A GEARBOX TALK!!! For newbies and oldies! hehe

[K Simmonds]

It's pretty simple to swap the flanges around on 01A gearboxs, they're only held in by a clip on shaft of the flange a bit like an outer CV joint.

Get two long bolts the correct thread for the flanges, wind them through the flange opposite each other on to a couple of bits of scrap steel up against the alloy housing of the box and they pop straight out.

A good time to fit new seals whilst you're at it.

[S_o_n_y]

Ahh so you pull them straight out without opening the box ? i just can swap the flanges between my gearboxes then ?

[S_o_n_y]

2.8 V6 C4 quattro's use a 01A Five speed with a 4.11 final drive they bolt straight up but you'll need to fabricate the side mounts which is easy enough with some 1/4" plate steel... If you can find one from a 30V the ratios will even be pretty close to spot on for a 20VT engine and it'll have the 108mm driveshaft flanges.

I do happen to have a good 30V one spare but sending it to Sweden will be dam expensive.

In sweden the 2.8 quattros have 3:89 final (sorry didnt see the C4. I mean C5. I have checked a few on the scarpyard. But the 2.4 quattro have the 4:11 but wrong flanges. But it seems to pop right out if you read the threadanswers here
Yes, a little bit to expensive to send it here :/

[K Simmonds]

That's odd as both the 12V and 30V 2.8 C4 quattros with 01A use 4.11 in the UK, the 2.6 quattro C4's are 3.89 . I have a 12V Avant quattro which is a super comfortable cruising barge.

Anyway, yes, it's really easy to swap the flanges around between 01A gearboxs using the two bolt method I described to get them out.

[S_o_n_y]

Found now a gearbox on the scrap for a Audi A6 1996 C4 2.6 quattro 5speed. Do you think this gearbox is a straight swap for my 01A i the S2 ?
And do you know if it could handle the power ? i have 300bhp on the wheels today but dont do launches with it

I will swap for a 01E in the future, but that was a little more work. I just want do cruise this summer

[ak139]

Cant swap B4 01A flanges into B5/C5 01A.
There are allso some spline size differences with 01A / 012 gearboxes.
But some small engine Passat/A4 012 fwd gearboxes have the right spline 108mm flange to fit C5/B5 01A box

2.4 should be 4.11
B5/C5 2.6/2.8 V6 have same ratio boxes both 3.89 and 4.11

There is 5 number date and 3 letter code on top of bellhousing to confirm.

Is your current box AKU?

[K Simmonds]

If it's a 01A it will physically fit with custom side mounts, plus you may need to move the mounting dowels around.

However, I have no idea what final drive C5 2.6 five speed will be.

You need to find the three letter gearbox code and spend hours Googling to find out what the final drive is, there are a couple of comprehensive lists.

As for strength all the 01A gearboxes are much the same internally and will take the same amount of power.

My 1300kg 3B S2 had over 380BHP & 550nm at the crank. I never really bothered with first gear, I found I could launch it faster if I just got off the mark in first, slipped it into second then floored it and I'd be in third within seconds and on my way to 115mph. According to a phone App I could do 0-60mph that way in 4.5 seconds, perhaps even faster sometimes when the air was really cold and dense.

My car was full RS2 spec with a Nothelle head and mental software that hit 2 bar of boost at just over 2K RPM and held it to around 4.5K rpm and the box held up fine, never missed a gear or made a bad noise.

So I'd advise against giving it full power in first gear, it just puts a lot of stress on the gearbox for no real gain in performance.

I have really close ratio low geared 01A five speed in my 1000kg 2.0 B3 80 quattro Saloon, it's geared for 120mph at a bit over 5Krpm. I'm going to be swapping the engine out for 1.8T with a Billet K04 01 Borg Warner racing turbo that should have virtually zero lag and be good for 300bhp and I'll probably drive that the same way as my S2 and have to change gear a lot!

Edit... Have just read the above post, I didn't know that the C5 01A's flanges are not compatible with earlier 01A's... I've only ever mucked about with boxes from B3/4 and C3/4 cars.

[ak139]

If you dont launch, you should be fine.

80 B4

CDV: for engine 2.6l 110kW
1st: 3.545
2nd: 1.857
3rd: 1.300
4th: 1.029
5th: 0.838
reverse: 3.500
final drive: 4.11 AZC

AXM: for engine 2.31 98kW, 2.0l 101kW (Italy upto 10/92)
1st: 3.545
2nd: 2.105
3rd: 1.429
4th: 1.029
5th: 0.838
reverse: 3.500
final drive: 4.111

CBR: for engine 2.8l 128kW
1st: 3.500
2nd: 1.842
3rd: 1.226
4th: 0.943
5th: 0.816
reverse: 3.444
final drive: 3.889 CAV

AKU '87 to '90 and "AXL" '90 and up.
1st: 3.545
2nd: 2.105
3rd: 1.300
4th: 0.943
5th: 0.769
reverse: 3.500
final drive: 4.111

A4 B5

96-98
DGW: for engine 1.9l 81kw
98-
EEP: for engine 1.9l 81kw
1st: 3.500
2nd: 1.944
3rd: 1.226
4th: 0.838
5th: 0.659
reverse: 3.444
final drive: 3.889

96-98
DJS: for engine 2.6l 110kw 2.4l 120kw
DJP: for engine 2.8l 128kw
DJR: for engine 2.8l 142kw
94-96
CXW: for engine 2.8l 128kw
CXZ: for engine 2.6l 110kw
CYA: for engine 2.6l 110kw
97-
DWN: for engine 2.4l 121/120kw
DWM: for engine 2.8l 140/142kw
1st: 3.500
2nd: 1.944
3rd: 1.300
4th: 0.943
5th: 0.789
reverse: 3.444
final drive: 4.111 DJS CXZ CYA DWN
final drive: 3.889 DJP DJR CXW DWM

94-96
CTF: for engine 1.8l 110kw
96-98
DJJ: for engine 1.8l 110/132kw
97-
DWR: for engine 1.8l 110/132kw
1st: 3.778
2nd: 2.176
3rd: 1.429
4th: 1.029
5th: 0.838
reverse: 3.444
final drive: 3.889

[S_o_n_y]

Ahh ok, see that the flanges dosent fit. Can you build a driveshaft instead ?
but the box i found now from the A6 C4 2.6 quattro 5 speed is named CPR, cant find it in your list.
Still waiting for pictures of it to check the flanges

Your Rs2 sounds similar to mine in power. Sounds like it held together just fine. Heres a picture of the powerfigures.

[S_o_n_y]

Cant swap B4 01A flanges into B5/C5 01A.
There are allso some spline size differences with 01A / 012 gearboxes.
But some small engine Passat/A4 012 fwd gearboxes have the right spline 108mm flange to fit C5/B5 01A box

2.4 should be 4.11
B5/C5 2.6/2.8 V6 have same ratio boxes both 3.89 and 4.11

There is 5 number date and 3 letter code on top of bellhousing to confirm.

Is your current box AKU?

Its is very hard to see the nr but i think it said ARV and it is 5 speed.

[K Simmonds]

That dyno plot looks very like how my RS2 spec 3B performed, though my car took off slightly earlier probably down to the gas flowed head and mapping.

What turbo are you running?

I'm currently having a coffee so I'll Google that gearbox and see what I can find.

[Ryan80]

That's odd as both the 12V and 30V 2.8 C4 quattros with 01A use 4.11 in the UK, the 2.6 quattro C4's are 3.89 . I have a 12V Avant quattro which is a super comfortable cruising barge.

Anyway, yes, it's really easy to swap the flanges around between 01A gearboxs using the two bolt method I described to get them out.

I've the 2.6 v6 B4 quattro manual avant and i'd agree its a lovely barge for cruising with the low down torque, but always feels at 60mph+ that it could do with another gear!

Am i correct in saying a b5.5 passat 2.5tdi 4motion 6 speed will fit and work? I've no idea what rear diff ratio mine has, or what the passat box would need?

[S_o_n_y]

I did have a Precision 6062 Gen1, but the spoolup was horrible. So i downsized to some China (****) from Maxpeeding with this specs:
Compressor Trim: 48.1
Compressor A/R: 0.5
Compressor Inducer: 52.7mm
Compressor Exducer: 76mm
Turbine Trim: 74.2
Turbine A/R: 0.57
Turbine Inducer: 64.8mm
Turbine Exducer: 55.8mm

And this is what i did get out of it at 2bar. So if i would have more power i need to upgrade again, but now im struggle with the gearbox instead, so i think im satisfied with the power at the moment

[S_o_n_y]

I've the 2.6 v6 B4 quattro manual avant and i'd agree its a lovely barge for cruising with the low down torque, but always feels at 60mph+ that it could do with another gear!

Am i correct in saying a b5.5 passat 2.5tdi 4motion 6 speed will fit and work? I've no idea what rear diff ratio mine has, or what the passat box would need?

With my 3days research i think the Passat b5.5 TDIs has the 01e box with 4:11. Ive only checked the 1.9tdi 4motion B5.5 up here in sweden, and that box will have the same Ratio that mine S2 has. But you need a rebuild of gearbox mounts (you can buy them custom aswell) and other driveshafts (i dont know witch) and a custom driveaxle to the back diff, and the gearlinkage from the Passat TDI aswell. Other than that you are good to go

[K Simmonds]

Those Maxspeeding turbo's seem to be surprisingly good for the money, I did get a knock off GT2871 from them on special offer for £100 from eBay to use on my Audi 80 1.8T build and was really surprised by the look of the build quality.

But then I got a bargain on a genuine Borg Warner K04 01 which is much easier to fit and will give me exactly the performance I want so the Chinese turbo can stay on the shelf for now, I may find a use for it on something else or even sell it if I get too bored of looking at it.

The turbo you have is quite a bit bigger on cold-side compared to an RS2 turbo and a little larger on the hot-side, is the waste-gate internal? It looks like it performs well though, spools pretty early for it's size. What's it supposed to be a copy of?

I can't find out what the final drive on that gearbox at the moment as I really should be working not searching for random gear-box codes, though Google is you're friend if your're persistent enough you will find it. Will take a look tonight if you're still stuck.

And as mentioned above if you want an 01A to survive don't launch it hard in first gear.