[StephenTazz]

For the 5-cylinder 2.5 litre ACV (102bhp/75kw) TDI engine launched in August 1995 on the T4a, VW provided the stronger 02G gearbox. Unique to the high power T4's, this gearbox is more able to cope with the extra torque generated by these state of the art engines.

The Audi based ACV engine was initially the most powerful engine installed in the T4, but the 02G gearbox paved the way for even more potent engines - the 111kw (150bhp) TDI and the VR6 narrow angle petrol engines.

The March 1998 introduction of the TDI Syncro saw the first use of the 02G gearbox in the four wheel drive models.

Common Data for TDI, TDI, VR6 and TDI Syncro




Clutch Plate Diameters

• 2.5 TDI ACV, AUF, AYC, AXL 219mm - twin mass flywheel
• 2.5 TDI AHY, AXG 240mm - twin mass flywheel
• 2.8 VR6 AES 219mm - twin mass flywheel
• 2.8 V6 AMV, AXK 4-speed automatic only

Available Final Drive Ratios

• 3.905
• 3.944
• 4.933

Common Internal Ratios

• reverse gear 3.700
• speedometer drive 0.591 (electronic speed transducer on TDI / TDI Syncro)
• 02D Rear Differential 1.000 (1:1 direct drive TDI Syncro only)

Gear Sets (for all body types)

TDI




AFK (inc T4a from 08.95), DXZ, EME, FJS

• 1st 3.909
• 2nd 2.118
• 3rd 1.346
• 4th 0.972
• 5th 0.729
• Final Drive 3.905
• Overall Ratio in 5th gear (final drive x 5th gear) 2.847:1 = Theoretical Road Speed @ 3,000rpm 81mph (130km/h)

TDI Syncro




DRH, EFA, FTV*

• 1st 4.300
• 2nd 2.313
• 3rd 1.346
• 4th 0.868
• 5th 0.627
• Final Drive 4.933
• Overall Ratio in 5th gear 3.093:1 = Theoretical Road Speed @ 3,000rpm 75mph (121km/h)

(*this gearbox is also optional on the 2wd TDI)

VR6




AFL, DYA

• as per TDI

TDI




DQR, EEZ

• 1st 3.909
• 2nd 2.118
• 3rd 1.296
• 4th 0.895
• 5th 0.694
• Final Drive 3.944
• Overall Ratio in 5th gear 2.737:1 = Theoretical Road Speed @ 3,000rpm 85mph (137km/h)

Dates and Chassis Ranges

• 08.95 T V W AFK*(TDI), AFL*(VR6)
• 03.98 V DRH***(TDI Syncro)
• 05.98 V W X EEZ**(TDI)
• 08.98 X Y 1 DXZ*(TDI), DYA*(VR6)
• 08.98 X Y 1 (to 02.01) EFA***(TDI Syncro)
• 07.99 X Y 1 2 3 DQR**(TDI)
• 03.01 1 2 3 EME, FJS (TDI), FTV (TDI Syncro)

* TDI and VR6 gearboxes not interchangable as bell housing is matched to each engine type
** the TDI gearbox has uprated input and output shafts and an uprated final drive
*** TDI Syncro gearbox with drive to 02D rear axle (see below for options)




02D Rear Differential Options (with 100mm driveshaft flanges)

• Differential Lock with ABS and Freewheel DUB, DTZ
• Differential Lock only DUA
• ABS and Freewheel only DTY

Gearbox Mountings

 

[anotherprojectcar]

Thank you for the information. Looking into 5 speed manual box to replace automatic in US spec T4 with AXK engine.
Will this unit work? and how can iget one?

Best regards. Mike

 

[Cole]

Here is the actual rare number to order the whole transmission from VW parts dept for about $2000.


02G300045CX for the DYA trans that should work with the VR6

 

[lutton74]

Hi if im reading correctly
DYA Gearbox for the VR6, Would the ratios be ok? And where on earth would i find one, myauto VR6 if fantastic apart from the auto,

Would be a great help,

 

[jellyheadjason]

Would the transfer box on a syncro tdi gearbox bolt onto a 2wd tdi gearbox?

 

[MrBone]

when doing the theoretical mph speeds - what tyre diameter measurement is being assumed here?

 

[steve124]

The supplied wheel combination as per your plaque on the inside door frame.

When you go up in wheel diameter you are supposed to reduce the height ratio so the rolling diameter stays the same so potentially if you had 15" or 18" wheels the rolling diameter could be the same with the correct ratio tyres.

 

[MrBone]

Ah ok thanks, am just doing some maths on that to use bigger diameter wheels/tyres combination to reduce rpm on a tdi syncro - seeing as changing 5th gear is not really an option here.

 

[tiggerjpt]

Would the transfer box on a syncro tdi gearbox bolt onto a 2wd tdi gearbox?

Definitely not. The oil channels to cool the transfer box are not in 2wd version. You need to remove gearbox to fit it anyway.

 

[steve124]

Ah ok thanks, am just doing some maths on that to use bigger diameter wheels/tyres combination to reduce rpm on a tdi syncro - seeing as changing 5th gear is not really an option here.

syncro are notoriously low geared......only option really is getting as big a wheel and tyre that will fit under wheel arch.

 

[MrBone]

syncro are notoriously low geared......only option really is getting as big a wheel and tyre that will fit under wheel arch.

anyone got experience of this? i.e. an idea of suitable wheel and tyre combos.

 

[LasseNC]

Can I fit this gearbox to an AAB engine?

 

[filmshoot]

Is the following syncro setup arl code 02d gearbox from a 94 2.4d the only gearbox that can mate to a 1z ahu afn 1.9tdi engine?
Or can the newer 02d gearboxes also work?

tapped out with a thumb or two...

 

[sulzeruk]

I have a 2.5 TD1 Syncro that is now 2 wheel drive. I have the engine and box out just now to refurb the suspension and underseal the chassis. The final drive ratio is 4.933, 5th gear is 0.627. I want to raise the geariung so it cruises with lower revs on the motorway. Is there a lower top gear available or would i need to lower the final drive ratio? There was a 3.905 and 3.944 available for the 02G gearbox? Anyone done it before?

 

[DanielN]

anyone got experience of this? i.e. an idea of suitable wheel and tyre combos.

We drive with 16" 215/70r, then the speed meter are accurate. But 215/75r would be great to.