[StephenTazz]

The 02B Gearbox is a beefed up 5-speed gearbox derived from the new cable operated 02A gearbox first found in the '89 Corrado, '88 Passat and Mk2 Golf G60 and grew into the 02Z gearbox found in the 4-cylinder T5 models.

Gear selection in the Transporter is relayed by heavy duty rods rather than cables and the final drive casings are enlarged to house a bigger - and stronger - crown wheel and pinion.

The Transporter clutch is either actuated hydraulically by an externally mounted slave cylinder (on all rhd vehicles, all vehicles with additional heater and all vehicles destined for Canada) or mechanically by a self adjusting cable.

This range of gearboxes was fitted from launch right across the T4 range on all models bar the TDI, TDI, VR6 and Syncro models:

1) Gearbox Data for the 2.5 TDI




Clutch Diameter

• 2.5 TDI AJT, AYY 219mm (with twin mass flywheel)

Final Drive Ratio

• 4.235:1 (common to all)

Common Internal Ratios

• reverse gear 3.600:1
• speedometer drive 0.600:1
• 1st gear 3.778:1

Gear Sets

T4b Caravelle




DUJ, EWB

• 2nd 2.118
• 3rd 1.304
• 4th 0.903
• 5th 0.700 (28:40)
• Overall Ratio in 5th gear (final drive x 5th gear) 2.965:1 = Theoretical Road Speed @ 3,000 rpm 78mph (126km/h)

T4b Transporter




DUH, EWA

• 2nd 2.063
• 3rd 1.348
• 4th 0.967
• 5th 0.744 (29:39)
• Overall Ratio in 5th gear 3.150:1 = Theoretical Road Speed @ 3,000rpm 74mph (119km/h)

Dates and Chassis Ranges




T4b

• 06.98 W X Y 1 (to 08.00) DUH, DUJ
• 09.00 1 2 3 EWA, EWB

2) Gearbox Data for 1.9 TD, 2.4D na and 2.5 petrol models




Clutch Diameters

• 1.9 TD ABL 215mm
• 2.4 D na AAB 215mm
• 2.4 D na AJA 219mm (with twin mass flywheel)
• 2.5 Petrol AAF, ACU, AEN, AEU 228mm
• 2.5 Petrol AET, APL, AVT 228mm

Available Final Drive Ratios

• 4.941:1
• 4.611:1
• 4.563:1

Common Internal Ratios

• reverse gear 3.600:1 18 tooth gear (3.800:1, 19 tooth - AYD,AYF)
• speedometer drive 0.600:1
• 1st gear 3.778:1

Gear Sets

T4a Caravelle Multivan




AYF, CCX*

• 2nd 2.118
• 3rd 1.360 (1.345 - AYF)
• 4th 0.971
• 5th 0.756 (34:45)
• Final Drive 4.941
• Overall Ratio in 5th Gear 3.735:1 = Theoretical Road Speed @ 3,000rpm 62mph (100km/h)

CCY, CHS, CRN

• 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)

CPV

• 2nd 2.063
• 3rd 1.348
• 4th 0.967
• 5th 0.769 (30:39)
• Final Drive 4.563
• Overall Ratio in 5th Gear 3.509:1 = Theoretical Road Speed @ 3,000 rpm 66mph (106km/h)

T4a Transporter




AYD, CCW, CHP, CRL

• 2nd 2.118
• 3rd 1.458 (1.429 - AYD)
• 4th 1.029
• 5th 0.837 (36:43)
• Final Drive 4.611
• Overall Ratio in 5th Gear 3.859:1 = Theoretocal Road Speed @ 3,000rpm 60mph (97km/h)

CPW

• 2nd 2.063
• 3rd 1.455
• 4th 1.034
• 5th 0.838 (31:37)
• Final Drive 4.563
• Overall Ratio in 5th Gear 3.824:1 = Theoretical Road Speed @ 3,000 rpm 61mph (98km/h)

T4b Caravelle




DJZ, DQL, EVY

• 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)

DCW, DQH, EVW

• 2nd 2.063
• 3rd 1.348
• 4th 0.967
• 5th 0.769 (30:39) 0.744 (29:39) - DQH, EVW
• Final Drive 4.563
• Overall Ratio in 5th Gear 3.509:1 = Theoretical Road Speed @ 3,000 rpm 66mph (106km/h) 3.395:1 - DQH, EVW = 69mph (111km/h)

T4b Transporter




DKA, DQM, EVZ

• 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)

DCU, DQG, EVU

• 2nd 2.063
• 3rd 1.455
• 4th 1.034
• 5th 0.838 (31:37)
• Final Drive 4.563
• Overall Ratio in 5th Gear 3.824:1 = Theoretical Road Speed @ 3,000rpm 61mph (98km/h)

Dates and Chassis Ranges




T4a from:

• 01.90 L M AYD, AYF
• 08.91 N CCW, CCX*, CCY
• 08.92 P CHP, CHS (1.9 ABL launch)
• 08.93 R (to 12.93) CRL, CRN
• 01.94 R (from 01.94) S T (to 12.95) CPV, CPW

* the CCX gearbox was also fitted to 1.8 PD, 2.0 AAC and 1.9D 1X engines




T4b from

• 01.96 T V (to 04.97) DCU, DCW, DJZ, DKA
• 05.97 V W X Y 1 (to 08.00) DQG**, DQH**, DQL, DQM
• 09.00 1 2 3 EVU**, EVW**, EVY, EVZ

** these gearboxes were fitted to 2.5 85kw petrol engines only from 05.97

3) Data for 1.9D na, 1.8 and 2.0 Petrol models




Clutch diameters

• 1.9 D na 1X 215mm
• 1.8 petrol PD 228mm
• 2.0 petrol AAC 228mm

Final Drive Ratio

• 4.941:1 (common to all)

Common Internal Ratios

• reverse gear 3.600:1 (3.800:1 - AYE, AYG)
• speedometer drive 0.600:1
• 1st gear 3.778:1
• 2nd gear 2.118:1

Gear Sets

T4a Caravelle




AYE, CCX*, CHR, CRM

• 3rd 1.360 (1.345 - AYE)
• 4th 0.971
• 5th 0.756 (34:45)
• Overall Ratio in 5th gear 3.735:1 = Theoretical Road Speed @ 3,000rpm 62mph (100km/h)

T4a Transporter




AYG, CCZ, CHT, CRP

• 3rd 1.458 (1.429 - AYG)
• 4th 1.029
• 5th 0.837 (36:43)
• Overall Ratio in 5th gear 4.136:1 = Theoretical Road Speed @ 3,000rpm 56mph (90km/h)

T4b Caravelle




DCV, DQJ, EVV

• 3rd 1.360
• 4th 0.971
• 5th 0.756 (34:45)
• Overall Ratio in 5th gear 3.735:1 = Theoretical Road Speed @ 3,000rpm 62mph (90km/h)

T4b Transporter




DCX, DQK, EVX

• 3rd 1.458
• 4th 1.029
• 5th 0.837 (36:43)
• Overall Ratio in 5th gear 4.136:1 = Theoretical Road Speed @ 3,000rpm 56mph (90km/h)

Dates and Chassis Ranges




T4a

• 01.90 L M AYE, AYG
• 08.91 N CCX*, CCZ
• 08.92 P CHR, CHT (1.8 PD engine dropped)
• 08.93 R S T (to 12.95) CRM, CRP

* the CCX also fitted 2.4D na and 2.5 petrol models




T4b (2.0 AAC engine only)

• 01.96 T V (to 04.97) DCV, DCX
• 05.97 V W X Y 1 (to 08.00) DQJ, DQK
• 09.00 1 2 3 EVV, EVX

To sum all this up - Caravelles have economy / touring gearboxes; Transporters have sports / close-ratio gearboxes for maximum torque multiplication (pulling power) at the expense of overall speed and economy (whichever way you wish to look at it)...

Footnote - Gearbox Mounting Differences

T4a Early Gearbox Mountings

T4b Late Gearbox Mountings (including 02G types)

 

[Paul Grnf]

I'm trying to find the final ratio of my '95 caravelle fitted with a 2.4D AAB (no rev counter). It appears from your table to be a T4a but what are the triple letter codes and where are they on the vehicle?

 

[Thom.milburn]

I would just like to add to this - as i require new gearbox mountings, those pictures are not 100% accurate - i appear to have a t4b lower mount and a variation of a t4a top mount, however i understand vagcat isnt brilliant for this.

Just a note to anyone taking pictures as gospel!

 

[manwithtool]

If no one minds I'm going to hijack this thread a bit. If my wife allows the expenditure or if I can hide the bills I'm going for it.

I'll try and attach some threads that I found useful, apart form this one !

http://www.vwt4forum.co.uk/showthread.php?t=83109&highlight=parts+gear+upgrade

hope that link works ? It's really useful and thanks to RSPARKS3107 for that.

Anyway, my van is a 1997 2.0 petrol with 188k miles. According to the sticker on the cover under the fuse box it has the DQJ box and does 62mph at 3000 rpm. This sounds about right to my ear (no rev counter). So according to the gearbox details listed early on in this thread I have a 5th gear ratio of 0.756 and final drive of 3.735:1. So if I fit a 5th gear with a ratio of 0.658 I end up with a final drive of 3.251:1 (feel free to check my maths.) this would appear to give me about 70mph at 3000rpm.

I have found a supplier for the gears and I'll post a link in a minute when I find it.

If anyone has any advice on where to buy them or anything else I'd be grateful.

 

[johnty22]

does anyone know if the o2g from a 102bhp model can be fitted to the 88bhp engine keeping the 88bhp bellhousing and clutch assembly ?? what complications are there to fitting the 02g box ? whats neeeded ? thanks

 

[dubbiedownunder]

Hi, where a bouts can I get the 5th Gear ratio of .658 online as I had a look and it seems they are around $400 not including delivery to Australia? Are there any cheaper alternatives out there, if you could sent the name or links, that would be wonderful
thanks