car1.0 Posted May 26, 2022 Report Share Posted May 26, 2022 I want to swap the gearbox to the different gear ratio. Are the shifters of type A and B interchangable or not? (if there are differences in the dimensions of the gearshift rod?) I have ESY gearbox and it makes the car very revvy and not enough speed at the top gear. Quote Link to comment Share on other sites More sharing options...
ObjectiveAway Posted May 27, 2022 Report Share Posted May 27, 2022 (edited) 8 hours ago, car1.0 said: I want to swap the gearbox to the different gear ratio. Are the shifters of type A and B interchangable or not? (if there are differences in the dimensions of the gearshift rod?) I have ESY gearbox and it makes the car very revvy and not enough speed at the top gear. Just remove the end cover and replace 5th speed, turns out it is not hard and you dont even need to remove gearbox. Sadly a lot of 085’s just have problems with reduction ratio not only 5th gear. 3,875 is good for final drive and 0,74 is good for 5th speed. ESY has 4,063 final drive and 0,892 5th speed. Therefore you can simply change 5th speed with better ratios. These gearboxes are swapable only if there are screw holes for cable shifter, therefore you can use only gearboxes from cars with cable shifters originally. You can switch from A to B but not otherwise. But you can use 5th speed gears from all 085 gearboxes which are designed for 2,7liters of oil. Edited May 27, 2022 by ObjectiveAway 1 Quote Link to comment Share on other sites More sharing options...
Rich Posted May 27, 2022 Report Share Posted May 27, 2022 If you wanted to use picture b (better imo) then you'd only have to change the shifter to a 6n polo one or something similar. 1 Quote Link to comment Share on other sites More sharing options...
car1.0 Posted May 27, 2022 Report Share Posted May 27, 2022 (edited) Thank you @ObjectiveAway , @Rick ! The gearbox was removed due to the failure. Clutch has become super hard and hammered into gearbox by torsion shocks while clutching. Gearbox has become solid, concreted. So sorry, only 5th swap is not possible. Calculating the final ratio of: ESY 5th gear 3,65 (4.06 * 0,9) with ETD 4th gear 3,87 (3,87 * 0,93) and they are quite similar revs and there is room for 5th gear 2,86 (3,87 * 0,74) There are 190 mm and 200 mm diameter clutch versions of 085 gearbox. Are they different - not compatible? (I have 190mm clutch) I consider DHB, DKF, DQW, DXP, ERD, ETD, FGF Edited May 27, 2022 by car1.0 Quote Link to comment Share on other sites More sharing options...
tigcraft Posted June 30, 2022 Report Share Posted June 30, 2022 Think it’s my turn now for a replacement box. I now really have what seems a noisy diff starting at 10mph upwards and very clear to about 40mph as after that the general road noise and wind masks it. Anyone got a spare tdi exb box? Quote Link to comment Share on other sites More sharing options...
ObjectiveAway Posted July 18, 2022 Report Share Posted July 18, 2022 Melted my 5th gear bearing. Repaired it without removing gearbox. Made a puller to get the very stiff gear off. A lot of melted plastic on gear, gearbox shaft and everywhere around. I was able to clean it and the shaft is in almost perfect condition. Took 5th gear with needle bearing from another gearbox. Assembly, fresh oil and works great, but I have tested it only for 30miles for now. 2 Quote Link to comment Share on other sites More sharing options...
mk2 Posted July 18, 2022 Report Share Posted July 18, 2022 Nice work 👍🏻 That puller you made looks really good. And obviously works. I need to check my gearbox oil levels (via the speedo gear). Quick and relatively easy job... Your pics remind me why this is essential maintenance work every couple of years. 1 Quote Link to comment Share on other sites More sharing options...
Rich Posted July 19, 2022 Report Share Posted July 19, 2022 Removing and pocketing fifth gear in a scrappy with very minimal tools isn't fun, somewhat near impossible. Gear pullers are awesome. Quote Link to comment Share on other sites More sharing options...
John90 Posted July 19, 2022 Report Share Posted July 19, 2022 On 7/18/2022 at 5:25 PM, mk2 said: I need to check my gearbox oil levels (via the speedo gear). Quick and relatively easy job... Your pics remind me why this is essential maintenance work every couple of years. How much extra above the standard level plug do you use? 500ml? Quote Link to comment Share on other sites More sharing options...
The Penguin Posted July 20, 2022 Report Share Posted July 20, 2022 I've had several of the problems mentioned in this thread, failing 5th gear on a 16v box, alignment/clutch issues on a 16V Sport and a 3rd gear synchro issue with my TDi of these only the TDi box went for repair/rebuild and it cost me £450, but it transformed the car, as the TDi is a hydraulic gearbox I'd say it was the best of the three as well. I may have a spare g/box kicking around in my garage, I bought it for the failing 5th gear car but its heater matrix failed and the car was scrapped, if its there I'll put a post out as a freebie Quote Link to comment Share on other sites More sharing options...
Plons_One Posted October 7, 2023 Report Share Posted October 7, 2023 #lupo #sdi #gearbox #gearboxservice #oil Hi! I would like to change oil in the gearbox but it looks like mine does have the filler hole/plug 😕 There is a visible place where it should be located. My gearbox looks like 085 and drain hole/plug is ok. Anyone had such problem? Do you know to fix it or how to change oil in it? I could use some workaround but how much oil should go inside? Also, can you help with a good service manual for this car? Pretty please Thanks! Quote Link to comment Share on other sites More sharing options...
lupo 1.7sdi Posted October 7, 2023 Report Share Posted October 7, 2023 Oil G005000 (G50), 2,7l Quote Link to comment Share on other sites More sharing options...
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