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Old 03-11-2010, 10:15 PM   This thread is in the EcoModder Project Library | #1 (permalink)
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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).



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

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Old 03-12-2010, 05:35 AM   #2 (permalink)
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: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?
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Piwoslaw's Peugeot 307sw modding thread

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Old 03-12-2010, 10:14 AM   #3 (permalink)
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Quote:
Originally Posted by Piwoslaw View Post
:envy:
Still a little bit of terror on my end, joy should ensue when it arrives.

Quote:
Originally Posted by Piwoslaw View Post
From England? Must have cost a fortune. How compatable is it, ie just drop-in or custom job?
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.

Quote:
Originally Posted by Piwoslaw View Post
Oh, and will you have to move the steering wheel to the right side of the car?
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.
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Old 03-12-2010, 10:45 AM   #4 (permalink)
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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)
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Piwoslaw's Peugeot 307sw modding thread

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Old 03-12-2010, 10:50 AM   #5 (permalink)
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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
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Old 03-12-2010, 10:53 AM   #6 (permalink)
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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.
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Old 03-12-2010, 11:11 AM   #7 (permalink)
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Quote:
Originally Posted by bhazard View Post
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.
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Last edited by dremd; 03-12-2010 at 11:14 AM.. Reason: formatting
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Old 03-14-2010, 04:04 PM   #8 (permalink)
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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
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Old 03-14-2010, 10:15 PM   #9 (permalink)
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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.
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Old 03-15-2010, 12:35 AM   #10 (permalink)
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So basically after 4th it switches to a taller final drive? Sounds like some complex internals...

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