ALH 5-spd swap

[spartan]

Not if you need the auto to manual parts like the OP does. That price is 1575 pounds.

[Whitbread]

Originally Posted by spartan

Not if you need the auto to manual parts like the OP does. That price is 1575 pounds.

The only parts you need that aren't in Ryan's kit are a clutch pedal, line, and bleeder fitting (if Ryan didn't leave it on the trans, he usually does). The slave cylinder will come with your clutch kit.

I pick up clutch pedals all day long off vortex/e bay/car-part for $50 or less (got one off ebay recently for $17!). Braided SS clutch line is $70 from USP Motorsports, bleeder block is $15 from VW. That's less than $150 in parts worst case. I've done over 30 auto-manual swaps so I'm VERY familiar with the job.

[RedDragon]

Originally Posted by whitbread

last i heard they were a little over $4k from vw.

wowsers!!!

[RedDragon]

Ok, so along with the swap id like to get Aaron's(Bora Parts) Stage III performance Pkg:
http://shopping.boraparts.com/produc...roducts_id=834

But i wont have the $$$$ for both. Is it better to have the stage III kit before the swap or is it not a big deal to do the swap, then when i can afford the stage III kit to have whoever install that?

[LukeWilson]

I think your dying trans will last 15 minutes if you were thinking about installing the performance package before doing the 5-speed swap. Do the manual trans swap and get everything else on the car into tip-top shape before you start up-ing the power.

When you do the trans swap, put in a beefy clutch as many others have suggested. That is the only thing in the kit that would have any relation to the trans swap. The turbo and nozzles can be done easily afterwards.

My $0.02.

[RedDragon]

Originally Posted by LukeWilson

I think your dying trans will last 15 minutes if you were thinking about installing the performance package before doing the 5-speed swap. Do the manual trans swap and get everything else on the car into tip-top shape before you start up-ing the power.

When you do the trans swap, put in a beefy clutch as many others have suggested. That is the only thing in the kit that would have any relation to the trans swap. The turbo and nozzles can be done easily afterwards.

My $0.02.

No i wasnt going to add anything till the auto was dead. So basically do a tune up on it? Check hoses belts ect... ve heard the term Stage 0 used before would that be correct to use?

I didnt even think about that, everything else is outside the trans.

[kcfoxie]

I did this to my 2003. My transmission was from my wrecked 1998 with 278 (I say 280)k miles on it. I have over 10k miles on the swap to date.

I bought this car and did all the suggested upkeep to the auto and drove from NC to New Mexico for the New Beetle GTG and averaged a pitiful 38mpg for the trip. Looking at logs the best highway tank was just shy of 46mpg, the 98 I was replacing tgot 42-43 in the city and 48-55 on the highway -- the last 6 highway trips had all been 52 or better MPG before the wreck.

This was not acceptable. I averaged about 34 in town.

After the swap you can check my fuelly... 42 is the average. I dropped to 38 at the end of the winter, needing a fuel filter change (this was made more evident after I flashed the car with performance software). I drove with all the windows down at 65 to/from Greensboro and got 48.6 (49.1 if I didn't "top up" with the extra .10 gallon)... with the sunroof shut (my 98 didn't have a sunroof) I bet I could have bested 50mpg on that trip.

I'm hoping to go to Mississippi this May and have a goal of avg speed 61mph and avg mpg of 54mpg (758 miles one-way).

So, based on this alone, if you clock decent mileage you will recoup the swap costs in about 2-3 years time. Less if you do a lot of highway traveling.

Plus a manual TDI will always carry a better resell value, because the autos will get scrapped and these will still be around.

Next upgrade is a taller 5th gear.

[RedDragon]

Originally Posted by kcfoxie

I did this to my 2003. My transmission was from my wrecked 1998 with 278 (I say 280)k miles on it. I have over 10k miles on the swap to date.

I bought this car and did all the suggested upkeep to the auto and drove from NC to New Mexico for the New Beetle GTG and averaged a pitiful 38mpg for the trip. Looking at logs the best highway tank was just shy of 46mpg, the 98 I was replacing tgot 42-43 in the city and 48-55 on the highway -- the last 6 highway trips had all been 52 or better MPG before the wreck.

This was not acceptable. I averaged about 34 in town.

After the swap you can check my fuelly... 42 is the average. I dropped to 38 at the end of the winter, needing a fuel filter change (this was made more evident after I flashed the car with performance software). I drove with all the windows down at 65 to/from Greensboro and got 48.6 (49.1 if I didn't "top up" with the extra .10 gallon)... with the sunroof shut (my 98 didn't have a sunroof) I bet I could have bested 50mpg on that trip.

I'm hoping to go to Mississippi this May and have a goal of avg speed 61mph and avg mpg of 54mpg (758 miles one-way).

So, based on this alone, if you clock decent mileage you will recoup the swap costs in about 2-3 years time. Less if you do a lot of highway traveling.

Plus a manual TDI will always carry a better resell value, because the autos will get scrapped and these will still be around.

Next upgrade is a taller 5th gear.

Thanks for adding that.

[RedDragon]

I have a friend that is selling a trans from a gasser with code 02J 300 044 F. Will that work?

[Whitbread]

Originally Posted by RedDragon

I have a friend that is selling a trans from a gasser with code 02J 300 044 F. Will that work?

Only if you want to spin 3500 rpms down the highway in 5th...

[kcfoxie]

Originally Posted by Whitbread

Only if you want to spin 3500 rpms down the highway in 5th...

It'll bolt up but the gearing is wrong. You could get a taller 5th gear to install in that gas trans to get the hwy fuel economy... but... I'd try and find a diesel transmission.

[RedDragon]

Got it, i thought there were some parts that could go into both. Thanks guys.

[kcfoxie]

Yeah, the gears. It's common to do a taller 5th mod and sell your stock gear to a 2.0/1.8t owner who wants better highway fuel economy... cause the TDI 5th is taller than their stock gearing.