6 speed swap in to my TDI Golf 4
 

Well guys, I just ordered a new to me DRW 6 speed transmission from England for my Golf. Should be fun + exciting. here are my new ratios (all the way on the left).

http://i463.photobucket.com/albums/q...s/boxcodes.jpg

I'll do my best to post pics once the parts arrive :-)

:envy:
From England? Must have cost a fortune. How compatable is it, ie just drop-in or custom job?
Oh, and will you have to move the steering wheel to the right side of the car?

Still a little bit of terror on my end, joy should ensue when it arrives.

Yeah, there is a guy shipping them to the states from UK, 6 speed was never available in a TDI MKIV in north America, but was/ is a common option in europe, so it's a direct bolt in, with new motor/ trans mounts, differant axles, differeant dust plate, and differant shifter (I got them all).

In Ecomodder dollars it cost a fortune, in normal mod dollars it isn't so bad, but for what it is, it's a steal.
Cost are also be offset by the following factors.
1) I need a clutch, this includes a brand new one
2) I need a starter (overrun) this includes a newer, lower mileage, better designed one
3) my 5 speed is salable
6) my axles might be salable.

No, only thing funny is re-routing the 5 speed clutch lune, or sourcing one from a LHD 6 speed.
Now if I was doing a auto - 6 speed swap I'd need a lot, lot more (lhd)parts.

Would getting LHD parts from the Continent (Germany, France, Spain) be much more expensive? Though there is always the language barrier... (I had the same problem when looking for a car)

I have no Idea what the pricing would be on the continent, only reason I went with this guy was glowing reviews from guys on my side of the pond, parts in stock, and what seems like a fair price.
Here is his 6 speed fs post on tdi club
TDIClub Forums - View Single Post - 6 Speed 02M gearbox conversions

Why do 4th and 5th appear to have the same ratio? The .8 6th doesnt seem all that tall either... my 5th has that ratio.

Well, 6 speeds in FWD cars are somewhat more complicated than in a RWD.

You have to look at the final drive 1 (3.238) for 1st, 2nd, 3rd, 4th and final drive 2 (2.615)for 5th, 6th and reverse. over simplified, final drives are dual rear end gears, what must considered is overall drive ratio per gear.

Here is the speed in gear chart for 5th + 6th all speeds are mph
RPM 5TH 6TH
5500 161.14 193.93
5000 146.49 176.30
4500 131.84 158.67
4000 117.19 141.04
3500 102.54 123.41
3000 87.89 105.78
2500 73.25 88.15
2000 58.60 70.52
1500 43.95 52.89
1000 29.30 35.26

created with Gear-Speed Calculator Program

Hope that helps, hit me up if you are still confused, took me a while to wrap my head around it also.

here are my existing gear ratios for comparison
DQY
1st 3.778
2nd 2.118
3rd 1.360
4th 0.971
5th 0.756
Final drive (all gears) 3.389

Installed in all US market TDI Beetle, Golf/Jetta IV
So, current speed in gear chart looks like

5500 31.92 56.94 88.68 124.21 159.53
5000 29.02 51.77 80.62 112.92 145.03
4500 26.12 46.59 72.56 101.63 130.53
4000 23.22 41.41 64.50 90.33 116.02
3500 20.32 36.24 56.43 79.04 101.52
3000 17.41 31.06 48.37 67.75 87.02
2500 14.51 25.88 40.31 56.46 72.52
2000 11.61 20.71 32.25 45.17 58.01
1500 8.71 15.53 24.19 33.88 43.51
1000 5.80 10.35 16.12 22.58 29.01

EDIT: so, basically 5th is 5th (just a hair taller) and 6th is a new, extra gear above 5th

I'd run these ratios on a 3 main gas boxer...
TDI inlines, they gotta win somewhere... ;)

the gear calc link, thanks. I have been using one for 4x4 trucks accurately.

Good luck with the 6 speed, the diesel deserves the best.

So basically after 4th it switches to a taller final drive? Sounds like some complex internals...

Correct, it reduces the number of moving parts by re-using the lower gears.

I'm not sure of the specifics, but the guys over at tdiclub claim it to be stronger and lighter than the US spec 5 speed, not that either of those matter very much to me.

Tempos have had that since '84...

My guess on the rationale for that is, too much an OD ratio is inefficient right at the gears i.e. the theory as I understand it is, the closer to 1:1 ratio gears have, the more efficient they are. So not going bananas on the OD ratio and engaging a taller final drive ratio could result in a more efficient transmission.

Wow, I totally didn't know that, how many gears?
Do you happen to know if other cars use a similar setup?

This will be my first (known) experience with multiple final drives, so humor me.

5 speed.

Not knowing about others except for the lil Plymouth Champ of the '80's with the "Twin Stick" (IIRC that's what it was called) but you had to shift the final drive with a second shift lever.

p.s. yeah me ol noggin had it right! :eek:

http://wikicars.org/en/Dodge_Colt

I suspect it increases the number of moving parts and complexity but results in a more efficient trans.

Hmm, can a 6sp go into a 02 4sp auto TDI jetta?

Would be nice

I also wonder if that guy in england could order a cheap Perudua Kenari 4 speed manual transmission?

I have wanted one in my electric for some time now.

Cheers
Ryan

shipped

DHL | United Kingdom | Tracking

Yes, you can swap a DRW in to a PD auto, but you will need to source clutch pedal parts from elsewhere. You will loose your cruise though, unless someone has found a fix for the PD cars.

Shoot him a pm on tdi club, I guess he could get one.

Wouldn't an 02 be an ALH? I thought PDs started in 04 over here.

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.

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

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.

Got a toy today from England.
http://gallery.me.com/dremd/100055/I...12694612160001

http://gallery.me.com/dremd/100055/I...12694612110001

http://gallery.me.com/dremd/100055/I...12694612070001

http://gallery.me.com/dremd/100055/I...12694612030001

http://gallery.me.com/dremd/100055/I...12694611990001

http://gallery.me.com/dremd/100055/I...12694611960001

http://gallery.me.com/dremd/100055/I...12694611190001

http://gallery.me.com/dremd/100055/I...12694612230001

And a few more bits

Very cool, dremd!

Added to the project library & watching with interest.

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.

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. . . . . .

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.

I will keep cruise control with the swap.
The later cars do loose cruise, however I *think* a fix exist.

The dealer wants $200 for boots, have you or anybody else used after market boots?
[/QUOTE]

I used aftermarket neoprene boots on my old Omni and they seemed fine. Haven't done it on the VW yet.

Just ordered a set of boots from first vw parts, under $100 shipped.
Hopefully the boot + stretch bolts get here fast.
I think I'll just get timken seals locally.
I also need to find out if the o2m uses G50, or G52 transmission fluid, I'd use redline mtf, but either of the factory fluids are much much thinner.

Edit: it uses G52 Vw fluid which is great because it is real thin.:thumbup:

Edit2:
2.3 liters at $30 a liter EEk:eek:

just found this nifty gear ratio change chart.
Higher percentage means taller gears, 1st to 1st, 2nd to 2nd and so on except 6th (compares to 5th).

Boots, bolts, seals, and fluid should get here tomorrow.
I'm getting excited.

Edit:
I kicked the dual mass flywheel and converted my little toe to dual mass as well.

Ouch!

I went single mass the other year as DMFs seem to be delicate - garage quoted me failure range from 10,000 to 100,000 miles, just random. Local VW based taxis which go to Mars and back in their life all get converted to SMF when brand new by the dealer which sells them. Only downside is a lot of chatter in neutral and a heavier pedal.

I stuch with the DMF for nvh, and I also ran across an article that dmf's improve economy slightly (I doubt it, but). Wish I could remembr the source.

Maybe here:
Dual mass flywheel - 5% FE increase?

Dude, you are the man
thank you very much.

What causes the FE increase ? Lower idle speeds ?