6 Speed 02M gearbox conversions

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ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
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ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
I must add that the parts required to do an Auto - manual swap CANNOT be sourced by me as we drive on the wrong side of the road!
 
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ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Dont forget when pricing up these conversions that your old setup (auto or manual) will be worth something to sell on after fitting a 6 speed!! People have been getting upwards of $1000 for their old setups, thats more than half of my kit price!!
 
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aNUT

Vendor , w/Business number
Joined
Nov 29, 2006
Location
Boulder, Colorado
TDI
'01 TT (ALH-ish), B7 Audi gasser, '05 Golf
Thumbs UP!

Thanks Ryan! Everything arrived safe, sound, as described, and much faster than I anticipated. I want to post my feedback publicly.
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Glad to know you are happy Aunthee, you know where i am if you need anything!

These are expensive but good value compared to some mods!
 

storx

Veteran Member
Joined
Jan 16, 2006
Location
Earth!!
TDI
2009 Jetta CR140, 2010 Corvette Z06
Question.. not for me.. actually for a friend i was telling he should convert his Audi TT to TDI since he needs to replace engine from bent rod from 2 step launch system he installed..
Do you sell 02m Quattro trans?
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Best bet is to install tdi gears into the quattro tranny, the stock tdi 4 motion/quattro's are rare and have seriously short ratios. I can get a box with damaged casing cheap!! just got offered it today!!
 

dieselpower04

Veteran Member
Joined
Jun 26, 2007
Location
Outside Tampa, FL
TDI
2004 Golf GLS TDI (sold)
Any idea what condition these come in? Miles? Service done? VERY interested in a 6 speed, trying to sell my 5 speed to cover costs
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
All the boxes i sell are in good working condition normally with 40-80K, i dont normally know about service history ect.

I have a 50k DRW box with everything needed to fit.

Your 5 speed should sell if you are not too greedy!

let me know if you want any more info!

Ryan
 
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ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Still got a few here!
 

Blownvette

Veteran Member
Joined
Sep 26, 2004
Location
Derwood, Maryland
TDI
1990 Corvette with V10TDI ,2004 (2)V10TDI’s
ryanp said:
Best bet is to install tdi gears into the quattro tranny, the stock tdi 4 motion/quattro's are rare and have seriously short ratios. I can get a box with damaged casing cheap!! just got offered it today!!
I sent you a PM.
 

dremd

Veteran Member
Joined
May 31, 2007
Location
South Louisiana
TDI
06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW
What kind of lead time is needed, how much deposit $ or £ to start the ball rolling? I'm heavily considering doing the swap in the summer.
Looking at an FHM.
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Lead times vary, no more than 2 weeks from deposit to shipping! most of the time i keep at least 1 box in stock.

Ry
 
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ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
It's on its way for you now Xavier, expect it late this week!

I've got an ERF and DRW in stock!

If you want any other parts included with a gearbox i can do a good deal!!
 

X@V

Top Post Dawg
Joined
Dec 13, 2004
Location
Sherbrooke, Qc, Canada
TDI
B7 A4 V6 2.5TDI, MK2 frankentdi 2.0 16V TDI PD
I have a question for you: are you able to get the telescopic axles? I think I will need to cut both axes because it's into a MK3!
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
I've never seen telescopic axles? PM Rub87, he has a 02m in his mk3 based seat ibiza!
 

X@V

Top Post Dawg
Joined
Dec 13, 2004
Location
Sherbrooke, Qc, Canada
TDI
B7 A4 V6 2.5TDI, MK2 frankentdi 2.0 16V TDI PD
On the VR6 24v here, don't know is it's possible on the TDI.

I will try to use the MK2 or MK3 shafts.
 

TDIMAXIMA

Top Post Dawg
Joined
Jul 5, 2004
Location
MARKHAM, ONTARIO, CANADA
TDI
2004 4motion Passat 5 speed 1.8t
Can I ask a stupid question here. How do you guys decide which is the best tranny for your setup? Also, ryan, have you shipped to Canada? Any idea of duties?
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
DRW's have the longest ratios, FMH and ERF gearboxes have more sporty ratios lower down with not much lost at the top, all do a very similar job.

The duties have been hit and miss, i'd say 2 out of 10 but they are normally like $50 but could be $200 if you are really unlucky!

Ryan
 
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X@V

Top Post Dawg
Joined
Dec 13, 2004
Location
Sherbrooke, Qc, Canada
TDI
B7 A4 V6 2.5TDI, MK2 frankentdi 2.0 16V TDI PD
Duties were $59 for me, in Sherbrooke, qc, Canada.

The best ratios... these are quite same (little difference)

For mine, I have a PD150 ARL engine into a MK3, I was needing the longuest ratios! For you car, I think the FMH would be a very good choice.
 

Scott_DeWitt

Vendor
Joined
Apr 7, 2004
Location
Texas USA
TDI
2000 Audi A4 1.9TDI quattro
TDIMAXIMA said:
wish i understood gear ratios..... ;)
GEAR RATIO PRIMER!

Gears work on the old Archimedes principal of mechanical advantage. Remeber "Give me a place to stand, and I will move the world?" Archimedes was speaking of mechanical advantage using torque and the distances from a lever arm. Imagine a see-saw with a pivot point that is adjustable. Move it toward the power source and a very little amount of movement is transferred to a large amount of movement at the other end, however it takes more weight (force) to move the see-saw. Now move the pivot point farther away from the source and you require less force, but more distance traveled.

Gear operate on the same principle. They consist of typically a pair of gears and their ratio is the ratio circumference of the gears with the gear transmitting the power on the bottom of that ratio.. IE a first gear of 3.50 can have a driven gear of 35 and a drive gear of 10 35/10 = 3.5. For every 3.5 revolutions of input you get 1 revolution of output, but torque is multiplied by a factor of 3.5!

Now take a 6th gear. You will have a driving gear of 40 and a driven gear of 24. Which makes the gear ratio .60. So for every .60 turns of the engine, the output turns 1 time however torque is multiplied by .6. A ratio numerically lower that 1:1 is often referred to as an "overdrive".

A numerically high gear ratio (called "Low" gears) will amplify the torque the engine is making at the expense of engine RPM, a numerically lower gear ratio (called higher gears) will reduce the torque with a trade off for decreased speed.

TDIMAXIMA said:
so lowest revs on highway = best mileage.

Now we have to take into account the torque the engine delivers. Diesels typically make their torque way down low and for the lowest fuel consumption you want to run your engine at peak torque, and for diesels that can be as low as 1,800 rpm.

Now you can go to low and loose a great deal of fuel as the engine is no operating off it's peak torque and can't generate enough power to accelerate a mass (your car) in the present gear, which is why we downshift.
 

X@V

Top Post Dawg
Joined
Dec 13, 2004
Location
Sherbrooke, Qc, Canada
TDI
B7 A4 V6 2.5TDI, MK2 frankentdi 2.0 16V TDI PD
Yes, if you're under your max torque on the road, you probably won't have a better fuel economy.

For mine, I have 205-45ZR15 tires instead of 205-55R16 for a MK4, so I need the longuest ratios. My engine will be about 1900rpm @ 100km/h into my MK3 instead of 1750 into a MK4.
 

dremd

Veteran Member
Joined
May 31, 2007
Location
South Louisiana
TDI
06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW
Excellent description Scott, only place I disagree is on peak torque,
what you really want is to be at peak BSFC (Brake Specific Fuel consumption) which often times corresponds with peak torque.
Bear in mind that BSFC charts are typically created ot wide open throttle, I'm not sure how that affects the plot, but what I wish is that they were 3D.
Use this chart for the ALH.

heres a good post on picking gear ratios http://ecomodder.com/forum/showthread.php/bsfc-chart-thread-post-em-if-you-got-1466-5.html#post42773
Tis entire thread is very useful http://ecomodder.com/forum/showthread.php/bsfc-chart-thread-post-em-if-you-got-1466.html
On a side note: just ordered a DRW from Ryanp.
 
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