The Volkswagen 020 Transmission, a staple in early Volkswagens, often sparks debate among enthusiasts. While reliable under normal driving conditions, its inherent design limitations become apparent when subjected to increased power and aggressive driving. This article delves into the strengths and weaknesses of the 020, exploring its evolution, common failure points, and viable alternatives like the 02A transmission.
A Historical Perspective on the 020
Originally designed as a four-speed transmission for engines producing around 70 horsepower, the 020 first appeared in the early 1970s. Volkswagen later adapted it into a five-speed in 1979. However, this modification involved adding to the existing case rather than a fundamental redesign. While minor improvements were introduced, such as spring-loaded drive flanges and a larger input shaft for 16V engines, core weaknesses remained.
The 020’s design limitations include insufficient spacing between the input and counter shafts, preventing the use of larger gears. The differential carrier, side gears, pinion gears, and reverse idle gear also remained undersized. Furthermore, the clutch design restricted maximum size to 210mm. These factors contribute to the transmission’s vulnerability under stress. Common failure points include cone head rivets and oil leaks due to the numerous seals.
Performance Considerations and the 02A Alternative
The 020’s durability is heavily dependent on maintenance and driving style. While capable of handling moderate power and torque, aggressive driving or significant power increases can exacerbate its weaknesses. For those seeking to substantially enhance their Volkswagen’s performance with a turbocharged or modified engine, the 020 might prove insufficient.
Volkswagen addressed the 020’s shortcomings with the introduction of the 02A transmission in models like the Corrado and Passat. The 02A boasts a larger case, increased shaft spacing for larger gears, a more robust differential, and a stronger reverse gear. It utilizes a standard 228mm hydraulic clutch and features improved drive flanges and a cable shift linkage. The 02A is generally considered a more suitable option for high-performance applications, offering greater strength and reliability. It can accommodate close-ratio gear sets and tall fifth gear options for enhanced performance and fuel efficiency.
Engine and Transmission Swaps: Considerations and Approach
Swapping a 020 for an 02A is a significant undertaking. It requires careful planning and fabrication of custom mounts. A recommended approach involves creating bolt-on upper and lower engine supports, installing the new engine and transmission with these supports, and then fabricating adapter mounts to ensure proper alignment.
When selecting gear ratios for performance applications, prioritizing lower first and second gears for acceleration is advisable. The choice of third and fourth gears depends on driving conditions and preferences, while the fifth gear should be as tall as possible for optimal cruising efficiency.
