol gearbox on my 2.4,i only changed the fifth gear after turbo'ing it,have a read of this to better understand the ratios T:

https://www.vwt4forum.co.uk/showthread.php?t=43861

 

check what type of gearbox mount your van has, around '91 or '92 vw changed the suspension crossmember & the rear gearbox mount from a compression type to a silentbloc type (the gearbox cases MIGHT be diferent to suit:* . )

any gearbox from a 4cylinder t4 will fit the 5cylinder engine BUT a 5cylinder (102hp) fitment '02G" gearbox will not fit a 4cylinder engine.

beware also of some '02G' gearboxes having diferent gearlinkages & driveshafts aswell as the clutch hydraulic 'slave' cylinder..


in Ireland t4's are somewhat cheaper than in the rest of the UK so if you can find sensibly priced low-millage parts then go for itT:

sorta something like thatI:



Rich.

 

Thanks Rich - it does indeed have a block type mount on the cross member & the bracket is broken. Just to add complication. There are almost no 91/92 t4s around unfortunately.

I've sourced a reasonable 02b from a 2002 Transporter.

Does anyone know if the old 91 gearbox rear mount bolt on to the newer 02b casting?

Is it as simple as fitting my old solid flywheel, clutch & external clutch slave?

I usually undertake all the mechanical works myself but planning to farm this one to a garage so want everything in order.
Luckily this is a "baby forces paid repair" as opposed to "baby forces sale"!

Phil

 

Hi guys,

Hope u don't mind me jumping on here but by isssue may be relevant...

Just done a lump swap '95 aab to '98 aab using the original gearbox from the 95 van (assuming it was the original box!...) new lump had a DM setup, but i left the original single mass setup on as it looked pretty much brand new, and I didnt want the DM anyway. No idea what box was on the donor, but it was a caravelle.

Since Ive had the bus, its been quite hard to engage gears. Still the same after swap. I noticed yesterday that I have an external pagid (aftermarket?) slave, which i stripped to check, and while in there measured the bore at 23mm. Bear with me...

96 models (just campers site) used an FTE slave, which (from other sources) has a 19mm bore, which by my calcs would give 3.7mm extra throw to the clutch pushrod, and should therefore release fully.. have checked pedal bracket and done full pressure bleed before getting to this stage.

Is there a definitive "which slave goes with which box" guide anywhere?
Could we have put the release brg in the wrong way round (used same setup as when stripped) cause this issue?
If I go for the FTe slave, Id have a travel of c 12mm. Is this too much? Currently c.8mm, but cant measure accurately.

Tia, and sorry for the hijack

Dave