mk4 six speed conversion

Wildhair377

Member
Joined
Apr 9, 2014
Location
Germantown ohio
TDI
2002 & 2003 Tdi Jetta
Hello, just working on a 02 TDI. I have 2 5 speed transmissions, one with all the shift cables and box. Are these 2 trans worth enough to sell and go six speed? I seen one pop up today for 2k.
 

red16vdub

Veteran Member
Joined
Aug 26, 2013
Location
(617) City of CHAMPIONS
TDI
03 JSW 5spd
personally unless you're car came with a 6spd or you actually got the parts to do the swap for free. I don't see the benefit, IMO I'll just do a 5th gear swap and used the rest of funds in other places like suspension refresh, but it is you're car.
Good luck!
 

Fix_Until_Broke

Top Post Dawg
Joined
Aug 8, 2004
Location
Menomonee Falls, Wisconsin, USA
TDI
03 Jetta, 03 TT TDI
If you're going to be putting down a lot of power and want the durability or just want to say "I have a 6 speed from Europe" then go for it.

If you're looking to save money in MPG's with lower cruising RPM's or just want lower highway RPM's for noise/comfort, etc, then just get a taller 5th gear. You'll have the same RPM's for ~$400.

Minimum cost for a 6 speed is $2k and that's if everything is good. Need a clutch - add $1k, want to fix the common shift fork issue - another $300-500. Add an LSD while you've got it apart for the shift fork issue - another $1k. Speed sensor broke in shipping - $80, Need an axle because one is bad - $200-700, etc...
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
Yeah I wanted the 6spd for strength and ended up costing my 4k when it was all said and done between clutch and LSD. If I drive it a couple more million miles maybe I'll recoup in fuel savings. But I did sell my 5spd swap when I was done that paid for some of it.
 

Wildhair377

Member
Joined
Apr 9, 2014
Location
Germantown ohio
TDI
2002 & 2003 Tdi Jetta
Yeah I seen the conversion also that goes in The five speed trans. I am most interested in better in mPG's. What are the diesel five-speeds going for to sell one with shift cables?
 

Fix_Until_Broke

Top Post Dawg
Joined
Aug 8, 2004
Location
Menomonee Falls, Wisconsin, USA
TDI
03 Jetta, 03 TT TDI
The 5 speed converted to a 6 speed seems to be a bit of a nitch solution for those who really don't want/need the strength of a 6 speed, but do a lot of driving in the 45-50 MPH range where the gap between 4th and a really tall 5th is an issue for some. I drove most of 100k miles with a 0.681 5th and 205/70/15's and never had a problem with the gap between gears and I drive 35 miles each day on roads at 40-55 MPH. Some don't like that though.

For MPG's only, I'd do the tallest 5th gear you can get. I had the 0.681 and would have gone taller but with all the trailer towing I do, it was the right compromise to not have to run in 4th all the time. If I didn't pull a trailer (or only pulled it once and a while or short distances) I'd for sure go with the 0.622 - A stock ALH TDI in proper running order will pull it just fine. You get the cruising RPM's of either 6 speed option, using all the axles/starter/clutch/shifter/etc that you already have, without the $2k-$5k price tag, without the extra 100lb of weight, without a weekend's worth of work. The compromise is a bigger gap between 4th and 5th.
 

Judson

Veteran Member
Joined
Jan 18, 2001
Location
Cheyenne, WY
TDI
2001 Jetta
Yeah I wanted the 6spd for strength and ended up costing my 4k when it was all said and done between clutch and LSD. If I drive it a couple more million miles maybe I'll recoup in fuel savings. But I did sell my 5spd swap when I was done that paid for some of it.
Speed costs money. This is my quandary as well:

1) VNT17 and be done with it, considering my current mods, and leave the tranny alone. $900.
2) Add a 6th gear onto my current transmission, or do a 5th gear swap. $400 or $1,500.

Total $2,400 at the worst.

OR, the really expensive way, if I really want to get beyond 180hp/300 ft. lbs. of torque:

1) 1756vk or bigger
2) new downpipe/exhaust
3) 6-speed tranny with quaife ltd. slip, new clutch, etc.
4) Rosten rods, which means cracking open the engine.

$6,500 at best, and probably more, as it doesn't even include labor, minus sale of the 5-speed... And this is just the beginning, as I'd probably want to upgrade my intake, intercooler tubes, and etc.

YIKES!

I'm leaning towards the former, since this isn't a sports car. If I want a sports car, I should probably buy one designed to be one from the factory...
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
I had the .658 in my 5spd. I didn't really ever have an issue with it as I like to drive fast.
 

andy2

Veteran Member
Joined
Sep 24, 2004
Location
Bowmanville,Ontario,Canada
TDI
13 Jetta,94 Golf drag car 585bhp,Samurai buggy BHW 300bhp,97 Ram cummins
3.16 final drive,.717 5th and LSD is a nice combo in the 02J.Likely costs less than a 6 speed swap especially if one already has an upgraded clutch.

I found the used 3.16 from the CTN (02A/AHU).Used .717 from CHA (02A/AAZ). Bought a used 02J Quaife LSD locally from wortex ;)
 

vanbcguy

Veteran Member
Joined
Feb 22, 2013
Location
Vancouver, BC
TDI
'93 Passat - AHU mTDI with GTB1756VK
What platform had the AAZ with an 02A? I thought they were all 020s?

Sent from my HTC One XL using Tapatalk
 

Wildhair377

Member
Joined
Apr 9, 2014
Location
Germantown ohio
TDI
2002 & 2003 Tdi Jetta
This gives me a lot to think about. My 02 I'm building has a vnt17 big injectors, dual disc south bend, 3 bar map, kerma tune. I bought it blown up and I'm in the process of fixing now. I've scored an 11 mm pump and getting ready to fix. Looks like I should just go with a bigger 5th and be done with it.
 
Top