The Brick-yard Homepage Brickwerks
Forum Home Forum Home > T3 Section > T3 Engine Upgrades
  New Posts New Posts RSS Feed - Audi A4 Passat gear box install
  FAQ FAQ  Forum Search   Events   Register Register  Login Login

Audi A4 Passat gear box install

 Post Reply Post Reply Page  123 15>
Author
Message
VW Nerd View Drop Down
Yardie
Yardie
Avatar

Joined: 20 Jan 08
Location: Bristol
Status: Offline
Points: 821
Post Options Post Options   Thanks (0) Thanks(0)   Quote VW Nerd Quote  Post ReplyReply Direct Link To This Post Topic: Audi A4 Passat gear box install
    Posted: 15 Feb 12 at 12:02
Hi All,

Looking at the amount of interest in the fitting of the Audi A4 and the VW Passat gear box transaxle into the back of any VW T3 vanagon which appeared in Martyn (bus boys thread)
http://www.brick-yard.co.uk/forum/charge-cooler-and-new-gearbox_topic62757.html
I felt it was only right to start a new thread on the fitting procedure of this gear box transaxle and afn tdi into the back of a VW T3 Vanagon.

The principle is simple enough.

Take the engine and gear box from either the Audi A4 or the VW Passat TDI with the inline engine and fit the whole lot into the back of any VW T3.

The first problem in doing this is that if you take the engine and gear box from the front of the car and fit it facing in the opposite direction in the back of your VW T3, you will end up with a vehicle with 5 or 6 reverse gears and one forward (which is not very practical)

So what I set about building was an adaptor plate that allows the gear box to be flipped upside down to then give the 5 or 6 forward gears and one reverse. It really is that simple.

The idea then is to use some of the fitting parts used by VW to install the diesel td engine into the VW T3 Vanagon. These parts would be the usual suspects inc, turbo diesel sump, water pipes, dip stick etc etc, but to maintain the flywheel, clutch, starter motor,gearbox input shaft from the donor car, thus saving a huge amount of cash on bespoke parts and rebuilding an inherently weak standard VW T3 transmission.

Up until now I have been using the very reliable Renaul t UN1 trans axle with my TDI conversions. 
http://www.brick-yard.co.uk/forum/new-project-1z-tdi-install_topic34781.html
The downside to using this box is its physical size. It is longer than the standard VW transporter gear box and means that you need to cut and modify the cross members under the van if you want to keep the engine in its stock location. The A4 Passat box on the other hand is short enough to fit into the unmodified body of the bus.
Also this gear box has been chosen by VW to work with their AFN (110 bhp) engines and also the PD engines which are rated to 150 bhp. This should give a reasonable amount of reliability with this gear box.

The goal at the end of this project is to supply parts or a complete fitting kit to allow T3 owners to convert their vehicles from either petrol or diesel to TDI.

Also if this is successful I plant to produce a fitting kit to allow the use of the PD engine range into VW T1 split screen, T2 bay window, T3 T3.

I can take no credit for the idea of using the inverted gearbox as Martyn (bus boy) has one in his van which I believe he bought pre modified and extensively tested by a T2 owner. This box has a cut and welded bell housing which although works, might not have the degree of accuracy that is available from my CNC machined adaptor plate.

Every one likes a photoTongue
although I can't see the picture (edit)

So here is the beginning of the project. The engine fitted with the adaptor plate with the inverted gear box attached.

undefined



Came across this useful list for transaxle codes. Might help with people who want to mix and match engine and gear box combo's.



Transaxle CodeCrown wheel & pinionGearRatio
DAE3.88913.36
22.06
31.38
41.04
50.82
DCM4.11113.778
22.176
31.3
41.029
50.838
DCN4.55613.5
22.118
31.3
40.943
50.789
DDU4.11113.778
22.176
31.429
41.029
50.838
DHC4.11113.778
22.176
31.3
41.029
50.838
DHE4.55613.5
22.118
31.3
40.943
50.789
DHF3.713.5
21.944
31.226
40.838
50.683
DHL3.88913.5
21.944
31.226
40.838
50.683
DHN3.88913.5
21.944
31.3
41.029
50.838
DHW3.713.5
22.118
31.3
41.029
50.838
DHY3.713.5
21.944
31.3
40.943
50.789
DHZ4.11113.778
22.176
31.429
41.029
50.838
DJA4.11113.778
22.176
31.429
41.091
50.889
DRE3.88913.5
21.944
31.3
41.029
50.838
DYB3.55613.5
21.944
31.222
40.875
50.686
DUK3.55613.5
21.944
31.222
40.875
50.686
DVP4.11113.778
22.118
31.3
40.943
50.789
DVS3.88913.5
21.944
31.226
40.838
50.683
DVT3.88913.5
21.944
31.3
41.029
50.838
DVX3.713.5
22.118
31.3
41.029
50.838
DVZ3.713.5
21.944
31.3
40.943
50.789
DWA4.11113.778
22.176
31.429
41.029
50.838
DWB4.11113.778
22.176
31.429
41.091
50.889
DWD3.88913.5
21.944
31.3
40.943
50.838
DWF4.11113.778
22.176
31.3
41.029
50.838
DWG4.55613.5
22.118
31.3
40.943
50.789
EAA3.87513.5
21.944
31.3
41.029
50.816
EAB3.87513.5
21.944
31.226
40.838
50.683
EAC3.87513.5
21.944
31.3
41.029
50.838
EEN3.713.5
21.944
31.226
40.838
50.683
EHV3.713.778
22.176
31.429
41.029
50.838
EMV3.87513.778
22.176
31.429
41.029
50.838
EZG3.713.778
22.16
31.429
41.029
50.838
FCB3.87513.778
22.176
31.429
41.029
50.838


Edited by VW Nerd - 22 Aug 14 at 09:32
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

AFN TDI Panel Van
Back to Top
mrhutch View Drop Down
Moderator Group
Moderator Group
Avatar
the ginger princess

Joined: 21 Aug 07
Location: Herefordshire
Status: Offline
Points: 5130
Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 12 at 12:12
Clap

superb Tim, I'm having one off you when you're ready mate
T3 1981 Westy Vanagon - thinks lubricant is a fuel
Back to Top
Titus A Duxass View Drop Down
Vanorak
Vanorak


Joined: 12 Feb 08
Location: Lossatal, Germ.
Status: Offline
Points: 2127
Post Options Post Options   Thanks (0) Thanks(0)   Quote Titus A Duxass Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 12 at 12:32
Very interesting, will this, or does this, work with 2E/AGG/ADY petrol motors?

It would be a good alternative gearbox for those who have already "modernised" their T3. 
Bollocks to it all!!
51°24′N 12°52′E
Back to Top
miilor View Drop Down
Newbie
Newbie


Joined: 27 Dec 11
Location: spain
Status: Offline
Points: 6
Post Options Post Options   Thanks (0) Thanks(0)   Quote miilor Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 12 at 13:25

hi i am looking at this option, how many degrees the motor is tilted from the t3? 50 º or 52 º

siempre estas conmigo
Back to Top
jack carlton View Drop Down
Groupie
Groupie
Avatar

Joined: 09 May 10
Location: durham dales
Status: Offline
Points: 171
Post Options Post Options   Thanks (0) Thanks(0)   Quote jack carlton Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 12 at 16:25
sooo would this work with any 2 wheel drive a4/passat combo?
petrol variants always seem a whole lot cheaper.
Back to Top
syncroandy View Drop Down
Yardie
Yardie
Avatar

Joined: 18 May 05
Location: North Lancs. UK
Status: Offline
Points: 629
Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 12 at 20:24
Tim, great to see the investment being put into providing the T3 community with another option for keeping our vans on the road.

Is this for i4 @ ~50 degrees only ? It'd be great to have the option of i5/v6 motors as well. Also, I think the later TDI lend themselves more to 15 degree installs, what with their different turbo's, sumps and engine bracket tappings. TBH with the scarcity of T3 TD bits (in some parts anyway) there's an argument for doing even earlier i4's at 15 degrees.

Edit: What are the starter/FW options ? I guess with the 5sp starter a notch may be needed as the original pocket is on the other side ? Perhaps the 6sp starter lacking a nose avoids making a notch ?


Edited by syncroandy - 15 Feb 12 at 20:30
'90 252 EJ25
'90 246 AFN

Syncrosport
Volkswagen Transporter, reloaded.
Back to Top
mcgill5 View Drop Down
Yardie
Yardie


Joined: 19 Aug 08
Location: shotts, north l
Status: Offline
Points: 251
Post Options Post Options   Thanks (0) Thanks(0)   Quote mcgill5 Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 12 at 21:22
want me to start collecting the gearboxes for you? given loads of them away when i strip passats etc for the engines? got an A4 out the back,its a start if you need it? (free) cheers mcgill
Back to Top
VW Nerd View Drop Down
Yardie
Yardie
Avatar

Joined: 20 Jan 08
Location: Bristol
Status: Offline
Points: 821
Post Options Post Options   Thanks (0) Thanks(0)   Quote VW Nerd Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 12 at 22:54
The plan for the moment is to put together the in line 4 over at 50 degrees.

The engine to gear box issue is now sorted and I now need to turn my attention toward building the engine and gear box mounts and sorting out the gear linkage.

As for the 5 and 6 cylinder models this should be straight forward. Just a case of rotating the fitting holes 180 degrees. 

Although the PD in line 4 cylinder uses a different set of holes to the 5 and 6 cylinder the arrangement with rotating 180 will be the same. Just need to check which gear box fitting holes clash with engine fitting holes. Making the plate will be a piece of cake.


Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

AFN TDI Panel Van
Back to Top
mazz View Drop Down
Yardie
Yardie
Avatar

Joined: 04 Mar 07
Location: shropshire
Status: Offline
Points: 584
Post Options Post Options   Thanks (0) Thanks(0)   Quote mazz Quote  Post ReplyReply Direct Link To This Post Posted: 20 Feb 12 at 22:32

keep talking guys im off to collect more Passat/A4 gearboxes :-)

MV Engineering-TDi conversion specialist
07989593569-01952 581818
mveservices@hotmail.co.uk
Back to Top
zyclamvw View Drop Down
Groupie
Groupie


Joined: 10 Nov 09
Status: Offline
Points: 127
Post Options Post Options   Thanks (0) Thanks(0)   Quote zyclamvw Quote  Post ReplyReply Direct Link To This Post Posted: 15 Apr 12 at 18:29
Hi
How's this progressing?
Any joy with the linkage? Asking as am really interested in this as an option for my bus
Ta
door hinge pin mod....... whos up for doing it then?
Back to Top
VW Nerd View Drop Down
Yardie
Yardie
Avatar

Joined: 20 Jan 08
Location: Bristol
Status: Offline
Points: 821
Post Options Post Options   Thanks (0) Thanks(0)   Quote VW Nerd Quote  Post ReplyReply Direct Link To This Post Posted: 16 Apr 12 at 09:23
I am installing the package into a bus while we speak and should be doing my first install in a few weeks for a customer with his AFN tdi conversion. I'll let you know how I get on.

Tim.
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

AFN TDI Panel Van
Back to Top
Racebiz View Drop Down
Groupie
Groupie
Avatar

Joined: 29 Mar 11
Location: S E Cornwall
Status: Offline
Points: 90
Post Options Post Options   Thanks (0) Thanks(0)   Quote Racebiz Quote  Post ReplyReply Direct Link To This Post Posted: 03 May 12 at 21:54
Hi Tim,

Any updates on the conversion - I'm sure there are plenty of us on here keen to know how progress is going.

cheers
98 T3 PD130 Viking Top
A4 1.9 TDI
Classic RangeRover 3.9 EFI
Back to Top
VW Nerd View Drop Down
Yardie
Yardie
Avatar

Joined: 20 Jan 08
Location: Bristol
Status: Offline
Points: 821
Post Options Post Options   Thanks (0) Thanks(0)   Quote VW Nerd Quote  Post ReplyReply Direct Link To This Post Posted: 04 May 12 at 09:27
As the job involves all of the usual work involved in a TDI conversion, I will have to do that part of the install before I can continue with the rest of the conversion. I have been collecting parts and prototyping the gear linkage and engine mountings.
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

AFN TDI Panel Van
Back to Top
Racebiz View Drop Down
Groupie
Groupie
Avatar

Joined: 29 Mar 11
Location: S E Cornwall
Status: Offline
Points: 90
Post Options Post Options   Thanks (0) Thanks(0)   Quote Racebiz Quote  Post ReplyReply Direct Link To This Post Posted: 04 May 12 at 21:16
Cheers for that Tim, I look forward to your next update and hopefully some pics as well.
98 T3 PD130 Viking Top
A4 1.9 TDI
Classic RangeRover 3.9 EFI
Back to Top
andy1300gt View Drop Down
Yardie
Yardie
Avatar

Joined: 24 Sep 09
Location: Higher Bugle
Status: Offline
Points: 425
Post Options Post Options   Thanks (0) Thanks(0)   Quote andy1300gt Quote  Post ReplyReply Direct Link To This Post Posted: 05 May 12 at 00:05
Arghh!
It's all rust in the end....

89 T3 Doka - AFN TDI
76 XJC 4.2 Daimler - Gone!
72 Austin 1300
Back to Top
BUS.BOY View Drop Down
Vanorak
Vanorak
Avatar

Joined: 15 Oct 04
Location: brizel
Status: Offline
Points: 1563
Post Options Post Options   Thanks (0) Thanks(0)   Quote BUS.BOY Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 12 at 15:54
Originally posted by andy1300gt andy1300gt wrote:

Arghh!


You just hit your finger with a hammer ?
************bristol t3 racers************
Back to Top
mrhutch View Drop Down
Moderator Group
Moderator Group
Avatar
the ginger princess

Joined: 21 Aug 07
Location: Herefordshire
Status: Offline
Points: 5130
Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 12 at 16:19
Originally posted by BUS.BOY BUS.BOY wrote:

 
You just hit your finger with a hammer ?

don't be silly mart, he's from bristol like you lot..  more thumbs than fingers down there..
T3 1981 Westy Vanagon - thinks lubricant is a fuel
Back to Top
andy1300gt View Drop Down
Yardie
Yardie
Avatar

Joined: 24 Sep 09
Location: Higher Bugle
Status: Offline
Points: 425
Post Options Post Options   Thanks (0) Thanks(0)   Quote andy1300gt Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 12 at 21:03
It's a long story. Lets just say I was just one step behind the curve. 
It's all rust in the end....

89 T3 Doka - AFN TDI
76 XJC 4.2 Daimler - Gone!
72 Austin 1300
Back to Top
mrhutch View Drop Down
Moderator Group
Moderator Group
Avatar
the ginger princess

Joined: 21 Aug 07
Location: Herefordshire
Status: Offline
Points: 5130
Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 12 at 21:22
c'mon spill!!

2-1 says you got 5 reverse and 1 forward gear! 
T3 1981 Westy Vanagon - thinks lubricant is a fuel
Back to Top
andy1300gt View Drop Down
Yardie
Yardie
Avatar

Joined: 24 Sep 09
Location: Higher Bugle
Status: Offline
Points: 425
Post Options Post Options   Thanks (0) Thanks(0)   Quote andy1300gt Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 12 at 21:30
I have just spent a fair few ££ getting a very good convestion in me van. Now there is a new way. Bah!
It's all rust in the end....

89 T3 Doka - AFN TDI
76 XJC 4.2 Daimler - Gone!
72 Austin 1300
Back to Top
 Post Reply Post Reply Page  123 15>
  Share Topic   

Forum Jump Forum Permissions View Drop Down

Forum Software by Web Wiz Forums® version 11.10
Copyright ©2001-2017 Web Wiz Ltd.

The WebThis site