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The T4 Syncro's initial launch in August 1992 saw the introduction of the 02D gearbox, a development of the 02B with an additional housing for the drive to the rear wheels. Options included a range of rear differential units to make the set, depending on whether a differential lock and / or antilock brakes with a freewheel device.

Common Data for 2.4D na and 2.5 Petrol Engined Syncro Models



Clutch Plate Diameter
  • 2.4 AAB 228mm
  • 2.4 AAB (from engine no 369935) 219mm - twin mass flywheel
  • 2.5 AAF, ACU, AEN, AEU 228mm
  • 2.5 AET, APL, AVT 228mm
Available Final Drive Ratios
  • 4.563
  • 4.611
  • 5.313
Common Internal Ratios
  • reverse gear 3.600 (18 tooth) / 4.275 (19 tooth 2.4D crawler option)
  • speedometer drive 0.600
  • Rear Differential 1.000 (1:1 direct drive)
Gear Sets

T4a Caravelle



ARL, CLZ
  • 1st 3.778
  • 2nd 2.118
  • 3rd 1.360
  • 4th 0.971
  • 5th 0.756 (34:45)
  • Final Drive 4.611
  • Overall Ratio in 5th Gear (final drive x 5th gear) 3.486:1 = Theoretical Road Speed @ 3,000rpm 66mph (106km/h)
T4a Transporter



ARF, CLY
  • 1st 3.778
  • 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)
CRV, CLW
  • 1st 3.778
  • 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)
CRW, CLX
  • 1st 3.778
  • 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 @ 3,000rpm 66mph (106km/h)
T4b Caravelle



DQP, EWD
  • 1st 3.778
  • 2nd 2.063
  • 3rd 1.348
  • 4th 0.967
  • 5th 0.744 (29:39)
  • Final Drive 4.563
  • Overall Ratio in 5th Gear 3.395:1 = Theoretical Road Speed @ 3,000rpm 69mph (111km/h)
T4b Transporter



DCZ, DQN, EWC
  • 1st 3.778
  • 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)
DCY
  • 1st 3.778
  • 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 @ 3,000rpm 66mph (106km/h)
DDA, DQQ (2.4D Crawler Option)
  • 1st 4.375
  • 2nd 2.267
  • 3rd 1.348
  • 4th 0.903
  • 5th 0.681 (32:47)
  • Final Drive 5.313
  • Overall Ratio in 5th Gear 3.618:1 = Theoretical Road Speed @ 3,000rpm 64mph (103km/h)
Dates fitted from (including rear differential codes)



T4a
  • 08.92 P R (to 12.93) ARF, ARL (*ARG, ARH, AYA, AYB)
  • 01.94 R (to 03.94) CRV, CRW (*ARG, ARH, AYA, AYB)
  • 04.94 R S T (to 12.95) CLY, CLZ, CLW, CLX, CTV (*CJK, CJL, CJM, CJN)
T4b
  • 01.96 T V (to 09.96) DCY, DCZ, DDA (*DFA, DFB, DFC, DFE)
  • 10.96 V (to 0.5.97) DCY, DCZ, DDA (*CNC, CZT, CZU, CZV)
  • 06.97 V W X Y 1 (to 08.00) DQP, DQN, DQQ (*CNC, CZT, CZU, CZV)
  • 09.00 1 2 3 EWC, EWD (*CNC, CZT, CZU, CZV)
* 02D Rear Differential Options



T4a with 108mm driveshaft flange
  • Differential Lock with ABS and Freewheel ARG, AYB, CJK, CJM
  • Differential lock only AYA, CJN
  • ABS and Freewheel only ARH, CJL
T4b with 100mm driveshaft flange
  • Differential Lock with ABS and Freewheel DFB, CNC, CZV
  • Differential lock only DFA, DFE, CZU
  • ABS and Freewheel only DFC, CZT
 

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There is no pilot bearing in the crank end, the input shaft for the trans just sits in the clutch splines and is supported internally on the trans end similar to all 02B, 02A, 02J, etc.
 

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Hello,
What clutch / flywheel combo is recommended for this 02d arl syncro when married to a 1.9tdi afn modded to 200hp? Is it the same as what ahu / 02b guys are running ?
 

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Hi.
Is there a lsd, limited slip differential available for the front wheels as an install kit for the arl 02d synchro transmission?
 

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Hello,
What clutch / flywheel combo is recommended for this 02d arl syncro when married to a 1.9tdi afn modded to 200hp? Is it the same as what ahu / 02b guys are running ?
Anyone? For some reason dark side is telling me not to buy this kit, as it will not fit.
Is this true? I thought all I need was a 228mm clutch and a 28 tooth flywheel?
http://www.darksidedevelopments.co.uk/products/darkside-g60-flywheel-with-sachs-sre-performance-clutch-kit-5-speed-02j-02a-02r.html

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I heard that quaiffe will do a run of 30 lsd for this transmission if we get together a group buy

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Heya virgin..
Not too sure about your question.
Maybe someone can chime in here?

Btw sorry I didnt receive your pm will clean my inbox now.

Also try to ask the gearbox builder from Czech republic..
Eurotuning.
Radim is his name

...just tapped out with a thumb or 2, please don't mind the abbreviations and grammatical faults.
 
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