NormanCoal 0 Posted October 8, 2009 The O2S box is a vw replicate of the Gemini box's - I've had/have one of each, and there is very little between the designs aside from the obvious difference of the straighter cut gearset (3-6) that the Gemini box has. Ideally, if you are using this on a forced induction car, you'd want to find one of the rarer diesel versions of the O2S, as it will get the FD high enough to make better use of the gears then. It is quite easy to get around the speedo drive issue btw, the O2S is based out of an O2A after all Quote Share this post Link to post Share on other sites
G60_Marc 0 Posted October 8, 2009 do you have a photo of the 6speed box BEFORE you stripped it apart? Here are a few photos i found on the net. climatronic wiring-Golf from May 01.pdf02S.jpg[/attachment:2phdt15s] 2.8l 24v Climatronic system.pdf02S - GEARBOX.jpg[/attachment:2phdt15s] 02S - GEARBOX2.jpg[/attachment:2phdt15s] Quote Share this post Link to post Share on other sites
Henny 0 Posted October 8, 2009 ta for pics... that link is useful too... looks like either of the GQL or GXV boxes would be pretty good in a G60 then... 'specially with an LSD... :D Quote Share this post Link to post Share on other sites
Kevin Bacon 5 Posted October 8, 2009 I'd imagine that the smaller rolling diameter of the wheels on the Corrado had a lot to do with that :( What size wheels does the 02S donor car use? Something daft like 215/50/16? Ideally, if you are using this on a forced induction car, you'd want to find one of the rarer diesel versions of the O2S, as it will get the FD high enough to make better use of the gears then. Great info, thank you :salute: Would any of the MK5 or A3 2.0TDis have this elusive gearbox? Or do they use the 02M? Quote Share this post Link to post Share on other sites
mrbeige 0 Posted October 8, 2009 I'd imagine that the smaller rolling diameter of the wheels on the Corrado had a lot to do with that :( What size wheels does the 02S donor car use? Something daft like 215/50/16? 225/45/R17 whic makes them larger rolling radius than the Corrado IIRC Ideally, if you are using this on a forced induction car, you'd want to find one of the rarer diesel versions of the O2S, as it will get the FD high enough to make better use of the gears then. Great info, thank you :salute: Would any of the MK5 or A3 2.0TDis have this elusive gearbox? Or do they use the 02M? The GQM box has the lowest final drive - 3.39 Quote Share this post Link to post Share on other sites
Henny 0 Posted October 8, 2009 so does that mean I've picked the wrong two boxes then having got the two highest? Final drive ratios always confuse the hell outta me... :scratch: :shrug: Quote Share this post Link to post Share on other sites
G60_Marc 0 Posted October 8, 2009 A few interesting 02S related links. http://www.dubforce.net/forums/index.php?showtopic=9163&hl=gearbox http://forums.vwvortex.com/zerothread?cmd=print&id=3302920 http://www.vwcaddy.com/showthread.php?t=13581 Quote Share this post Link to post Share on other sites
Kevin Bacon 5 Posted October 8, 2009 225/45/R17 whic makes them larger rolling radius than the Corrado IIRC Looking at these common corrado wheel/tyre sizes, you can see the MK5 platform's RR is loads bigger! 205/50/15 = 1787mm 205/45/16 = 1802mm 205/40/17 = 1817mm 225/45/17 = 1935mm The GQM box has the lowest final drive - 3.39 Which is a VR6 one and should bolt into the O2S OK? Quote Share this post Link to post Share on other sites
mrbeige 0 Posted October 8, 2009 225/45/R17 whic makes them larger rolling radius than the Corrado IIRC Looking at these common corrado wheel/tyre sizes, you can see the MK5 platform's RR is loads bigger! 205/50/15 = 1787mm 205/45/16 = 1802mm 205/40/17 = 1817mm 225/45/17 = 1935mm Yup, that'd do it!! The GQM box has the lowest final drive - 3.39 Which is a VR6 one and should bolt into the O2S OK? It is, aye :D Quote Share this post Link to post Share on other sites
mrbeige 0 Posted October 8, 2009 so does that mean I've picked the wrong two boxes then having got the two highest? Final drive ratios always confuse the hell outta me... :scratch: :shrug: If I've got this right, the smaller the number the taller the gearing for the final drive Quote Share this post Link to post Share on other sites
Henny 0 Posted October 8, 2009 great links... OK, so off the wall question here for someone who's actually stripped one of these O2S boxes and stuck it into a VR6 casing... Do you reckon that an O2S could be used as a donor to fit into a Rallye gearbox case? Ie, keeping the 4x4 outlet as well as the 6 speed? I really need to learn a bit more about gearboxes :scratch: Quote Share this post Link to post Share on other sites
2.9andy 0 Posted October 8, 2009 Dont forget ive used the lowest ratio version of this box here, mine is a GQP code. If you used one of the other versions it would probably be similar to a vr box with a g60 final drive, with a longer 6th. As it is i think my box is even closer geared than that combination, i did do all the gear calculators for it before but its late and i cant be bothered to do it again at the moment. The step from 1st to 2nd feels just right, so the taller ratio version would still have this, but slightly higher overall. Personally i love this one and wouldnt change it! Kev, you mentioned checking it out for yourself at the beginning of the thread, your still more than welcome to, and you can add your opinion on the box to this thread as someone who knows what they are talking about. Ive only had one corrado and havent lived vw's, but i do know i nearly sold the car because of its gearbox spoiling the drive before....! Quote Share this post Link to post Share on other sites
2.9andy 0 Posted October 9, 2009 Oh, yes the speedo drive. Obviously using the vr6 bellhousing you already have the hole for the speedo drive, then when fitting the diff, you take the bearing and nylon drive gear off the 02a diff, and swap it onto the 02s(02j) diff, job done. You'll just have to do the same with the front half of the g60 box Quote Share this post Link to post Share on other sites
CTWG60 0 Posted October 12, 2009 Did someone mention Gearboxes!! :lol: Gearbox:- GXV+ 0.73 6th Tyre:- Goodyear Eagle F1 195/50 x 15 ------------------------------------------------------------------------------------------- Top Gear gives 23.456 MPH/1000 RPM and a top speed of 145.428 MPH at 6200 RPM Engine speeds in top gear:- 30 MPH = 1279 RPM 40 MPH = 1705 RPM 50 MPH = 2132 RPM 60 MPH = 2558 RPM 70 MPH = 2984 RPM 80 MPH = 3411 RPM 90 MPH = 3837 RPM 100 MPH = 4263 RPM Top Speed in 1 gear = 28.085 MPH And changes into 2 gear at 3723 RPM dropping 2477 RPM Top Speed in 2 gear = 46.768 MPH And changes into 3 gear at 4507 RPM dropping 1693 RPM Top Speed in 3 gear = 64.341 MPH And changes into 4 gear at 4772 RPM dropping 1428 RPM Top Speed in 4 gear = 83.592 MPH And changes into 5 gear at 5028 RPM dropping 1172 RPM Top Speed in 5 gear = 103.070 MPH And changes into 6 gear at 4394 RPM dropping 1806 RPM Top Speed in 6 gear = 145.428 MPH ****************************************************************************************** Gearbox:- GXV Tyre:- Goodyear Eagle F1 195/50 x 15 ------------------------------------------------------------------------------------------- Top Gear gives 19.910 MPH/1000 RPM and a top speed of 123.445 MPH at 6200 RPM Engine speeds in top gear:- 30 MPH = 1507 RPM 40 MPH = 2009 RPM 50 MPH = 2511 RPM 60 MPH = 3013 RPM 70 MPH = 3516 RPM 80 MPH = 4018 RPM 90 MPH = 4520 RPM 100 MPH = 5022 RPM Top Speed in 1 gear = 28.085 MPH And changes into 2 gear at 3723 RPM dropping 2477 RPM Top Speed in 2 gear = 46.768 MPH And changes into 3 gear at 4507 RPM dropping 1693 RPM Top Speed in 3 gear = 64.341 MPH And changes into 4 gear at 4772 RPM dropping 1428 RPM Top Speed in 4 gear = 83.592 MPH And changes into 5 gear at 5028 RPM dropping 1172 RPM Top Speed in 5 gear = 103.070 MPH And changes into 6 gear at 5177 RPM dropping 1023 RPM Top Speed in 6 gear = 123.445 MPH ****************************************************************************************** Best way to fix the high revs in 6th is to fit an 0.73 6th gear about £150 from vw but you'll save that in fuel in no time! I'll dig out part numbers if your bothered. Was thinking of going GXV to reduce losses in wheel toque between gears but 1st would be a bit useless in an FI car! :( On 15" anyway! Any requests??? :lol: :D Looks like it's going to quiet in work today! :clap: Quote Share this post Link to post Share on other sites
CTWG60 0 Posted October 12, 2009 Some other interesting options. Gearbox:- O2S GXV with GQM 3.39 Diff Tyre:- Goodyear Eagle F1 195/50 x 15 ------------------------------------------------------------------------------------------- Top Gear gives 23.141 MPH/1000 RPM and a top speed of 143.473 MPH at 6200 RPM Engine speeds in top gear:- 30 MPH = 1296 RPM 40 MPH = 1729 RPM 50 MPH = 2161 RPM 60 MPH = 2593 RPM 70 MPH = 3025 RPM 80 MPH = 3457 RPM 90 MPH = 3889 RPM 100 MPH = 4321 RPM Top Speed in 1 gear = 32.642 MPH And changes into 2 gear at 3723 RPM dropping 2477 RPM Top Speed in 2 gear = 54.355 MPH And changes into 3 gear at 4507 RPM dropping 1693 RPM Top Speed in 3 gear = 74.780 MPH And changes into 4 gear at 4772 RPM dropping 1428 RPM Top Speed in 4 gear = 97.155 MPH And changes into 5 gear at 5028 RPM dropping 1172 RPM Top Speed in 5 gear = 119.793 MPH And changes into 6 gear at 5177 RPM dropping 1023 RPM Top Speed in 6 gear = 143.473 MPH ****************************************************************************************** Gearbox:- GQM st. 3.39 Diff Tyre:- Goodyear Eagle F1 195/50 x 15 ------------------------------------------------------------------------------------------- Top Gear gives 27.262 MPH/1000 RPM and a top speed of 169.022 MPH at 6200 RPM Engine speeds in top gear:- 30 MPH = 1100 RPM 40 MPH = 1467 RPM 50 MPH = 1834 RPM 60 MPH = 2201 RPM 70 MPH = 2568 RPM 80 MPH = 2935 RPM 90 MPH = 3301 RPM 100 MPH = 3668 RPM Top Speed in 1 gear = 32.642 MPH And changes into 2 gear at 3723 RPM dropping 2477 RPM Top Speed in 2 gear = 54.355 MPH And changes into 3 gear at 4152 RPM dropping 2048 RPM Top Speed in 3 gear = 81.175 MPH And changes into 4 gear at 4528 RPM dropping 1672 RPM Top Speed in 4 gear = 111.159 MPH And changes into 5 gear at 4804 RPM dropping 1396 RPM Top Speed in 5 gear = 143.473 MPH And changes into 6 gear at 5263 RPM dropping 937 RPM Top Speed in 6 gear = 169.022 MPH ****************************************************************************************** Quote Share this post Link to post Share on other sites
CTWG60 0 Posted October 12, 2009 Taking it off on a tangent here but this is as close as I can get to my ideal 6 speed 02S box on 15" wheels. Ingredients are. 1. Custom machined 02S input shaft by SQS! 2. Output gears for 1 & 2 from a CHN VR6 box or similar 3. GQM 02S box as the build box. 4. input and output 4th and 5th from a GXV Which would give you 1st 3.3 2nd 1.94 3rd 1.52 4th 1.27 5th 1.03 6th 0.73 FD 3.39 Gearbox:- O2S theoretical Tyre:- Goodyear Eagle F1 195/50 x 15 ------------------------------------------------------------------------------------------- Top Gear gives 27.262 MPH/1000 RPM and a top speed of 169.022 MPH at 6200 RPM Engine speeds in top gear:- 30 MPH = 1100 RPM 40 MPH = 1467 RPM 50 MPH = 1834 RPM 60 MPH = 2201 RPM 70 MPH = 2568 RPM 80 MPH = 2935 RPM 90 MPH = 3301 RPM 100 MPH = 3668 RPM Top Speed in 1 gear = 37.390 MPH And changes into 2 gear at 3645 RPM dropping 2555 RPM Top Speed in 2 gear = 63.601 MPH And changes into 3 gear at 4858 RPM dropping 1342 RPM Top Speed in 3 gear = 81.175 MPH And changes into 4 gear at 5180 RPM dropping 1020 RPM Top Speed in 4 gear = 97.155 MPH And changes into 5 gear at 5028 RPM dropping 1172 RPM Top Speed in 5 gear = 119.793 MPH And changes into 6 gear at 4394 RPM dropping 1806 RPM Top Speed in 6 gear = 169.022 MPH ****************************************************************************************** Gives me a good launch gear, FT in 2nd with no wheel spin, hard acceleration with little loss of wheel torque in 3rd, 4th and 5th and then a noce 6th to take it easy in. :D Now who has a £1000 to give me to get this little lot sorted! :lol: Quote Share this post Link to post Share on other sites
CTWG60 0 Posted October 12, 2009 Dont forget ive used the lowest ratio version of this box here, mine is a GQP code. Of the O2S boxes I know of the GXV and GQL boxes have shorter ratio's again. If the turbo conversion site data is correct I haven't worked them out from the ETKA software. Some balls you have there pulling two boxes apart blind as t what you might find! Thanks as I was very curious about the 02S and 02A compatibility with regards to bell houses. :notworthy: ****************************************************************************************** Gearbox:- GQP Tyre:- Goodyear Eagle F1 195/50 x 15 ------------------------------------------------------------------------------------------- Top Gear gives 22.541 MPH/1000 RPM and a top speed of 139.753 MPH at 6200 RPM Engine speeds in top gear:- 30 MPH = 1331 RPM 40 MPH = 1775 RPM 50 MPH = 2218 RPM 60 MPH = 2662 RPM 70 MPH = 3105 RPM 80 MPH = 3549 RPM 90 MPH = 3993 RPM 100 MPH = 4436 RPM Top Speed in 1 gear = 30.317 MPH And changes into 2 gear at 3723 RPM dropping 2477 RPM Top Speed in 2 gear = 50.483 MPH And changes into 3 gear at 4507 RPM dropping 1693 RPM Top Speed in 3 gear = 69.453 MPH And changes into 4 gear at 4434 RPM dropping 1766 RPM Top Speed in 4 gear = 97.116 MPH And changes into 5 gear at 5044 RPM dropping 1156 RPM Top Speed in 5 gear = 119.372 MPH And changes into 6 gear at 5296 RPM dropping 904 RPM Top Speed in 6 gear = 139.753 MPH ****************************************************************************************** Quote Share this post Link to post Share on other sites
aminder 0 Posted April 20, 2010 Oh, yes the speedo drive. Obviously using the vr6 bellhousing you already have the hole for the speedo drive, then when fitting the diff, you take the bearing and nylon drive gear off the 02a diff, and swap it onto the 02s(02j) diff, job done. You'll just have to do the same with the front half of the g60 box Hi mate, So just to confirm it's just a bell housing swap from a VR6 02A to the 02S box? And bearing + nylon drive gear. Which diff did you end up using? how about the driveshaft cups? Did you use ones off the 02A or the 02S ones where same size. I've done a 16v passat swap onto my VR, my mates interested in doing this so just doing some research as I'll be helping out..... Probably go for the highest ratios though :D Also I'm assuming you changed the bearings on the 02A bell-housing side? Quote Share this post Link to post Share on other sites
