Frans is the Man...
Can you please elaborate for me? So im looking to do this same thin on an 05 passat wagon I just got. From what i understand (familliar with the alh) I will need a trans Out of a TDI, if i don't wanna rev to the moon all the time right? what transmission code/s should i look for and what are some (or all would be great, I'd even be willing to throw some $ your way for the info) models have the TDI w/manual trans so i can look for a parts car for the swap??? would love the info been looking at salvaged cars a bit but, I may just have to buy a trans on its own and parts car for the rest......
There are quite a few discussions about this. DO get a Euro Transmission... the ratios are correct for the TDI. There are two five speeds, one with a slightly higher top gear (FHN). It's harder to find. I got the more readily available one (DUK) and kinda regret not holding out. The six speed transmission is, apparently, more fragile and no one seems to want to sell you one that has not been re-built. That's not a good sign, for me at least. I want as bomb-proof a set-up as possible. There is also an issue with the crank, IMHO, too much work, and expense, to justify for the extra gear. If i was independently wealthy I'd have held out for the six speed but I was doing the Balance shaft delete at the same time and the budget topped out pretty quickly! Anyway, Frans at Dutch Auto Parts is the place, he is very knowledgeable and his stuff is always first rate, in great shape. At least, mine was, and most folks seem to have the same opinion of him. There is some logic in not getting a parts car but getting a "kit" from frans... pedal parts, everything. He's pretty thorough. That said, labor is the biggest component of a project like this, and even if you do it yourself having to break down a parts car, then get rid of it... vs. getting the stuff from frans and putting it in... YMMV. I spent some serious money on this project but in my opinion, IT WAS WORTH IT! I LOVE the car. A stage 2 Malone tune, heavy clutch... the car just sings and should have been delivered this way. With the BSD, the rotational mass is reduced and I just love the performance of the car. See my thread, above, for all the gory details! BTW, in case you might be looking for a TDI wrench to help you out, Mike McCann in Mass. is fantastic.
Hope this helps...