Calling all gearbox experts....

[Beddo88]

Hello all,

I've finally sourced a replacement gearbox for my poor, synchro losing car.

A friend had a very cheap 4T unit he has sold me, which should have the impact of gearing the car up a bit for motorway journeys, exactly what I was looking for. BUT, there are a couple of issues, for which I would appreciate your kind gentleman's help.

Clutch choice:

I currently have an ACD box, with a 210mm clutch. The 4T box I've got to replace it is listed as having a 190mm clutch, is it possible to fit the larger clutch to the 4T box or will this impact the starter location/working on the flywheel?

Flanges:

Currently 100mm, new box is 90mm. I will swap these, which beings me onto question 2:

Parts sourcing:

While I've got it in pieces, I would like to replace the input seal and will obviously replace the seals on the flanges when they are swapped over. Any ideas on where I can source the seals etc for these?

Thanks in advance,
Dan

[Beddo88]

SO it would appear all of the parts I'm after can be sourced in one kit here...

http://www.ebay.co.uk/itm/VW-020-02K-O2 ... 19df2c2113

Can anyone clarify the clutch question for me though? Would be great to get that on order ASAP, really want to fit a new box before silverstone classic at the end of the month...

[Beddo88]

OK.. I've now convinced myself that a 210mm clutch will fit OK...

Will keep you all informed as to the progress... can only go well. Right...?

[MikeH]

I'm not 100% but I think the clutch should fit - I think all the 020 bell housings are the same size internally. Check the clearance between the output flanges and the gearbox case before you pull them off and try to fit the bigger ones. The passenger side one is too tight with some early casings. I'm not sure how old a 4T box would be.

[Beddo88]

Well, I've fitted the new seals from the 4T box, and both flanges (90mm) ones are identical. From what I've read, to be compatible for flanges the box needed to have one 'green' flange adapter and the other one needed to be 'normal'. The 4T matches this so hopefully all will be well!

Currently sadly, it's actually not the more worrysome of the jobs this week...