Swapping the 1.6L for a 1.8L and 5 speed

[Jarred]

so what actuall part is different? the CV on the end of the shaft? can the large CV be put on current shaft and used that way?

yes, but not straight on. the driveshafts need to be 'cleared' to fir the bigger CV.s i'm unsure on exact specs, cause I've never done it, but i've seen it done with an angle grinder , the proper way would be to get a machine shop to take off the reg distance, or find 90mm driveshaft flanges (bit on the gbox) i believe they're rareish and hard to find.

[gldgti]

you can also just put 90mm flanges on the 5-speed box.

[Jarred]

you can also just put 90mm flanges on the 5-speed box.

The impression I got, although I havn't looked very far into it, was that 90mm flanges only came on a 5 speed mk 1's, ie GTI's, and hence, not many floating around, unless they can be bought brandnew?

[dub be good to me]

I had no problem bolting my 90mm CVs to a diesel 5spd..

EDIT: Now that I think about it the box was from a Mk2 Diesel.. mid 80's I think

[gldgti]

The impression I got, although I havn't looked very far into it, was that 90mm flanges only came on a 5 speed mk 1's, ie GTI's, and hence, not many floating around, unless they can be bought brandnew?

90mm flanges are everywhere..... 4 speeds

[GRN_VAGN]

Hmmm confusing stuff

Think the 5 speed i got is a Mk2 item? not tooo sure, might have to ask the previous owner..

[Jarred]

90mm flanges are everywhere..... 4 speeds

I've been told that the flanges are different between 4 speeds and 5 speeds?? the offset of them or something.

[gldgti]

I've been told that the flanges are different between 4 speeds and 5 speeds?? the offset of them or something.

ahh i think your right.... but some seem to work... hmm

[Golf Loon]

There are 3 kinds of flanges

90mm 4 speed ones, that only fit 4 speeds.

90mm 5 speed ones which have a step in for the oil seal and stick out further than the 4 speed ones.
(These are found on MK1 GTI gearboxes and Early Mk2, including diesels)

100mm ones as found on later Mk2 and Mk3s.

Actually there are also 90mm ones on Golf 4 1.6 boxes, but they are different as they are held in with a bolt, not a circlip.

Hope that clears it up, I know my gearboxes

[Jarred]

yea it does, thanks loon!

btw, do you happen to have any 90mm 5 speed flanges lying around?