6 speed conversion kit

EuroTuning said:

Conversion kit
http://www.eurotuning.cz/images/file/gearbox_conversion_kit_us.pdf
VW tuning mag article
http://www.vwtuningmag.com/gearbox-conversion-kit/

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Are those gears lapped, ground or left in hobbed finish?

Scott, See posts 85 to.91 for detailed pictures of all the kit parts Johnny_law posted.

Well Radim confirmed that they know about the loss of cruise control issue with some ECU / gearbox combinations in 6th, but they do not have a solution for it yet. Let's hope Marc comes through. I'll let everyone know if a fix is found.

Did Radim share with you which ECU / gearbox combinations they know have the issue with loss of cruise control?

Unfortunately, no. Here was his response.

"Hello Curtis,
We still don't know why cruise control doesn't work at added gear at some cars. However, we are trying to find it out. We'll inform you when we know more.
Regards,
Radim"

jcboulware said:

Unfortunately, no. Here was his response.

"Hello Curtis,
We still don't know why cruise control doesn't work at added gear at some cars. However, we are trying to find it out. We'll inform you when we know more.
Regards,
Radim"

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Take a look at these two threads: http://forums.tdiclub.com/showthread.php?t=282430&highlight=5th+gear+cruise+problem

http://forums.tdiclub.com/showthread.php?t=199926&highlight=cruise+control

Think that first link will give you some clues about the problem.

Both Jeff (Rocketchip) and Kerma can fix the cruise control with non-stock gearing with most TDIs..

Bump...

Does anyone here have a kit on order with Eurotuning, and if so, do you have an estimated/firm delivery date?

I sent the funds for my kit three weeks ago, they confirmed that the funds were received. Radim has indicated there are some delays due to unexpected demand, but I have not heard from him or anyone else at Eurotuning for two weeks despite three emails looking for a status update.



*hopes for some sort of reply*

Isn't most of Europe on holiday in July?

Tony

TonyJetta said:

Isn't most of Europe on holiday in July?

Tony

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And August??

Ski in NC said:

And August??

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Well, it is the first week of August....

Tony

I gather Radim got back from holiday a few days ago.

I've no problem with supplier delays, vacations (well earned I'm sure) and the like, all I want is a little communication.

Windex, I agree! Communication seems to be the biggest issue with almost every sup0plier, except a few outstanding tdiclub suppliers!

Tony

Hi all,

Wanted to update - yes it was vacation, a little bit of lost in translation, and some supplier issues. Radim got back to me, and all is well with the kit. Thanks for the update Radim!

It took three tries, but Mark Malone did it. 2004 BEW (1.5 stage w/ EGR delete), Eurotuning 6 speed manual, with a fully functional cruise control. Thanks Malone Tuning.

jcboulware said:

It took three tries, but Mark Malone did it. 2004 BEW (1.5 stage w/ EGR delete), Eurotuning 6 speed manual, with a fully functional cruise control. Thanks Malone Tuning.

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Good news. Did you get an indication of what the problem was?

From what I understand it's a ECU programming issue with the 2004 and newer cars. The ECU is "looking" for a speed and rpm coorelation that makes sense based on the programmed factory final drive ratio of 0.75. If the speed and rpm do not match what the computer knows should be correct, it will not allow the cruise control to engage.

This is the same issue guys have when the go to the .658 fifth gear as well.

Mark had to reprogram the computer with the final drive of 0.59 so that the ECU would could understand the new speed and rpm ratios. I'm sure there was some other stuff and it was more complicated than just plugging in a new final drive ratio, but I didn't get that far into it with him. I'll ask, it may be interesting.

Windex said:

Now, what would the payback be say comapared to a 5th gear swap to a .658 or .622 5th gear swap on its own?

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Finally did my first full tank of fuel since the 6 speed conversion.

900 plus miles all around San Diego county, just normal daily driving with no attempts to buck up the mpg.

39.4 mpg - just near the top of my normal range (36-42). Not unexpected because I had been running a .622 fifth gear for more than a year. Also do not have my Scangauge II hooked up.

All told, I have 1500 miles since the conversion and I still love the smooth, even shift points. My very long 6th gear is not an issue. Running 3.157 final drive and oversize 185/70 x 14 tires. Not a single issue for me since the conversion.

If you are thinking about going to a longer 5th gear, I seriously suggest you spend the considerable extra money for the six speed conversion. It is just that nice!!!

Pulled the trigger. My kit is somewhere on a boat in the Atlantic as far as I can tell.

John, what kind of power mods are you running? I wouldn't want to contemplate such a long 6th without some extra ooomph to avoid shifting all the time (to compensate for the weight of a B4V).

Right now I'm running Malone Stg II with PP520s. Methinks it should be a good match for the 6th.

john.jackson9213 said:

Finally did my first full tank of fuel since the 6 speed conversion.

900 plus miles all around San Diego county, just normal daily driving with no attempts to buck up the mpg.

39.4 mpg - just near the top of my normal range (36-42). Not unexpected because I had been running a .622 fifth gear for more than a year. Also do not have my Scangauge II hooked up.

All told, I have 1500 miles since the conversion and I still love the smooth, even shift points. My very long 6th gear is not an issue. Running 3.157 final drive and oversize 185/70 x 14 tires. Not a single issue for me since the conversion.

If you are thinking about going to a longer 5th gear, I seriously suggest you spend the considerable extra money for the six speed conversion. It is just that nice!!!

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Windex,

Just Sprint 520 nozzles and the TDtuning stage 3 tune, with boost upped to 20 lbs. instead of 17.5 lbs. I like the low end punch and not worried about high end horsepower.

Radim,

Is the .52 gear set availible for the T-5 now?

john.jackson9213 said:

Radim,
Is the .52 gear set availible for the T-5 now?

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No, John, we don't offer .52 ratio yet. You are driving with ratio .59 for a few months now, do you really think heavier ratio would be better for you?
Radim

EuroTuning said:

No, John, we don't offer .52 ratio yet. You are driving with ratio .59 for a few months now, do you really think heavier ratio would be better for you?
Radim

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With the 3.157 final drive in the CTN transmission - No.

But with a 3.38 final drive in another transmission - perhaps just a little.

Have not taken a long road trip yet, but love the way the car drives with the 6 speed conversion.

Wanted to update, my kit finally arrived. - well packed and all items accounted for. Should be installing this weekend if weather cooperates.

I will be pulling the tranny and disassembling, as I have a rear main seal and clutch to do at the same time.

Have 1000km of driving to do for work next week - should be a good chance to get some fuel economy numbers...

Installed the kit this weekend
Build quality on the kit is very good
Took the transmission out and replaced the clutch and 2nd gear syncro at the same time
Transmission was stupid heavy and very awkward to get back in on my own
Got it all back together and went for a drive - 6th gear revs real low on the highway
Pops out of gear in 5th; the only way to keep it in 5th is to hold the shift lever forward. Adjusted the shift cable all the way forward as well - no improvement - going to have to take it apart again and adjust the shims on the shift rail-rod.

Odd... I was very careful to make sure that the shift fork was centered on the syncro dog in both directions. Well, at least I don't have to take the transmission out again in order to add shim(s) to the shift rail/rod.

Radim, if you have any helpful hints from any of your customers that have experienced the same, I'd be most appreciative.

Windex said:

Installed the kit this weekend
Build quality on the kit is very good
Took the transmission out and replaced the clutch and 2nd gear syncro at the same time
Transmission was stupid heavy and very awkward to get back in on my own
Got it all back together and went for a drive - 6th gear revs real low on the highway
Pops out of gear in 5th; the only way to keep it in 5th is to hold the shift lever forward. Adjusted the shift cable all the way forward as well - no improvement - going to have to take it apart again and adjust the shims on the shift rail-rod.
Odd... I was very careful to make sure that the shift fork was centered on the syncro dog in both directions. Well, at least I don't have to take the transmission out again in order to add shim(s) to the shift rail/rod.
Radim, if you have any helpful hints from any of your customers that have experienced the same, I'd be most appreciative.

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Hello Adam,
This can be caused only by the adjustment of the selector fork. As you may assume, you will have to add a washer between the shift rail and the selector fork, as the shift rail is so to say „short“ now and will not shift the dog gear into the lock. The best is to test everything with the aluminium cover, which is only put on, not sealed, without bolts, to shift alternately gears 5 and 6 and try, if it is after shifting a gear possible to move the selector lever in the shifting direction a little, the selector fork will be pressed to the end but will return a little and released after releasing the selector lever. This should be identical with both speeds, 5 and 6.
Regards,
Radim

Windex,

Did you get this running properly?

Yes, got it running properly.

Per Radim's reply above, If I were to do it over again, I would install the end cover loosely, get the transmission installed (for those like me doing the install out of the car) install the shift shaft and cables, then remove the cover again.

Then (an assistant helps here) shift back and forth from 5th to 6th to neutral over and over and determine the number of shims needed to make sure the synchronizer hub/dog is centered in neutral, and that it engages fully in both 5th and 6th.

I checked this on the bench, and gravity must have skewed my measurements of the synchro position when the shaft was vertical.

Once the gears were horizontal in the car, it was plain that the shift rod needed to be lengthened with the provided shims - in my case it was 2x1mm to make it perfectly centered. the .5mm was not used.

I had my 14 y/o shift the lever back and forth from 5th to 6th with the 2 shims installed, and the synchro engaged equally in both gears - before, it would not engage fully into 5th.

All is good now - though my first tank involved a 5 hour drive in a rainstorm and a some heavy headwinds. So no awesome F/E numbers to report yet.

Further, make sure that the 5/6 synchro hub shown in this picture is centered evenly between the 5th and 6th gear teeth when the transmission is in the car and the car in neutral.


Also make sure that the hub engages fully and touches the gear teeth in both 5th and 6th when using the gearshift lever. When you let go of the gearshift lever, it will retract slightly and leave a small clearance.