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The definitive Gearbox thread


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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.

gearbox controll .jpg

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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.

gearbox controll .jpg

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 by ObjectiveAway
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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. 

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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 by car1.0
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  • 1 month later...

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? 

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  • 3 weeks later...

 

Melted my 5th gear bearing. Repaired it without removing gearbox.
 

93E44B80-854B-450E-8F19-1C1D4D2B6F9F.thumb.jpeg.b5d95813e8d3f3375e0615c702792994.jpeg
Made a puller to get the very stiff gear off.

 

5E0E75A0-607F-44F1-B7B7-6E97E4DE4DF4.thumb.jpeg.451b6f102f0b4dced429137cd6a86f68.jpeg

268ACE02-1F6D-4C2E-8829-63524BC55572.thumb.jpeg.aba16ed6fa2399bfe4a79231e2266238.jpeg

A lot of melted plastic on gear, gearbox shaft and everywhere around.

 

3B5E07FB-5EC4-4FDD-A6EA-6CE95808ADB9.thumb.jpeg.103a7a6db0ee72b51d130f3a6e8bac6a.jpeg

I was able to clean it and the shaft is  in almost perfect condition.

 

4B71C050-8BA4-4940-A991-183480DDC027.thumb.jpeg.fe5755757a87080466f80caef9ab4eac.jpeg

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.

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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. :)

 

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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?

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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

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  • 1 year later...

#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!

IMG_20231006_145459.jpg

Screenshot_2023-10-07-04-45-08-420_com.mi.globalbrowser.jpg

Screenshot_2023-10-07-04-50-32-946_com.mi.globalbrowser.jpg

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