Getting a stealth remap

[Birchall]

The TDI90's gearbox is different in that some of the ratios are slightly longer, but the basic gearbox is the same. All A2 TDIs use 02J transmissions, which are rated up to 250Nm of torque (184 lbft).

There are plenty of remapped TDI75s that are pushing this limit, and a remapped TDI90 will go beyond. However, the chances of you doing your 'box damage is pretty small.
If you're spinning the engine at the rotational speed where you get peak torque and you then pop the clutch in 1st gear, you could damage that gear's teeth or the bearings, etc. However, that's not a normal thing to do. In normal driving, peak torque will happen when you're already driving, the gearbox is already spinning, etc. As such, there are no sudden impacts. Despite there being a fair number of remapped TDI90s kicking around, no one has ever experienced gearbox issues as a result.
VR6 engines attached to 02J transmissions well exceed the gearbox's rated limits by some margin, but as long as the driver isn't deliberately abusive there shouldn't be an issue.

Cheers,

Tom

Yes, wot he said !!!

Steve B

 

[dan_b]

What about the clutch/ flywheel?

 

[timmus]

What about the clutch/ flywheel?

That 90's flywheel is already a fragile piece of kit, though more torque once the clutch is engaged is unlikely to exacerbate that problem. The 90's DMF will thank you for engaging the clutch smoothly rather than being a 'clutch basher'.

I think the clutches are rated to 300Nm. I've driven plenty of remapped A2s (including 2 remapped TDI90s) and have never experienced any clutch slipping. Having more torque is bound to spin the clutch sooner as the clutch gets towards the end of its life. The same is true for having a longer 5th or 6th gear, but the advantages far outweigh this minor consideration.

Tom

 

[luzt]

The TDI90's gearbox is different in that some of the ratios are slightly longer, but the basic gearbox is the same. All A2 TDIs use 02J transmissions, which are rated up to 250Nm of torque (184 lbft).

There are plenty of remapped TDI75s that are pushing this limit, and a remapped TDI90 will go beyond. However, the chances of you doing your 'box damage is pretty small.
If you're spinning the engine at the rotational speed where you get peak torque and you then pop the clutch in 1st gear, you could damage that gear's teeth or the bearings, etc. However, that's not a normal thing to do. In normal driving, peak torque will happen when you're already driving, the gearbox is already spinning, etc. As such, there are no sudden impacts. Despite there being a fair number of remapped TDI90s kicking around, no one has ever experienced gearbox issues as a result.
VR6 engines attached to 02J transmissions well exceed the gearbox's rated limits by some margin, but as long as the driver isn't deliberately abusive there shouldn't be an issue.

Cheers,

Tom

Nerd warning:
Not all TDIs use the 02J, the 1.2TDI has the DSK (first months of production)/ FLE gearbox.

 

[timmus]

Nerd warning:
Not all TDIs use the 02J, the 1.2TDI has the DSK (first months of production)/ FLE gearbox.

Apologies, I should have said "all manual A2 TDIs use 02J transmissions". The 1.2TDI was never sold in the UK, so my generalisations tend not to take it into account.

 

[luzt]

Apologies, I should have said "all manual A2 TDIs use 02J transmissions". The 1.2TDI was never sold in the UK, so my generalisations tend not to take it into account.

Accepted
Would like to know the max torque for the FLE gearbox as I'm interested in a remap as well! Even though it's a "bit of a drive"...