which gearbox for pug conversion

[topcat74]

Bought a 79 camper with a pug 1.7 diesel conversion using what I assume is that standard gearbox. I'm changing the engine to a Pug 1.9TD but wanted to know which gearboxes are being used in such cases. Is the standard 4 speed to fragile for all that torque? are there any 5 speed that will fit or has anyone had a 4 speed box altered to suit

[famous phil]

Hi and welcome ,

With the bay campers I found the higher ratio 2.0L box ideal for the 306 1.9 non turbo diesel type engine , at 71bhp this engine is only 3hp less than the golf 1.9td but capable of higher RPM's ,
so in my old bay 6 birth viking I was able to cruise above our motorway speed limit with good acceleration , on a long trip to the coast along slow winding roads it could be left in top gear most of the time ,

the 1.9td's are 92bhp standard and will need a higher ratio box than fitted to the bay , a few folk have fitted the high ratio T3/T25 AAP 5 speed trans but seem to think they hang low
_________________
Auto Union Munga Jeep ,T4 2.4td , T4 2.5tdi ,Mercedes S Class on LPG , 66 splity deluxe , GP mk1, 3 type 25s 1 with 1.9dt pug engine + 1 with N/A pug engine ,,there are 6 t25s with pug power in Darlington

[topcat74]

Thanks for your reply.

Is then T25 box transplant a simple affair? Sitting low does not bother me as van will ride and standard height and not be lowered. What about drive shafts? I was also going to do a rear brake disc conversion so what could I use?

[famous phil]

drive shafts will bolt up , I've never looked into the t3/t25 box transplants - just seen a few at the shows , not been involved with the rear disc conversions for bays either but there should be an odd one on here that have
_________________
Auto Union Munga Jeep ,T4 2.4td , T4 2.5tdi ,Mercedes S Class on LPG , 66 splity deluxe , GP mk1, 3 type 25s 1 with 1.9dt pug engine + 1 with N/A pug engine ,,there are 6 t25s with pug power in Darlington

[13 window deluxe]

the highest geared (read most sought after and expensive) 5 speed t25 box is the aap from the 2.1injection t25 this has the same diff and is only very marginally taller geared (a few percent) than the 2.0litre cp box! its longer due to 5th gear housing, mounts totally differently, has a mid side shift gearchange instead of nose shift so it's a lot of effort for a few percent lower revs on the motorway!!! if it was me i would either fit slightly taller rear tyres or a new taller 4th in your original box dont go mad though as you will have a large jump 3rd to 4th and you might not have the torque to pull 4th up bigger hills.
for rear disks there are a few kits about mainly for t25/3 (same hub as late bay) most use audi rear disks wit a custom caliper bracket and cables
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[topcat74]

any ideas who sells these rear disc conversions kits ?

think i will stick to the original 2 litre box and have the 4th gear chnaged.

[khh48]

[13 window deluxe]

futbus or ultimate engineering are the most common off the shelf kits try google t25/t3 rear disk conversions
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[t1mreed]

i have just fitted a 1.9 pug turbo diesel to my bay and am running a standard two litre box with taller back tyres and it seems spot on , damd good acceleration to about 80, much quicker than than with the old type 4 engine, and if you cruise along at about 70 on the motor way i gat about 50 to the gallon, i have not felt any problems with gearing, just came back from devon and had no problems with the 1 in 4s or the big long buggers on the motor way, went up some at 80 all the way.

[topcat74]

t1mreed, thanks for the heads up on the gearbox issues. by using the standard box and at 70mph whats the engine revving at? Is it really loud. I'm being quoted more than £1500 to have my 2 litre box rebuilt with a taller 3rd and 4th gear. Is it worth it for a few revs

[ElusiveStranger]

I don't know much about diesels, got a stamp and I'll write it down on it with space to spare.

But reading the above:
£1500 to rebuild your box (a few seem happy with theirs)...
Diesel's £1.30 odd a gallon

That's 1153 litres or 260 gallons. Umm say 40mpg
10, 400 miles or g/box rebuild?

Buy a few beers instead.
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more
Bugger, missed out on "Live fast, die young"

[t1mreed]

i agree with elusivestranger i did not rebuild mine because of the cost, and my box was i good shape. mine is noisy above 75 ish but i am running solid rubber engine mounts not oil filled ones which i know helps and i am also running a large cone filter which has a vloud induction roar. i have just taken mine of the road for a couple of weeks to redo some of my initial install, but have nothing but praise for the conversion, driving like i have stolen it for the last five months i have averaged 38 to the gallon and to devon got 47 average

good luck if you need help ask the forum, it would have taken me a lot longer and cost a lot more without this invaluable source of information.