4 Speed manual gearbox 020 — VW
4 Speed manual gearbox 020 on VW: factory workshop procedure. Full factory text, tools and checks.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📋 Procedure
Code letters · GK · GZ · 2G
From · 8.82 · 1.83 · 8.82
Manufactured · to · 7.83 · 7.83 · 6.83
Model · Sirocco · Caddy, golf1)
Allocation · Engine · 1.6 l 63 KW · 1.6 l 51 KW / 55 KW · 1.6 l 40 KW / Diesel / 1.5 l 51 KW / 1.6 l 55 KW / 1.6 l 63 KW1)
Final drive · 74:19=3.895 · 62:17=3.647 · 75:18=4.167
1 st gear · 38 : 11 = 3.455
2 nd gear · 35 : 18 = 1.944
Ratios / Z2 : Z1 = i · 3 rd gear · 36 : 28 = 1.286
4 th gear · 30 : 33 = 0.909
Reverse gear · 38 : 12 : 3.167
Speedo · 16 : 7 = 2.29 2) · 15:7=2.14 3) · 17:7=2.43 3)
Code letters · GK · GZ · 2G
Oil capacity · 1.5 litres
Specification · Gear oil GL 4 (MIL-L 2105) SAE 80
Clutch control · mechanical
Clutch plate dia. · 190 mm · 210 mm
Drive flange dia. · 90 mm
Types: · Dynamic roll / Circunference · approx. 1.75 m
Overall ratio in top gear · 3.541 · 3.316 · 3.788
Speed in top gearat 1000rpm · 29.7 Km/h · 31.7 Km/h · 27.7 Km/h
Remarks: · GDI5) · GDI5)
1)
South Africa
2)
Speedo pinion natural (Milky-grey)
3)
Speedo pinion red
4)
Speedo pinion green
5)
GCI = Gearchange and consuption indicator
Code letters · GC · GR · GN
From · 8.82 · 8.82 · 8.82
Manufactured · to · 7.83 · 7.83 · 12.72
Model · Golf, Jetta · Jetta · Scirocco
Allocation · Engine · 1.5/1.6 L / 51-55 KW / 1.6 L 40 KW / Diesel · 1.6 L 63 KW · 1.5 L 51 KW
Final drive · 74:19=3.895
1 st gear · 38 : 11 = 3.455
2 nd gear · 35 : 18 = 1.944
Ratios / Z2 : Z1 = i · 3 rd gear · 36 : 28 = 1.286
4 th gear · 30 : 33 = 0.909
Reverse gear · 38 : 12 : 3.167
Speedo drive · 16:7=2.29 natural (milky-grey)
Code letters · GC · GR · GN
Oil capacity · 1.5 litres
Specification · Gear oil GL 4 (MIL-L 2105) SAE 80
Clutch control · mechanical
Clutch plate dia. · 190 mm (Diesel 200 mm)
Drive flange dia. · 90 mm
Types: · Dynamic roll / Circunference · approx. 1.75m
Overall ratio in top gear · 3.541
Speed in top gearat 1000rpm · 29.7 Km/h
Remarks: · Cones · GCI
Cones: see W. B. No. 5 - page 2
GCI : Gearchange and consuption indicator
Code letters · GL · GY · 4A
From · 8.82 · 8.83 · 8.83
Manufactured · to · 7.83
Model · Golf, Rabbit · Caddy · Rabbit, Jetta
Allocation · Engine · 1.6 L 40 Kw / Diesel / 1.7 L 48 Kw / 57 Kw · 1.6 L 40 Kw / Diesel / 1.6 L 51 Kw / 55 Kw / 1.7 L 57 Kw · 1.6 L 40 Kw / Diesel / 1.7 L 48 Kw / 57 Kw
Final drive · 74:19=3.895 · 75:18=4.167 · 67:17=3.941
1 st gear · 38 : 11 = 3.455
2 nd gear · 35 : 20 = 1.750
Ratios / Z2 : Z1 = i · 3 rd gear · 33 : 31 = 1.065
4 th gear · 26 : 37 = 0.703
Reverse gear · 38 : 12 = 3.167
Speedo drive · 16:7=2.286 1) · 17:7=2.429 2) · 16:7=2.286 1)
Code letters · GL · GY · 4A
Oil capacity · 1.5 litres
Specification · Gear oil GL 4 (MIL-L 2105) SAE 80
Clutch control · mechanical
Clutch plate dia. · 200 mm · 210 mm · 200 mm
Drive flange dia. · 90 mm
Types: · Dynamic roll / Circunference · approx. 1.75m
Overall ratio in top gear · 2.737 · 2.928 · 2.769
Speed in top gearat 1000 rpm · 38.4 Km/h · 35.9 Km/h · 37.9 Km/h
Remarks: · GCI · GCI · USA, Japan / Canada / GCI, Cones
1)
Speedo pinion natural (milky-grey)
2)
Speedo pinion green
Cones: see W. B. No. 5 - page 2
GCI : Gearchange and consuption indicator
Code letters · 5B · 4R · 2Z
From · 8.83 · 8.83 · 8.83
Manufactured · to
Model · Caddy · Golf / Jetta · Scirocco
Allocation · Engine · 1.6 L 40 Kw / Diesel · 1.6 litre 51 KW / 55 KW
Final drive · 74 : 19 = 3.89 · 74 : 20 = 3.70
1 st gear · 38 : 11 = 3.455
2 nd gear · 35 : 18 = 1.944
Ratios / Z2 : Z1 = i · 3 rd gear · 36 : 28 = 1.286
4 th gear · 30 : 33 = 0.909
Reverse gear · 38 : 12 : 3.167
Speedo · 17:7=2.429 1) · 15.7=2.143 2)
Code letters · 5B · 4R · 2Z
Oil capacity · 1.5 litres
Specification · Gear oil GL 4 (MIL-L 2105) SAE 80
Clutch control · Mechanical
Clutch plate dia. · 210 mm · 190 mm
Drive flange dia. · 90 mm
Types: · Dynamic roll / Circunference · approx. 1.75 m
Overall ratio in top gear · 3.864 · 3.333
Speed in top gearat 1000rpm · 27.2 Km/h · 31.5 Km/h
Remarks: · Cones · Cones · GCI / Cones
1)
Speedo pinion green
2)
Speedo pinion red
Cones: see W. B. No. 5 - page 2
5)
GCI = Gearchange and consuption indicator
TDC sensor adapter in clutch housing =>page
34-86
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The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.