RYAN P's 6 speed 02M Conversions and ALL Euro TDI Parts

Strange, mine just clears the flange by like 1/4" all around

couldn't find an answer with a search...

i got a fairly young Soutbend Stage 2 Daily Clutch and a Single Mass 14lb Flywheel on my O2J/ALH. is there a chance i could keep them if i went with RyanP's 6-speed conversion kit?

Im afraid the 6 speed has a larger flywheel and clutch!

thanks for an instant reply! was just wondering if i could save money...

Anyone wanting group discounts or planning to make a large order please PM or email!! We have some good offers at the moment!

BTW, we now have Gift Certificates for our website:

http://www.darksidedevelopments.co.uk/products/darkside-developments-gift-certificate.html

Has anyone near Washington, DC performed the 6-speed tranny upgrade on a 2004-2006 Jetta BEW PD? I'm looking for a mechanic in the area that can work on these upgrades as well as turbo and injector upgrades and tuning. Anyone have a recommendation?

I'm in northern va and just finished swapping my 03 ALH literally this week with this exact kit from here not sure how much different it can be to do this on yours did injectors and tune his kits are probably the most complete and I'm a tech btw

Interested in this for my 03 TDI 5 speed.

Drop me an email/PM, I have everything on the shelf ready to ship!

Speak soon

Ry

slyk said:

Can someone help me out with the shifter adjustment on these? Here's what I'm tracking is the procedure:

1) Place shifter in neutral-ish, get the nail/pin to line up and drop it in so the shift knob cannot move.
2) Place the selector under the hood in the "locked" neutral position with the pin in place
3) Adjust the shift end links until the counterweight/shift selector can move freely in the vertical direction (up/down free play)

Is that correct? I seem to be having a hard time adjusting the end links right...can't get any up/down free play in the counterweight.

Suggestions? The tranny shifts "ok" but not as smooth as my 5spd in the other car... Thanks!

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slyk said:

I watched the videos and it seems exactly like what I was doing. I did use the appropriate gear oil, part # G052171A2. It came in a really swoopy bottle that was easier than any other gear oil I've ever tried to put into a transmission.

The transmission is still noticeably notchier than my 5spd w/130k, even my wife says it's not as "nice" to shift the 6spd. I'll try another round of adjustment this weekend...

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boertje said:

When you lock the trans for the shift cable adjustment, you cannot move the lever relay on the trans at all so the cable adjustments should fall easily into place.
The trans will "feel" different with shifting than the 5 speed but should still be smooth.
Also, what gear(s) is it notchy in?

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Way delayed response on this, but despite several attempts at adjusting the transmission is still pretty notchy while shifting. If I shift slowly I can feel the syncros/gears grinding a bit even. 1st gear is hard to get into unless really slow or stopped, and then 2/3/4 are all notchy, with 1/2/3 being the worst. 5th and 6th seem to be ok though.

I've noticed with 4th gear if I pull straight back it sometimes won't go into gear (stuck on fork?), but have to move it a tiny bit to the right if that helps with diagnosing at all.

Also, I've noticed that there is quite a bit of slack in the drive train now. What I mean is, if I leave the clutch out (engaged) in gear, and let off the throttle, there is a pretty noticeable lurch, and then another noticeable "jump" or maybe slight clunk when I re-apply throttle. Much more than any of the other 4 TDIs I've owned. Is this a sign of the differential being worn?

I've only put 13k miles on this setup since I got it but I'm getting concerned the transmission is the weak point in my drive train. Is this stuff normal??

Is this on genuine oil?

The fork usually goes on 1/2nd or 3rd, never seen 4th!

It is on genuine oil, part # G052171A2.

Not sure if it's the forks, syncros, diff, or what's going on. It's totally still drivable, I'm just concerned. Next time I'm headed past a guru's shop I will have them adjust the linkage in case I have that messed up despite several tries..

If I were you, I'd got through the alignment procedure again. Had a similar problem with the last bug I did in that after I did the proper alignment, nothing seemed to match. After much tweaking I finally got it dialed in.

hi
I am searcing for left driveshaft for my 6speed 02m gearbox.Part no. 1j0 407 271 ep
witch cars have this instaled;,vw,seat ,audi,Skoda, year, model,.....what is racomended price for used?
(someone wants too sell me one for 120euro )

Has anyone around Winnipeg MB done this upgrade? I have few questions regarding the duty and brokerage, etc. Please PM me, thanks

Dennis (TDIguy2)

TDIguy2 said:

Has anyone around Winnipeg MB done this upgrade? I have few questions regarding the duty and brokerage, etc. Please PM me, thanks

Dennis (TDIguy2)

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You wouldn't mind sharing(PM) this info once its passed on to you,would you ?
Thanks.

Wanting info on a conversion kit for a gas to diesel 2002 eurovan.

?? thanks.

Just emailed you back

Thanks

Hey Ryan, can you give me a cost estimate for getting an 02M TDI gearset shipped to 96822?
No preference to any specific trans. I've got a 20th AE and I'm thinking about keeping the 02m when I TDI swap it

PM'd!

Hi I was wondering if it is possible to put the LHD manual transmission from a 2010 tdi into a 2006 tdi with a GQQ transmission? Any info would be appreciated, thanks.

Yes i cant see why not! ensure you get everything!

Hey there,

Looking to swap a 6 speed into the place of a 01M FDB auto in a 2001 Golf GLS TDI USDM

I'm unsure about what clutch/flywheel to go with because I may want to plan for some performance mods so could I please have a quote for everything I would need besides that shipped to 44106 (business or residence).

Also, do parts come with a declaration stating mileage?

How do I decide which version (sub code) of the 6 speed I want?

Thank you,
-Marc

ryanp said:

Is this on genuine oil?

The fork usually goes on 1/2nd or 3rd, never seen 4th!

Click to expand...

Is the broken fork issue common, or really just an occasional thing with aggressive shifters? Here is one of several threads on it http://forums.vwvortex.com/showthread.php?3800795-O2M-Anyone-successfully-strengthened-shift-forks

Sent from my SGH-I777 using Tapatalk

nun101 said:

Hey there,

Looking to swap a 6 speed into the place of a 01M FDB auto in a 2001 Golf GLS TDI USDM

I'm unsure about what clutch/flywheel to go with because I may want to plan for some performance mods so could I please have a quote for everything I would need besides that shipped to 44106 (business or residence).

Also, do parts come with a declaration stating mileage?

How do I decide which version (sub code) of the 6 speed I want?

Thank you,
-Marc

Click to expand...

Hi Marc

What sort of Power / Torque are you going to get to in the future? Then we can spec the right clutch.

We do not ship with specific documents stating mileage, but all are removed from vehicles we have driven there, then the fluid is drained and checked for any debris.

I suppose its a case of figuring out what RPM you want to be at whilst at a certain speed, then match the box up. There is the gear speed calculator above.

ta79pr said:

Is the broken fork issue common, or really just an occasional thing with aggressive shifters? Here is one of several threads on it http://forums.vwvortex.com/showthread.php?3800795-O2M-Anyone-successfully-strengthened-shift-forks

Click to expand...

We have only really seen it with aggressive shifting or when the car is used when the clutch is on its way out. If we are talking the box apart (for a diff swap for example) we strengthen them.

Thanks!

hey, I have a question, hopefully simple, what do these use for a starter? how could I easily get a replacement over in the US? are they the same as the 1.8T 6 speeds?

Yes, same starter as a 6 speed here.

The TDIs are a higher KW, but I know some people use them all the time with no trouble

The ones in red are easy to find. Boraparts I believe stocks the Bosch reman sr0433x and I've used the Chinese Bosch clone Lester 17820 which is cheaper than the Bosch reman with good results. Personally, I prefer using the Bosch.

Here is starter info.

Starter
02M starter - Look for a diesel specific starter which should be 2.0kW.

02M 911 023 (also -A and -F)
Actual Bosch:0-001-125-018, 0-001-125-019, 0-001-125-048, 0-001-125-049 2kW
Various other part numbers for the starter for the 02M 6 speed.
BOSCH: 0001125018
12V 2.0KW 10T CCW
VOLKSWAGEN GOLF, JETTA L4 V6 1.8L, 2.8L, 3.2L
LESTER 17820
BOSCH 0-001-125-019
BOSCH 0-001-125-048
BOSCH 0-001-125-049
BOSCH SR0433X
VW-AUDI 02M-911-023A
VW-AUDI 02M-911-023F
VW-AUDI 02M-911-023R
WAI 2-2341-BO
VW 02M-911-023C Valeo D7SR50 Valeo D7SR150

How about a quote with a clutch and single mass flywheel that will take whatever the stock bottom end can handle? 300-350 ft*lbs at flywheel (i think) shipped to 44106.

Thank you.