I would check out the transmission info on this web page
http://volksweb.relitech.com/helmut/GEARBOX.HTM and pay attention to the
overall gearing in 1st and 4th gear.  The TD has no more torque at idle than
the NA engine, so I wouldn't stray very far from the highest overall gearing
used by VW for 1st gear.  Accelerated clutch wear from slippage will no
doubt occur if 1st gear is too steep.  Standing starts going uphill could be
very interesting.

4th gear is a different issue.  VW put higher ring/pinion gearing in the
1.6TD vans.  The ABH transmission is listed as having 0.78 4th gear and 5.50
ring & pinion for a 4.29 overall ratio.  The AAS 5 speed has 0.82 x 4.83 =
3.96 overall ratio.  You can figure out what the overall gearing with the
different ring/pinion ratios and combine them with various tire sizes to get
a final drive ratio that is a bit higher than the factory 4 speed setup.

Installation of a 5 speed transmission involves a lot more work and expense
than you might imagine.  I have 2 diesel Vanagons, 4 speed and 5 speed.
Briefly, the factory method uses different engine carrier bars, motor
mounts, coolant hoses, expansion tank, air intake elbow, oil filler and
dipstick in the engine compartment.  The entire shifting mechanism from the
knob to the transmission, as well as the front transmission mount are also
different.  I cannot speak intelligently on the details of installing a
South African 5 speed, but the cost of the transmission alone (don't ask
about availability) is very high.

All things considered, I feel VERY lucky to have found a factory 5 speed
diesel van.  With the stock 185R14 tires, the engine turns about 3000 RPM at
55 MPH, which is pretty comfortable with the 1.6NA engine.

Mike Snow

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@GERRY.VANAGON.COM]On Behalf
Of Sylvain B
Sent: Thursday, October 12, 2000 3:59 PM
To: vanagon@GERRY.VANAGON.COM
Subject: New tranny for a 1.6l TD westy...

I am thinking about changing the 4 spd tranny of my 1982 westy that was
previously converted from a 48 hp 1.5l na Diesel to a 68 hp 1.6l TD.
With the original tranny, i find that the engine really revs too fast on top
gear. I guess it must be running at about 4000-4500 rpm at 60 mph.
Maybe with the 48 hp engine it was ok but with the 68 hp that i have now, i
feel that a lower top gear would be much more "comfortable" for me and the
engine.
What new transmission should i look for?
One from a water cooled engine?
One from a WBX?
Or is it possible to just rebuild my old one with different gear ratios?
Will the 1.6l TD really be able to take a lower gear ratio?
Is there some 5 speeds tranny that i could find?

Sylvain B�langer
1982 1.6l TD Westy
Montreal, Quebec

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