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Thread: MK1 caddy Gearbox FAQs

  1. #1
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    MK1 caddy Gearbox FAQs

    This thread is intended to be a list of questions most asked and hopefully corresponding answers! To start with it will be brain dump so will need some polishing!

    Links 020 Section 02A Section Driveshaft section


    General Questions

    Q: I keep reading about 020 and 02A gearboxes, what is the difference?
    A: There are several differences between an 020 generation gearbox and 02A generation 'boxes. I'll try and separate them out a bit to hopefully make more sense.
    • Background info: Put simply the 020 generation of gearboxes were used in early watercooled VWs, the MK1 and Mk2 Golf generation of vehicles. 02A gearboxes are from a later generation of cars from about 1990 onwards.
    • Shift mechanism: 020 uses a series of rods to select the required gear, 02A uses a cable based system.
    • Mounting points: mk1 golfs/jettas and most importantly caddys are designed to use 020 gearboxes, 02A gearboxes do NOT fit the mk1 chassis with std gearbox mounting hardware but they can be fitted
    • CV joint size: All caddys were fitted with 020 gearboxes from the factory which had 90mm CV joints. All 02A gearboxes have 100mm CV joints. More info on this below.
    • Strength: 02A gearboxes are designed/built to take more power/torque. Coupled with being newer than 020 you're more likely to find a lower millage 02A box which should be in better condition


    Q: What does 020 / 02A / 02J / 02M mean?
    A: The individual parts for the gearboxes will start either 020 or 02A or 02J or 02M depending on the type of gearbox, which is where the terms come from.

    Q:What gearbox do I have?
    A: 020 and 02A etc are misleading terms when trying to identify the gearbox you have, however they are useful to specify which generation of gearbox you have as mentioned above.
    VW gearboxes will have a 2 or 3 letter code to identify the gearbox type and the ratio of the gears fitted. This is why a VW parts man will look at you funny if you ask for 02A parts - they need the 3 letter code to look up spares! For instance I'm using CDA gearbox which is an 02A from a mk3 golf 16V

    020 Gearbox codes: http://www.fastgolf.org.uk/modules.p...howpage&pid=11

    Q: Where can I find my gearbox code?
    A: On the gearbox or the V5 registration document
    (pics of locations to follow)

    Q: I'm American, what's a gearbox?
    A: Gearbox = Transmission



    020 questions

    020 Gearbox code info: http://www.fastgolf.org.uk/modules.p...howpage&pid=11

    Q: How do I identify if my 020 Gearbox is 4speed or 5speed?
    A: The best way is via the gearbox code as this will give you further info about the ratios etc. There are visual differences which are obvious if you know what to look for!
    Pictures here

    Q: I need to fit a new clutch to my 020 gearbox. Can I do it on my own? If so how?
    A: Yes it can be done at home by one person - it's not a bad job but will require quite a few tools. Read the guide in the link below to gauge if your level of skill is high enough!!
    http://www.fastgolf.org.uk/modules.p...howpage&pid=18


    Q: I want to replace my 4speed 020 gearbox with a 5speed 020 gearbox in my caddy, what do I need?
    A: You will need a 5speed gearbox. 5spd gearbox mounts - the one by the battery is different to a 4spd. The gearstick cup, selector rods and selctor level are different too. This has been covered again and again thread link below contains all you need include pics of the parts.
    http://www.vwcaddy.com/showthread.php?t=39518

    Q: I've got an 020 5speed gearbox in my caddy but I can't get all the gears?
    A: You might not have a complete 5spd linkage or it may just need adjusting. see link below for adjustment
    http://www.vwcaddy.com/showthread.php?t=8538

    Q: I've fitted an 020 5speed gearbox and now my driveshafts don't fit, what's going on?
    A: You may have an 020 with 100mm output cups/flanges. These were fitted to later mk2 golfs and mk1 carbios, these were never std fitment on caddys.
    See 100mm Vs 90mm for more info

    Q: I want to change the output cups / flanges on my 020 gearbox
    A: An external link this time
    http://www.brokevw.com/020flange.html


    02A questions

    Q: What cars were fitted with 02A gearboxes
    A: 02A gearboxes are from a later generation of cars from about 1990 onwards. Passat B35i, Corrado, Mk3 Golf, Mk2 Golf - G60 only! Pretty much any front wheel drive VW of this era with a transverse mounted engine.

    Q: I want to fit an 02A to a mk1 caddy, what do I need?
    A:There are several things you need the details I'll put in a separate post but the basic list is as follows
    • 02A gearbox
    • Flywheel/clutch assembly to match your gearbox
    • 02A mounts to fit a mk1 chassis
    • cable shift box + cables
    • 100mm driveshafts
    • clutch actuating parts
    • speedo drive


    100mm Vs 90mm questions

    Q: What's the difference between a 90mm and 100mm driveshaft?
    A: Describing a driveshaft as 100mm or 90mm is technically incorrect as neither of those measurements relate to any dimension of the driveshaft itself. The 100mm or 90mm refers to the diameter of the CV joints fitted to the driveshafts. As the 90mm CV joints are shorter than 100mm CV joints the 100mm driveshafts are shorter to make sure a complete 100mm driveshaft assembly is the same overall length as a 90mm assembly.
    Driveshaft length info: http://www.vwcaddy.com/showpost.php?...57&postcount=2

    Q: I've fitted the correct 100mm driveshafts but they don't turn freely?
    A: All answered in the technical article linked below
    http://www.vwcaddy.com/showthread.php?t=42579

    Q: Can I fit 100mm CV joints to my original 90mm driveshafts?
    A: Physically you can but it's not a good idea. The extra length of the 90mm shaft removes the float from the driveshaft assembly which prevents the CV joints from working properly and causes the CV joint to chew on itself!!
    At the time of writing there are 4 separate instances on this forum where doing this has resulted in knackered CVs and in one case taken the gearbox output flange with it.
    Last edited by DubMonkey; 16-06-2010 at 09:08 AM.
    Alan says: Selling the $hit in the garage pays for new toys

  2. #2
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    020 questions

    020 Gearbox code info: http://www.fastgolf.org.uk/modules.p...howpage&pid=11

    Q: How do I identify if my 020 Gearbox is 4speed or 5speed?
    A: The best way is via the gearbox code as this will give you further info about the ratios etc. There are visual differences which are obvious if you know what to look for!
    Pictures here

    Q: I need to fit a new clutch to my 020 gearbox. Can I do it on my own? If so how?
    A: Yes it can be done at home by one person - it's not a bad job but will require quite a few tools. Read the guide in the link below to gauge if your level of skill is high enough!!
    http://www.fastgolf.org.uk/modules.p...howpage&pid=18


    Q: I want to replace my 4speed 020 gearbox with a 5speed 020 gearbox in my caddy, what do I need?
    A: You will need a 5speed gearbox. 5spd gearbox mounts - the one by the battery is different to a 4spd. The gearstick cup, selector rods and selctor level are different too. This has been covered again and again thread link below contains all you need include pics of the parts.
    http://www.vwcaddy.com/showthread.php?t=39518

    Q: I've got an 020 5speed gearbox in my caddy but I can't get all the gears?
    A: You might not have a complete 5spd linkage or it may just need adjusting. see link below for adjustment
    http://www.vwcaddy.com/showthread.php?t=8538

    Q: I've fitted an 020 5speed gearbox and now my driveshafts don't fit, what's going on?
    A: You may have an 020 with 100mm output cups/flanges. These were fitted to later mk2 golfs and mk1 carbios, these were never std fitment on caddys.
    See 100mm Vs 90mm for more info

    Q: I want to change the output cups / flanges on my 020 gearbox
    A: An external link this time
    http://www.brokevw.com/020flange.html
    Last edited by DubMonkey; 11-06-2010 at 04:00 PM.
    Alan says: Selling the $hit in the garage pays for new toys

  3. #3
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    02A questions

    Q: What cars were fitted with 02A gearboxes
    A: 02A gearboxes are from a later generation of cars from about 1990 onwards. Passat B35i, Corrado, Mk3 Golf, Mk2 Golf - G60 only! Pretty much any front wheel drive VW of this era with a transverse mounted engine.

    Q: I want to fit an 02A to a mk1 caddy, what do I need?
    A:There are several things you need the details I'll put in a separate post but the basic list is as follows
    • 02A gearbox
    • Flywheel/clutch assembly to match your gearbox
    • 02A mounts to fit a mk1 chassis
    • cable shift box + cables
    • 100mm driveshafts
    • clutch actuating parts
    • speedo drive
    Last edited by DubMonkey; 11-06-2010 at 04:10 PM.
    Alan says: Selling the $hit in the garage pays for new toys

  4. #4
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    Mr Monkey, you speak of 020 and 02a, but no mention of the 02j or 02m?? could you elaborate further?? also which gearboxes will accept a transfer box?? cheers Mr Monkey from your local fruit sponsor.
    The sign reads 'Welcome to Bradford'.
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  5. #5
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    Quote Originally Posted by caddysimps View Post
    Mr Monkey, you speak of 020 and 02a, but no mention of the 02j or 02m?? could you elaborate further?? also which gearboxes will accept a transfer box?? cheers Mr Monkey from your local fruit sponsor.
    there's always one!

    Those are more complex again as some of the parts in them are 02A
    Alan says: Selling the $hit in the garage pays for new toys

  6. #6
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    Driveshafts

    Q: What driveshafts fit the mk1 Caddy?
    A: You need mk1 caddy/mk1 golf/mk1 jetta/mk1 or mk2 Scirocco. There are some exceptions from other vehicles but they will always be a compromise and are not recommended.

    Q: What's the difference between a 90mm and 100mm driveshaft?
    A: Describing a driveshaft as 100mm or 90mm is technically incorrect as neither of those measurements relate to any dimension of the driveshaft itself. The 100mm or 90mm refers to the diameter of the CV joints fitted to the driveshafts. As the 90mm CV joints are shorter than 100mm CV joints the 100mm driveshafts are shorter to make sure a complete 100mm driveshaft assembly is the same overall length as a 90mm assembly.
    Driveshaft length info: http://www.vwcaddy.com/showpost.php?...57&postcount=2

    Q: I've fitted the correct 100mm driveshafts but they don't turn freely?
    A: All answered in the technical article linked below
    http://www.vwcaddy.com/showthread.php?t=42579

    Q: Can I fit 100mm CV joints to my original 90mm drivehafts
    A: Physically you can but it's not a good idea. The extra length of the 90mm shaft removes the float from the driveshaft assembly which prevents the CV joints from working properly and causes the CV joint to chew on itself!!
    At the time of writing there are 4 separate instances on this forum where doing this has resulted in knackered CVs and in one case taken the gearbox output flange with it.

    Q: Why can't I remove the driveshaft bolts with a Allen key?
    A: Because the bolt has a spline head. The proper tool is a size 8 spline or tripple square to fit the M8 bolts
    bolt.jpg
    Last edited by DubMonkey; 08-07-2010 at 09:47 AM.
    Alan says: Selling the $hit in the garage pays for new toys

  7. #7
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    Nicely Done Sir! Obviously to much time on your hands.... that's well spent on here

    Well done cheers Dubs!!

  8. #8
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    .....nice one monk's

    S

  9. #9
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    Cheers fellas

    We're nowhere near done though, still loads to ask and get answered so keep coming with questions, answers, pictures and content please

    Monkey
    Alan says: Selling the $hit in the garage pays for new toys

  10. #10
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    BUMP

    C'mon peeps I know you can all type! You've got the style to copy, now give me some content and or some pictures to illustrate my ramblings.

    Even constructive criticism if you don't think my explanations read well or are difficult to understand

    Monkey
    Alan says: Selling the $hit in the garage pays for new toys

  11. #11
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    Bump!!!

    No one got anything to say???
    Alan says: Selling the $hit in the garage pays for new toys

  12. #12
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    is there a list of the ratios for all the common boxes anywhere?
    Mk1 '91 1.6 GTD build so far...

  13. #13
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    Quote Originally Posted by mugglesquop View Post
    is there a list of the ratios for all the common boxes anywhere?
    there will be find it and post it for the good of everyone!!
    Alan says: Selling the $hit in the garage pays for new toys

  14. #14
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    This is good work monkey

  15. #15
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    Quote Originally Posted by 13ad13oy View Post
    This is good work monkey
    Thank you, now answer the other question that came up recently

    "Can I fit a GTI gearbox to my 1.6D"
    Alan says: Selling the $hit in the garage pays for new toys

  16. #16
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    Quote Originally Posted by Dub_Monkey View Post
    there will be find it and post it for the good of everyone!!
    http://www.clubgti.com/forum/showthread.php?t=115595
    Mk1 '91 1.6 GTD build so far...

  17. #17
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    Quote Originally Posted by mugglesquop View Post
    Well done fella

    Will make sure that info gets copied on here in case it disappears from CGTI for some reason
    Alan says: Selling the $hit in the garage pays for new toys

  18. #18
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    Quote Originally Posted by Dub_Monkey View Post
    Well done fella

    Will make sure that info gets copied on here in case it disappears from CGTI for some reason
    if i get a chance later, i'll sift through it
    Mk1 '91 1.6 GTD build so far...

  19. #19
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    Quote Originally Posted by Dub_Monkey View Post
    Driveshafts
    Q: Why can't I remove the driveshaft bolts with a Allen key?
    A: Because the bolt has a spline head


    bolt.jpg

    Last edited by 13; 06-07-2010 at 07:56 PM.

  20. #20
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    What gearboxes fit the 1.8 turbo?

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