I have an Audi 016 AAZ gearbox and wanted to do something about not having a sixth gear. Sitting on 110 km/h it was doing around 3000 rpm.
The other problem with the AAZ is that first gear is almost useless - it is too low and you need to change to second gear almost immediately; some drivers ignore first gear and just start in second most of the time.
I considered an Audi 01E box. This provides a sixth gear but still suffers from a too-low first gear. It is also not cheap to change from a 016 to a 01E.
My next approach was to see what could be done by changing the final drive ratio. Other threads have described how the standard final drive ratio of 3.89 can be changed to 3.22. What I wanted to do was to "eliminate" first gear and "gain" a new sixth gear; here are the effective overall ratios for the gears with the last column deliberately staggered a gear to indicate the approach to the solution and how it compares:<table>
<tr><td>Gearbox</td><td>01E</td><td>016</td><td>016</td><td> </td></tr>
<tr><td>Model</td><td>DPV</td><td>AAZ</td><td>AAZ</td><td> </td></tr>
<tr><td>Final</td><td>3.88</td><td>3.89</td><td>2.92</td><td> </td></tr>
<tr><td>First</td><td>13.58</td><td>14.00</td><td> -</td><td> </td></tr>
<tr><td>Second</td><td>7.33</td><td>8.29</td><td>10.50</td><td>(1st)</td></tr>
<tr><td>Third</td><td>5.12</td><td>5.68</td><td>6.21</td><td>(2nd)</td></tr>
<tr><td>Fourth</td><td>4.15</td><td>4.16</td><td>4.26</td><td>(3rd)</td></tr>
<tr><td>Fifth</td><td>2.83</td><td>3.35</td><td>3.12</td><td>(4th)</td></tr>
<tr><td>Sixth</td><td>2.33</td><td> -</td><td>2.51</td><td>(5th)</td></tr>
</table>
I approached Albins (who make the crown wheel and pinion for the 3.22 ratio) and we arrived at a ratio of 2.92. (Albins offroad gear - products: Accessories)
Jim Cowden fitted the new crown wheel and pinion (and added the elsewhere-described strengthening plate and also supplied me with a new engine bay brace to make it easier to remove the gearbox in future).
After some test drives I am very happy with the result. Perhaps I have given away some off-the-line performance but my priority is road rather than track use and first gear is useable at last.
Assuming a conservative rev range of 2000 - 5500, in-gear speeds are:<table>
<tr><th colspan="2">AAZ 3.89 (OLD)</th></tr>
<tr><td>First</td><td>18 - 49 km/h</td></tr>
<tr><td>Second</td><td>30 - 82</td></tr>
<tr><td>Third</td><td>44 - 120</td></tr>
<tr><td>Fourth</td><td>59 - 163</td></tr>
<tr><td>Fifth</td><td>74 - 203</td></tr>
</table><table>
<tr><th colspan="2">AAZ 2.92 (NEW)</th></tr>
<tr><td>First</td><td>24 - 65 km/h</td></tr>
<tr><td>Second</td><td>40 - 109</td></tr>
<tr><td>Third</td><td>58 - 160</td></tr>
<tr><td>Fourth</td><td>79 - 218</td></tr>
<tr><td>Fifth</td><td>99 - 271</td></tr>
</table>
And 110 km/h now equates to just over 2200 rpm.
Kym
The other problem with the AAZ is that first gear is almost useless - it is too low and you need to change to second gear almost immediately; some drivers ignore first gear and just start in second most of the time.
I considered an Audi 01E box. This provides a sixth gear but still suffers from a too-low first gear. It is also not cheap to change from a 016 to a 01E.
My next approach was to see what could be done by changing the final drive ratio. Other threads have described how the standard final drive ratio of 3.89 can be changed to 3.22. What I wanted to do was to "eliminate" first gear and "gain" a new sixth gear; here are the effective overall ratios for the gears with the last column deliberately staggered a gear to indicate the approach to the solution and how it compares:<table>
<tr><td>Gearbox</td><td>01E</td><td>016</td><td>016</td><td> </td></tr>
<tr><td>Model</td><td>DPV</td><td>AAZ</td><td>AAZ</td><td> </td></tr>
<tr><td>Final</td><td>3.88</td><td>3.89</td><td>2.92</td><td> </td></tr>
<tr><td>First</td><td>13.58</td><td>14.00</td><td> -</td><td> </td></tr>
<tr><td>Second</td><td>7.33</td><td>8.29</td><td>10.50</td><td>(1st)</td></tr>
<tr><td>Third</td><td>5.12</td><td>5.68</td><td>6.21</td><td>(2nd)</td></tr>
<tr><td>Fourth</td><td>4.15</td><td>4.16</td><td>4.26</td><td>(3rd)</td></tr>
<tr><td>Fifth</td><td>2.83</td><td>3.35</td><td>3.12</td><td>(4th)</td></tr>
<tr><td>Sixth</td><td>2.33</td><td> -</td><td>2.51</td><td>(5th)</td></tr>
</table>
I approached Albins (who make the crown wheel and pinion for the 3.22 ratio) and we arrived at a ratio of 2.92. (Albins offroad gear - products: Accessories)
Jim Cowden fitted the new crown wheel and pinion (and added the elsewhere-described strengthening plate and also supplied me with a new engine bay brace to make it easier to remove the gearbox in future).
After some test drives I am very happy with the result. Perhaps I have given away some off-the-line performance but my priority is road rather than track use and first gear is useable at last.
Assuming a conservative rev range of 2000 - 5500, in-gear speeds are:<table>
<tr><th colspan="2">AAZ 3.89 (OLD)</th></tr>
<tr><td>First</td><td>18 - 49 km/h</td></tr>
<tr><td>Second</td><td>30 - 82</td></tr>
<tr><td>Third</td><td>44 - 120</td></tr>
<tr><td>Fourth</td><td>59 - 163</td></tr>
<tr><td>Fifth</td><td>74 - 203</td></tr>
</table><table>
<tr><th colspan="2">AAZ 2.92 (NEW)</th></tr>
<tr><td>First</td><td>24 - 65 km/h</td></tr>
<tr><td>Second</td><td>40 - 109</td></tr>
<tr><td>Third</td><td>58 - 160</td></tr>
<tr><td>Fourth</td><td>79 - 218</td></tr>
<tr><td>Fifth</td><td>99 - 271</td></tr>
</table>
And 110 km/h now equates to just over 2200 rpm.
Kym