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

NWVintage

Active member
Joined
Mar 6, 2013
Location
Seattle, WA
TDI
2014 Jetta Sportswagen, 2002 Jetta GLS Wagon 02M
It can be a struggle to get the box in with the mount attached but it can be done if the engine is low enough.
Yeah, so I've heard. Supposedly you can get a trans into a MKII without removing all of the engine mounts but I've never been able to make that happen either. Seems like maybe its a personal problem:rolleyes:.

Those bolts would be fine to re-use.
Yeah, probably but I'm a play-it-safe kind of guy and the Bentley said to replace them... Somewhat ironically, I did reuse the ball joint-to-control arm bolts - I didn't have them and, at that stage of the game, I was ready to be done...

Anyone doing this may also want to consider taking apart the CV's and servicing them while they're out of the car. I gave the boots a good look over and decided to run them and see if they make any noise. The big end of both outer boots slipped off in the first 100miles and there's grease everywhere. Guess what I'm doing today... No insinuation that this had anything to do with Ryan - just a precaution I wish I'd decided to take. Splattered grease is such a PITA to clean up!
 
Last edited:

Gordon_Shumway

Well-known member
Joined
Mar 14, 2005
Location
Littleton, CO
TDI
2003 jetta
Auto to 6 speed swap

Maybe its because its far to late for me, but I am confused as to the price on a auto to 6 speed swap. I see the listings of
5 to 6 Speed Swap - £1200 GBP
New Sachs PD150 Dual Mass Flywheel, Clutch Kit and Releaser - £300 extra
Complete Auto - Manual Setup - £300 GBP Extra
Peloquin Installation including Upgraded forks - £900 GBP extra
6 Speed Clutch Fluid Line - £60 Extra (Included in Auto-Manual Parts)
and
Clutch Pedal Assembly, for £300 GBP extra
It looks like I don't kneed the 6 speed clutch fluid line but I think I every thing else (and a mechanic). If that is right then its 1200+300+300+900+300=£3000 or $3,878.50 and that is with shipping to the USA?. Is there any thing else I need like the tranny from a junk yard or is that every thing?

My car is still running good, but its nice to be know what I will be looking at.

Thank you for helping me with my late, late night confusion.

Mike
 

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 ........
Hi Mike,

Are you wanting a Limited slip diff? The basic kit is £1200 Inc Shipping. Your maths are a little out, haha!

Thanks

Ryan
 

Gordon_Shumway

Well-known member
Joined
Mar 14, 2005
Location
Littleton, CO
TDI
2003 jetta
I have an automatic and at sometime it will go out, or so I am told with my type of transmission. I do not know what parts are needed.

Thank you for the fast reply

Mike
 

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 ........
Hi Mike,

They all seem to fail at some point i guess!

The Auto - Manual setup is £300 more and a Brand new Clutch and Flywheel a Further £300 so the total would be £1800 or at todays Rate around $2700

Thanks

Ryan
 

Gordon_Shumway

Well-known member
Joined
Mar 14, 2005
Location
Littleton, CO
TDI
2003 jetta
And that is for every thing I need? Or do I still have to go to a junk yard for other parts? Sorry for all the questions, just want to make sure I get it completely understood.

Thanks
 

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 ........
No thats everything, you just need the oil and a 5/16" (IIRC) hose coupling for the trans cooler bypass.

The guide on the first page covers everything!

Thanks

Ry
 

skinneyhead

Active member
Joined
Mar 21, 2013
Location
mokena,il
TDI
2005 passat wagon
ryan new TDI owner here,my TC went south and probably took the tranz too, from reading all the posts on the TDI site I figure I should just go to a manual.Are you able to get a FHN or GGB 012?
 

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 ........
Hi Steve, Will PM you now!

Thanks

Ryan
 

ibyte

Veteran Member
Joined
Mar 3, 2005
TDI
2000 jetta tdi gls sedan 5spd
Complete PD150 Intake with EGR and Elbow Pipe - £175
Can also be supplied with EGR Cooler for £10 Extra
In total 180 pounds shipped to California -?
Will the items above bolt on to my 2000 jetta 1.9 tdi alh ve ?
I live in California-SMOG so need to look vw original for SMOG visual inspection.
Will all air hoses, vacuum hoses and electrical plugs still fit?
Will this trigger a check engine light?

Same Questions for items below if bought at a later time.

PD150 TIP kit
R32 DSG Snorkel
R32 Airbox
new R32 MAF

Thanks
what is approximate shipping time to california?
 
Last edited:

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 ........
Well, £185 shipped ;b

This will just look like stock and fit like stock, no CEL either.

Shipping will take 25-48hrs

Thanks!

Ryan
 

oldpoopie

Vendor
Joined
May 14, 2001
Location
Portland Oregon
TDI
2001 golf gl, 2006 jetta, 1981 ALH swapped rabbit pickup, 1998 beetle
Complete PD150 Intake with EGR and Elbow Pipe - £175
Can also be supplied with EGR Cooler for £10 Extra
In total 180 pounds shipped to California -?
Will the items above bolt on to my 2000 jetta 1.9 tdi alh ve ?
I live in California-SMOG so need to look vw original for SMOG visual inspection.
Will all air hoses, vacuum hoses and electrical plugs still fit?
Will this trigger a check engine light?

Same Questions for items below if bought at a later time.

PD150 TIP kit
R32 DSG Snorkel
R32 Airbox
new R32 MAF

Thanks
what is approximate shipping time to california?

On an ALH youll need the coolant hose that enters the drivers side of the egr cooler too. The alh one is too short to reach the pd150 barb.
 

ibyte

Veteran Member
Joined
Mar 3, 2005
TDI
2000 jetta tdi gls sedan 5spd
I cant find the item belowon your website

Complete PD150 Intake with EGR and Elbow Pipe - £175
Can also be supplied with EGR Cooler for £10 Extra
 

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 ........
Cheers for that Justin, Did not know! Some guys use the ALH cooler and PD150 pipe to the valve.

ibyte - Those parts are not listed on my site, drop me a PM and I'll show you how to pay through our site or via paypal!

Thanks

Ryan
 

proffjl

Member
Joined
Apr 4, 2013
Location
auburn Alabama
TDI
2003 VW Golf TDI Auto to 6speed swap
Just completed the auto to 6 speed swap this weekend. The kit from Ryan was great. It included virtually every part, nut and bolt needed. He shipped it crazy quick too, something like 3 business days from europe.
 

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 you are happy!! Come back anytime!

Thanks!
 

boertje

Veteran Member
Joined
May 24, 2002
Location
Coeur d'Alene, ID
TDI
'01, '01, '03, ‘06 NB - TDIs all.
Updated the howto. Added part numbers for the box mount to trans bolts. Corrected the part numbers for the bolts used to connect the axles to the trans flanges for the 02M. Added part number for a Valeo starter for the 02M. Added comments on wiring a bug for auto to manual swap.
 
Last edited:

ejg3855

Veteran Member
Joined
Jan 31, 2009
Location
WNY
TDI
1Z
Is it possible to get pig tails with the MAP sensors for those of us swapping into an older car?
 

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 ........
Yeah i have MAP harnesses with long pigtails for £15

Thanks!!

Ryan
 

kenzie2029

Active member
Joined
Aug 9, 2012
Location
Eugene, OR
TDI
2005 Golf TDI GLS
I've been bugging Ryan for a few weeks with questions, fitments, and suggestion. I finally pulled the trigger last Wednesday and received my parts on Monday! That was from the UK to Eugene, OR, crazy quick. Very cool! Will order parts from Darkside again!
 

slyk

Veteran Member
Joined
May 4, 2007
Location
San Antonio, TX
TDI
'03 Jetta Wagon, 6spd
Shifter Adjustment?

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!
 

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 ........
The DieselGeek videos on YouTube give good instructions on how to do it right.

Did you use 02M VW Gear Oil?

Ry
 

slyk

Veteran Member
Joined
May 4, 2007
Location
San Antonio, TX
TDI
'03 Jetta Wagon, 6spd
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...
 

boertje

Veteran Member
Joined
May 24, 2002
Location
Coeur d'Alene, ID
TDI
'01, '01, '03, ‘06 NB - TDIs all.
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?
 

sardo_67

Veteran Member
Joined
Feb 15, 2010
Location
CT
TDI
2015 Golf SEL 6spd
Ryan, i bought a trans kit from you last year and just moved it from my first car to my 2nd. i've been trying to get replacement parts for mine like axles.

can you update the first post with what exact make and model car we should use to look up parts at the local parts place? or if a list of the OEM part numbers, that would be very helpful such as getting a replacement slave cylinder.

just an idea.
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2015 Sportwagen; Golf GLS 2002 (swap from 2L gas); 2016 A3 e-tron
I bought from and finished the install just over a year ago - love driving it. Soooo much better than just the .681 taller 5th that I had before.

I did have an issue crop up a little over a month ago, though, when my clutch (bought the new Sachs from Ryan) started slipping. Now, sure, I have Malone Stage4, T4 injectors, VNT17, etc., but still, it should've been holding that.

Chatted with Ryan and we couldn't come up with a reason why it might be slipping. Best we could figure is that somehow the clutch disk had become contaminated. So, Ryan shipped me a new clutch disk at no charge (although my local DHL office here on Vancouver Island still felt the need to ding me $25 for some brokerage fees or whatever...argh).

Anyway, took off the transmission and turns out the output shaft seal (part 02M 311 113A, IIRC) behind the throwout bearing had blown and I had transmission oil seeping into the bell housing and onto the clutch disk. That'll do it.

THe fact that the clutch disk had oil on it and was still able to hold under everything but hard acceleration at the torque peak (1900-2200rpm), I think, is a testament to the holding power of that disk.

I post this, not to disparage Ryan - I felt he went above and beyond in being willing to provide me with a new clutch disk, no questions asked.

I do think it's worthwhile pointing out, though, that we're paying ~$2000 for a *used* 6sp. transmission, shipped two-day from Europe - not $6K (maybe $8K?) for what it would cost *new* to get all of the stuff he includes.
That said, I still think it's a fair deal and wouldn't hesitate to buy again from him (and have, in fact, picked up a couple other bits from him).

And while you have that transmission waiting to go in, it might not be a bad idea to pop out that seal and replace it with a new one - it's a $6 part and you have no idea how aggravating it is to do the whole in/out for the sake of a dinky little part.

Anyway, stuff happens.
Seals blow.
That's life.
(And on the plus side, I am getting much better at taking out and putting back in a six-speed transmission! :))

Thanks for the good product and great service, Ryan.
 
Last edited:

ejg3855

Veteran Member
Joined
Jan 31, 2009
Location
WNY
TDI
1Z
Ordered a 150 manifold, 4bar, pigtail last tuesday parts showed up on friday.

Awesome service, thanlks.
 
Top