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Discussion Starter #1 (Edited)
I like to cruise through the http://www.kraftswerk.com site for various questions I might have from time to time. I used their site to learn about what transmissions were readily available in various cars and what gearing they had. Also I used their rebuild prices to weigh out my options of whether to buy new, used or rebuild it myself(assist a local VW master mechanic)
Since I did not like the price for the rebuild through Kraftswerk for a G60 tranny $1300 I then contacted BSI and they were very fast to respond to 2 of my emails but the 3rd one that required a them to give me a price quote was almost 2 months. But they did say they would rebuild it for $700-$800 I believe. But the ball was already rolling and I had begun buying parts for my transmission rebuild.
For a little while I considered buying a http://www.eurospecsport.com complete OEM tranny with 6spd add on tranny for $2250 I really didn't like the gear ratios and the 6spd gear ratios available really don't apeal to me. Proferrably if I could pic my 5&6 I'd run a .838 5th and a .717 6th but with the 6spd add on kits the 5&6th gears are one piece so you only have the option of: 5TH=.89 6TH=.75 or 5TH-.96 6TH=.85 EurospecSport's ad on kit costs $1475
If you desire to learn about how the different gearing will affect your car at different MPH and RPMs then this is a very good gear calculator. Download the Excel speed gear: calculatorpage: http://www.merkurtech.com/merk...n.php

as for the tire diameter I use this page for that calculation:
http://www.turbotsd.com/DIY/ti....html
I had talked with a number of people that have done various tranny swaps into the G60 and for performance most like the 3.6?? ring and pinion some that went with 3.389 or 3.45 complained of being a little sluggish in the performance but they usually enjoy the lower RPMs on the highway. The person that I listen to the most on this was from Ireland and his car has a lot more performace goodies than mine so I listened to him carefully. He wish he had kept the G60 final drive when he installed a tranny with the CCM gearing because his car was not as peppy as with the G60 tranny. Some of the people that opt for the Passat 3.9 tranny end up finding 1st to be useless and find themselves riding with high rpms while on the highway in 5th gear.
G60racer has the same gearing that I'm going with and he loves it. Its the CDM gearing out of a SLC VR6 corrado. I have not yet rebuilt my tranny but I look forward to this gearing as it will give me more 1st & 2nd gears which every G60 driver complains about being too short. But I think I'll be useing the G60 5th gear to drop the revs a little while on the highway. When the $$$ permit I'd like to swap in a .755 or .717 5th gear to drop the revs even more. If anybody wants to play while on the highway I always drop to 4th(its just the way I am)
It should be mentioned that 1st and 2nd gears are machined together on the input shaft so they have to be swapped together. So when looking at another VW's gearing for selections just remember you can not mix and match 1st and 2nd gears from factory VW trannys
I'm happy to see this forum is finally here. I got tired of searching Tranny, Transmission, syncro, 02a, o2a, 02j, o2j, 2nd gear and all othe other usual topic key words. Have fun. Frank
O2A ratios:
_________1st___2nd___3rd___4th___5th___R&P___Notes
ATA====3.778 =2.105 =1.345=0.971=0.795=3.684==Corrado G60
AYL====3.778=2.118=1.429=1.029=0.837=3.684==Corrado G60
CAW====3.77=2.118=1.458=1.034=0.838=3.647==Corrado G60
CDM====3.300=1.944=1.308=1.034=0.838=3.647==Corrado VR6
AGC====3.778 =2.105=1.345=0.971=0.795=3.944= Passat 16V
AYK====3.778=2.118=1.429=1.029=0.837=3.684= Passat 16v
CES====3.778=2.118=1.429=1.029=0.837=3.684== Passat?
CHA====3.778=2.118=1.360=0.917=0.717=3.944==AAZ TD B4 Passat
CGY====3.778=2.118=1.458=1.029=0.837=3.684== Passat?
CNL====3.778=2.118=1.458=1.029=0.837=3.684==VR6 Passat?
CCM====3.300=1.944=1.308=1.034=0.838=3.389==VR6 Passat, Jetta, Golf
CTN====3.778=2.118=1.360=0.971=0.755=3.157==Jetta/Golf/Passat TDI Beware these have 02J style output flanges. I've heard that people need to order 02J diffes for them. I'll know soon as I have one for my TDI Corrado and I plan to install a peloquin.

DQY====3.778=2.118=1.360=1.029=0.755=3.389==Jetta/Golf TDI
ASD====3.300=1.944==1.308==1.09==0.717==3.16==TDI I've heard of a few being bought in the USA but I believe its a euro MK3 TDI tranny
CHN==== Golf
CHU==== 4.24 R&P and its from a 2L Passat
CRU====3.300=1.944=1.308=0.971=0.755=4.24===B4 Passat ABA
CDA====3.30==1.944=1.308=1.029=.838=3.68===MK3 ABF (euro 2L 16V)
O2C trannys (SYNCRO):
CBC,CHD=3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro CDN
AYR ====3.778=2.118=1.345=0.971=0.756=3.944== Passat Syncro
CDH====3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro
Ok here are the Part numbers for the different 5th gears
For the .755 gearing you'll need:
02a311361Q is $142.77
and 02a311158E is $226.05
For the .717 gearing you'll need:
02a311361M is $142.77
and 02a311158R is $226.05
Modified by G60ING at 12:29 AM 2-4-2007




Summary of "Overdrive" Ratios (with part numbers)



  • 30:39 = 0.769 (02A 311 361 N : 02A 311 158 L)
  • 34:45 = 0.756 (02A 311 361 Q : 02A 311 158 E)
  • 29:39 = 0.744 (02A 311 361 AD : 02A 311 158 AE)
  • 33:46 = 0.717 (02A 311 361 M : 02A 311 158 R)
  • 28:40 = 0.700 (02A 311 361 AM : 02A 311 158 AF)
  • 32:47 = 0.681 (02D 311 361 : 02D 311 158)
  • 27:41 = 0.658 (02Z 311 361 A : 02Z 311 158 A)
  • 23:37 = 0.622 (02Z 311 361 : 02Z 311 158)
Borrowed from this very imformative thread:
http://www.vwt4forum.co.uk/showthread.php?t=33958
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (G60ING)

That´s exactly what I´m doing...
Using a CHN final (3,388) instead of my AYN (3,684) for higher speed on 1st (3,778), 2nd (2,117) and 3rd (1,344) gear. I´m also using the CHN 4th gear (1,034) to get a closer ratio bethween 3rd and 4th gear. But leaving the AYN 5th (0,755) for nice highway crusing.

With that setup i can drive over 100km/h @ 7000rev on 2nd gear and close to 300km/h on 5th.
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (G60ING)

quote:[HR][/HR]I like to cruise through the http://www.kraftswerk.com/home.html [HR][/HR]​
is that site misquoted or just not working?
 

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Discussion Starter #6
Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (Allyn)

Oh BTW here is some 02J tranny codes provided by a kind Vortexer that looked them up on his bentley http://****************.com/smile/emthup.gif
1.8T trannys coded: EBQ, EMT, EGX, FBW:
_1st___2nd___3rd___4th___5th___R&P_
3.300-1.944-1.308-1.029-0.837-3.938
TDI trannys coded: DQY, EBJ, EGR:
_1st___2nd___3rd___4th___5th___R&P_
3.788-2.118-1.360-0.971-0.756-3.389
2.0 trannys coded: DZQ, EBP, EGT, EKG, EKH, EMS, EZK, FBV:
_1st___2nd___3rd___4th___5th___R&P_
3.778-2.118-1.360-1.029-0.837-4.235
VR6 trannys coded: DZC, EHC, EGF, EWW, FBY, FCF
_1st___2nd___3rd___4th___5th___R&P_
3.625-2.071-1.474-1.038-0.844-3.389

1.8T trannys coded: EHA
_1st___2nd___3rd___4th___5th___R&P_
3.300-1.944-1.308-1.029-0.837-3.65
The EHA gearing is confirmed by Bentley:
http://www.bentleypublishers.c...a.pdf


Modified by G60ING at 11:40 AM 1-2-2008
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (G60ING)

good info http://****************.com/smile/emthup.gif
 

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Re: (G60ING)

I'm going to bring this back from the past... I need to know a tire diameter to enter it into the gear/speed calculator....
205/40-16 on an 8" wide rim.
And I want a part number for a 3.67 Ring and Pinion.


Modified by '95MullberryVR6 at 12:40 PM 10-12-2004
 

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Re: ('95MullberryVR6)

Here's how to do the math to figure out the tire size. Just for speculative purposes here.
245/60/15
The first number (245) is the width of the tread in millimeters. The second number is the percent of the width that the tire is tall (from the tread to the rim) in other words. 60% of 245 is 147 mm tall. There's 22 mm in an inch so the tire is 6.68 inches tall on each side of the rim, which is 13.36 in plus the rim size is 28.36. So to sum it up
(245 * .6 / 22) x 2 + 15 = total tire and wheel height without taking into effect the forces of gravity and weight of the car squishing the tire.
Now I'll do yours
205 x .4 / 22 = 3.73 x 2 = 7.45 + 16 = 23.45 total height


Modified by mechsoldier at 1:05 PM 10-12-2004
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (G60ING)

i have a 93 vr6 willl a g60 tranny work in my car...
thanks
 

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Discussion Starter #14
Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (GearHeadNJ)

the bell housing needs to be swapped with a VR6 bell housing and you need to reshim all of the shafts and swap the bearings and races from one bell housing to another but it can be done as I have a VR6 tranny in my G60 corrado
I will tell you right now the G60 gearing will make you hate 1st and 2nd gear as they will be a lot shorter. Read the topics I have posted throughly and play with the gear calculator and you will see how things change. As a person that has played around with the ratios a little I would not suggest a VR6 person install G60 1st and 2nd gearing
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (G60ING)

Is it possible to install a Passat (1995?) vr6 5speed tranny into my 92 Corrado vr6? I think I have pretty much lost 5th gear. No amount of adjusting forward or back on the bracket on top of the tranny helps. I changed the fluid (no shavings or chunks in the old fluid) with 2.1 qts synthetic gear oil and that didn't help. Sometimes I can get 5th if I am up to about 60mph but never below that.
How hard is it to replace just 5th gear? What parts would I need? Has anyone remotely near Baltimore done this? I have heard it can be done with the tranny in the car?
Can anyone help? Please?
 

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Discussion Starter #16
Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (FHATTCATT)

The passat tranny will bolt right in with no problems at all. The R&P ratio is different but not too different.
5th gear is not difficult to replace but your problems may be more then just 5th gear. Take a look at the topic I made in this forum for tearing a 02a tranny down to its sub assemblies. and I think there was just a 5th gear topic in the corrado forum
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (FHATTCATT)

You can replace 5th gear with the tranny in the car but if ther is damage to any of the other parts like the pinnion shaft or the input shaft then the tranny has to be take out. Also if a replacement of 5th gear will fix the car then you should be concerned about metal shavings causing problems to the rest of the tranny's bearings
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (G60ING)

im gonna bump this thread because i was looking for a while for all of this info... good stuff

-jared
 

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Re: 02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints (jwspin)

back from the dead bump
any luck swapping a 6th gear from a vr6 into a EGT mk4 tranny
 
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