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5th Gear Mod |
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D&D 
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"deuce" Joined: 11 Sep 09 Location: Shropshire Status: Offline Points: 20097 |
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 Topic: 5th Gear ModPosted: 17 Mar 10 at 15:34 |
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Did the mod on my 2.4d today & i'm well happy with the results, revs have dropped from 3650 @ 70mph to 3000
These are the part numbers for the 0.70 ratio cogs I used, it took about an hour to swop them over.
02A 311 158 AM
02A 311 361 AM
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Carthago 32.1 T4 LWB
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traversd
Vanorak 
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Posted: 17 Mar 10 at 16:04 |
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Does it affect the drive at all ? I.e. Pulling in 5th / Hills etc ? And what sort of cost / special tools are involved ? Might quite like this for me 1.9TD
Edited by traversd - 17 Mar 10 at 16:16 |
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Vanfest 2011 - Skittles Vodka
Camperjam 2011 tug n chug team Camperjam 2013 - Lost to the Bodybuilders, but delivered in a Syncro Tough Mudder - Fried Piggy For - Charity So, Rae is a girl then yeah. |
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D&D
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"deuce" Joined: 11 Sep 09 Location: Shropshire Status: Offline Points: 20097 |
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Posted: 17 Mar 10 at 16:32 |
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I'm running an acv turbo on my 2.4, it pulls fine with only 0.5bar boost & tweeked fuel screw. I know you've had trouble with your engine but now its fine up your fueling & boost. Your 1.9 should have a .768 ratio so will pull the .70 easily.
Google 'Vw 5th gear mod' & you'll find loads of picture walkthroughs. It cost me £200 for the parts or your can get .71 cogs out of an ASD gearbox(Mk3 Golf/Passat/Seat).
I've got some long trips this year so know i'll get my money back on fuel savings
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Carthago 32.1 T4 LWB
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nind
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Joined: 24 Feb 07 Location: United Kingdom Status: Offline Points: 410 |
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Posted: 17 Mar 10 at 20:39 |
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Hello mate,
I searched the Vw t4 forum and finally found these part numbers:
O2a311361am x1
o2a311158af x1 o2a3o1215a x1 Is this correct ?
Thanks !
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D&D
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"deuce" Joined: 11 Sep 09 Location: Shropshire Status: Offline Points: 20097 |
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Posted: 17 Mar 10 at 20:44 |
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yep,
215a is the gasket you don't need
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Carthago 32.1 T4 LWB
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traversd
Vanorak
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Posted: 18 Mar 10 at 13:50 |
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Hmm think I will wait a while to make sure the engine is all good as it's still running in etc...knowing my luck i'll up the boost and wreck it again !
That mod is def interesting though as it would certainly make cruising quieter / less expensive which is what i bought it for ! |
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Vanfest 2011 - Skittles Vodka
Camperjam 2011 tug n chug team Camperjam 2013 - Lost to the Bodybuilders, but delivered in a Syncro Tough Mudder - Fried Piggy For - Charity So, Rae is a girl then yeah. |
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cushymac
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Joined: 02 Jun 10 Status: Offline Points: 9 |
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Posted: 02 Jun 10 at 10:00 |
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D&D, you sound like the guy I need to talk to about 2.4's! I have a very sluggish P reg 2.4 non turbo and it is massively thirsty and slow. I don't mind about the speed but I would love to up the MPG. What return do you get ? Did you do the turbo and 5th gear mod yourself?
Cheers
S
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nind
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Joined: 24 Feb 07 Location: United Kingdom Status: Offline Points: 410 |
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Posted: 02 Jun 10 at 10:28 |
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There was a guy on here, that said his 2.4 was dog slow. In the end he found it to be the a blocked cat.
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Steve B
Vanorak
Joined: 26 Apr 05 Location: Mong free zone Status: Offline Points: 13190 |
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Posted: 02 Jun 10 at 11:20 |
Worth a read.
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D&D
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"deuce" Joined: 11 Sep 09 Location: Shropshire Status: Offline Points: 20097 |
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Posted: 03 Jun 10 at 20:50 |
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Both mods are fairly simple so can be done on the drive without special tools. Like Steve said it may be worth going down the fuel pump timing first tho? I'm picking up a bog standard T4 coachbuilt next week so will try the timing first, if that fails i'll turbo & chuck another 5th in it, keep you posted..
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Carthago 32.1 T4 LWB
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cushymac
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Posted: 03 Jun 10 at 22:58 |
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Cheers, appreciate it. Have you got any mpg figures after the gear mod?
"Both mods are fairly simple so can be done on the drive without special tools. Like Steve said it may be worth going down the fuel pump timing first tho? I'm picking up a bog standard T4 coachbuilt next week so will try the timing first, if that fails i'll turbo & chuck another 5th in it, keep you posted.." |
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D&D
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"deuce" Joined: 11 Sep 09 Location: Shropshire Status: Offline Points: 20097 |
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Posted: 04 Jun 10 at 09:28 |
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its certainly better on a run, I haven't got exact figures though. Revs dropped from 3650 to 3000 when in 5th so it must be better on a run
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cushymac
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Posted: 07 Jun 10 at 10:05 |
If you do it can you take some pics please. Have never had to do anything with a gearbox so I would be delving into unknown territory. I am having my timing belt replaced tomorrow so I will stress the importance of setting the timing correctly. Thanks for the help and advice so far.
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T4trickster
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Posted: 12 Jun 10 at 19:03 |
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Right guys I've fitted large 5th gears(0.65:1) in all T4s, the 1.9TD can pull one of my 0.65:1 kits no probs 2.4 same as pulls fine NON turbo 1.9 should stick to 0.70.
I don't know why people are spending money on 0.70 gear sets as this is the 2.5 tdi 5th ratio, 0.68 is still available from vw every now and then but getting hard to find, and I still have some genuine vw 0.65 kits I'm willing to let go as I've got someone making them for me as part of a 6 speed conversion the original vw sets I dont need anymore (only used them to copy from).
As for 6 speed yes its been done and I'm in the process of putting together a kit with a view to marketing it, our test bed is a 1.9 tdi powered van watch this space!!
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D&D
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"deuce" Joined: 11 Sep 09 Location: Shropshire Status: Offline Points: 20097 |
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Posted: 12 Jun 10 at 21:46 |
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What cruising speeds/revs are you getting from the 2.4d with your gears?
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Carthago 32.1 T4 LWB
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T4trickster
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Posted: 13 Jun 10 at 16:34 |
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defo well under 3000 can't remember off hand i'll give the chap a buzz and ask him... the 1.9 tdi powered van does 90mph around 3k if my memory serves me well
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kens_soup
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Joined: 28 Apr 10 Location: Hull, Yorkshire Status: Offline Points: 78 |
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Posted: 17 Jun 10 at 07:32 |
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Priced the bits up with a mate who works at VW and apparently one of the gears is on backorder :(
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kens_soup
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Posted: 01 Jul 10 at 07:45 |
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The ASD gearbox that i can pillage the 5th gear out of... any particular engine or os it pretty much all 5 speed asd boxes??
Edited by kens_soup - 01 Jul 10 at 07:46 |
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Bernardo
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Posted: 02 Jul 10 at 07:54 |
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Hi All,
Having just done the 5th gear mod I can say it does make one hell of a difference.I went to TPS Autoparts and ordered the 0.681:1 gears (02D 311 361 and 02D 311 158)£185.77p inc.vat.They will probably tell you it`s on back order but mine was received within 8 Days.I am disabled and have no facilities for working on my van so I went to a gearbox and clutch specialist,a very clued up chap.50 minutes later inc test run all done.I have no fuel figures yet because it was done only last week but it drives so much better at a true 60mph and 2450rpm.
The van is a 2000 1.9td 800 special with De-cat and SS side exit thanks to PPTuning at Louth,Lincs.EGR removed completely and Hi Flo filter from T4srus.Next job is TMIC and then find some guru to tweak her up in exchange for Purple Drinking Vouchers.
Another way of increasing economy is changing wheel dimensions,I went from 195/70/15 to 215/65/16 and this corrected my speedo according to sat nav and a friends calibrated vehicle.This is not everyones cup of tea but suits the way I drive and I hate pouring hard earned cash into David Cameron`s Benifit Club for hard done by MPs(Thieving Buggers)
Regards,
Bernard Edited by Bernardo - 04 Jul 10 at 15:24 |
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Blessed are the "Cracked" for it is they who let in the light
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andyluffs
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Posted: 02 Jul 10 at 08:42 |
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I have a 2.5 petrol syncro, is this mod possible on my box? (not sure of gearbox code though) I could do with improving my fuel economy!
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FIGHT APATHY! I would but I just can't be arsed
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cushymac wrote: