6 speed swap in to my TDI Golf 4

[tasdrouille]

Originally Posted by dremd

Absolutley.
My 02 is an ALH
I was answering a question regarding an 04 jetta

I see a question regarding an 02, but not an 04.

[dremd]

Originally Posted by tasdrouille

I see a question regarding an 02, but not an 04.

I see that now. My dislexia repeated the "4" from 4 speed.
Entirely my fault

[Dust]

Would be interested to know how your MPG goes up or down.

[dremd]

Originally Posted by Dust

Would be interested to know how your MPG goes up or down.

My hypothesis is that highway mpg will go up slightly, however I refuel from commercial (measurable) sources so rarely that good data will be slim.
Primary gain should be quieter highway cruise, and better ability to take advantage of aero mods.

If I drove pure highway, I'd just go with a taller 5th, but the car gets about 50% of miles under 50 mph, and also tows frequently, so a big jump from 4th to 5th was out.

Planning to take possession tomorrow (just getting back from supercar nationals today) then I'll need to round up stretch bolts, seals, and fluid before install. I have to replace the overdue timing belt first though. . . . .

Edit: If 6th reduces mileage, I'll just use 5th which is very nearly identical to my current 5th.

[dremd]

Got a toy today from England.
















And a few more bits

[MetroMPG]

Very cool, dremd!

Added to the project library & watching with interest.

[Dust]

Same clutch work as the 5 speed?

[dremd]

Originally Posted by Dust

Same clutch work as the 5 speed?

Nope, but my 5 speed clutch has slipped at WOT for over a year now, so I had no loss. I purchased a brand new 6 speed clutch which should last for the remainder of the cars life.

[dremd]

Going to the dealer (stealer) tomorrow to get seals and whatnot.

Does anybody have experiance changing cv boots? I'd like to swap them while they are not in a car.

Also found a stripped shifter hold down bolt going to re-thread with smaller tap tomorrow, hopefully that works otherwise I'll get an upgraded shift fork (hardened). But once I get inside transmissions I tend to go wild. . . . . .

[COcyclist]

I'm following with interest too. Sometimes I absentmindedly search for one more gear after 5th, on the highway. I'm not sure I would want to lose cruise control. Do you expect to still have it after the swap?

I have done the CV boots with the axles on and off the car. Do it now with the axles out. It takes a little time and perhaps a special boot clamp tool but it's a way better solution than messing with the split boot repair. Also, the outer boots generally take more of a beating than the inner ones so you may be safe to keep the inner boots.