RyanP's 02M 6 Speed Tranny Conversions for VW Golf Mk4 (A4)

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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 ........
LAST UPDATED January 2013 - CONVERSIONS ARE STILL AVAILABLE!!!

PLEASE SUBSCRIBE TO MY NEW CONSOLIDATED THREAD HERE:

http://forums.tdiclub.com/showthread.php?p=4052519#post4052519

Thanks!



Hi,

I decided to do a new 6 Speed Conversion Topic as I know the old one was getting dated. You can find that here

We have sold over 200 of these 6 Speed conversions now, so there are a lot of very happy people cruising on the freeway in 6th!

The standard 5 to 6 Speed setup comes with all the items you see in the picture. It is everything you need to upgrade from a 5 Speed Manual to the 6 Speed. A few more parts are needed to swap out an Auto (see below for prices).



5 Speed Manual to 6 Speed Parts list:

02M 6 Speed Gearbox
2 x Drive Shafts
Used Dual Mass Flywheel and Clutch Kit
Gearbox Mount
Dog Bone Mount
Starter Motor
Dust Tins from the Engine
Shifter Mount and End Links
All bolts required (New where needed)
Linkage Cables (if required)



Please remember that if you are converting from a 5 Speed, you will have everything available to sell your old setup as a complete conversion for the Auto guys.

I can also supply the kits with a Brand New PD150 OEM Sachs Dual Mass Flywheel and Clutch kit with Release Bearing, when shipped with a 6 Speed they are £300 GBP extra. These are good for 200hp and 330lbs/ft.



We can also get any of the SouthBend Kits shipped directly to the USA and Canada at good prices.

Here are the different 02M Subcode ratios that are available to compare:



To compare RPM and Speeds against all the VW TDI Gearboxes, see the following calculator:
VW TDI Gearbox Ratio Calculator - Thanks Dave (Deebeaux)

AUTO TO MANUAL CUSTOMERS

I can supply all the extra parts you require, including the Clutch Pedal Assembly, for £300 GBP extra.



FOR THE AUTO TO 6 SPEED SWAP, PLEASE TAKE A LOOK AT THIS FATASTIC GUIDE BY BOERTJE - Auto to 6 Speed 02M Swap with Wiring Instructions

So to summarise:

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)

All prices quoted are in £ / GBP / British Pound and INCLUDE DHL EXPRESS SHIPPING to the USA and Canada. For estimated conversion rates, please check http://www.xe.com/.
I can take payment by Bank Transfer, Credit Card through my website (2% charge to cover fees) or PayPal (4% charge to cover fees).

For a limited time, with any 6 Speed Conversion we are offering a FREE PD150 TIP Kit or PD150 Intake.

Thanks for looking!

Ryan
 
Last edited:

boertje

Veteran Member
Joined
May 24, 2002
Location
Coeur d'Alene, ID
TDI
'01, '01, '03, ‘06 NB - TDIs all.
This kit will work with the bug too although the ECU is located under the dash panel just in front of the instrument cluster. Its really fun to get to. Other than that, its the same process.
 

JBE

Member
Joined
Apr 19, 2011
Location
MI
TDI
2005 Passat TDI, 2000 Golf TDI
You can count me as one of those 120 satisfied customers. The auto to 6 speed swap was a piece of cake, and Ryan was great to deal with. Worth every penny. Thanks Ryan!
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
I can't stop grinning after the 5spd to 6spd swap. Can't imagine the joy of auto to 6spd.
 
Joined
Feb 23, 2009
Location
Earth
TDI
'00 GOLF
I haven't finished the task of my swap "526", and can't wait till she's compressin' some sixth.
Ryan is straight up and a excellent communicator. Best deal, since I bought my car.

Many thanks Ry,

Cheers
 

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 ........

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 a few in stock, drop me a pm if you need to discuss the finer details!

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 ........

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 stock of these!
 

NewOwner

Veteran Member
Joined
Mar 20, 2009
Location
North East
TDI
2002 Jetta
I am also one of the happy customer. Ryan is great to deal with. Other side of him is "kind and humble" - Thank you Ryan.
 

iwannajettatdi

Veteran Member
Joined
Jun 17, 2003
Location
Salem, OR
TDI
2015 Brilliant Black Audi Q5 3.0TDI, 2014 Tempest Blue metallic Jetta Sportwagen TDI, 2002 Blue Eurovan Weekender BHW TDI

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 ........
5 shipping out on monday :)
 

iwannajettatdi

Veteran Member
Joined
Jun 17, 2003
Location
Salem, OR
TDI
2015 Brilliant Black Audi Q5 3.0TDI, 2014 Tempest Blue metallic Jetta Sportwagen TDI, 2002 Blue Eurovan Weekender BHW TDI
I look forward to getting started on this task. It's going to be a week or so before I have the time to do it, but it's going to be super epic.

I've found the auto --> 6 speed swap .pdfs, but are there any that are 5 speed --> 6 speed?

In trying to be as prepared as possible, I have the 30mm socket, and I'm planning on getting the triple square 12 point bits.

- What sizes will I need in the 12 points? (for the clutch/pressure plate, right?)
- Are there any other special bits or sockets that I'll need?
- Any tips/pitfalls to avoid from the veteran transmission guys?

Thanks.

-Ryan
 

boertje

Veteran Member
Joined
May 24, 2002
Location
Coeur d'Alene, ID
TDI
'01, '01, '03, ‘06 NB - TDIs all.
I look forward to getting started on this task. It's going to be a week or so before I have the time to do it, but it's going to be super epic.

I've found the auto --> 6 speed swap .pdfs, but are there any that are 5 speed --> 6 speed?

In trying to be as prepared as possible, I have the 30mm socket, and I'm planning on getting the triple square 12 point bits.

- What sizes will I need in the 12 points? (for the clutch/pressure plate, right?)
- Are there any other special bits or sockets that I'll need?
- Any tips/pitfalls to avoid from the veteran transmission guys?

Thanks.

-Ryan
If you get the new Sachs clutch, youll need a 9mm socket for the pressure plate bolts.
I believe the flywheel bolts are 12 point triple square 12mm.
As far as the 5 to 6 speed swap goes, the auto to manual swap pdf should have what you need to know for doing the 5 to 6 swap. Obviously you already have a shifter and clutch and also the wiring would not apply. I have done 2 auto to manual swaps and one 5 to 6 speed and next week I will do another 5 to 6. I tried to put the PDF together in such a way that it could be used either way.
You can use your old hydraulic line for the six speed if you gently tweak the line to route it towards the release bearing bleeder. Also if you get the ERF trans code then you have the holes on the left wheel well side of the trans to nicely fasten the power steering line using a standoff bolt and rubber lined clip. You will have to tweak this line a little to form it to the trans and clear the side skirting. You will need to make a brace to hold the hydraulic line as to prevent stress on the plastic bleeder. You can use the bolt with stud that is used to fasten the trans to mount.
I hope that helps.
I used these tools.
http://shopping.boraparts.com/product_info.php?products_id=543
And...
http://shopping.boraparts.com/product_info.php?products_id=581
 
Last edited:

robzuk

Veteran Member
Joined
Aug 16, 2004
Location
Md
TDI
1999 Golf, 2001 Golf, 1987 Cabrio
I got my 9mm 12 point at SEARS, it was the only place other than off the Snap On or Matco truck to get one. Most places only carry 6 point and you need a 12 for the clutch/flywheel.
 

EMD_Driver

Veteran Member
Joined
Oct 6, 2011
Location
Ravenel, SC
TDI
2006 Jetta
That's good news Ryan, I'm getting bored over here haha!
I'm not bored, but extremely anxious!

If you get the new Sachs clutch, youll need a 9mm socket for the pressure plate bolts.
I believe the flywheel bolts are 12 point triple square 12mm.


I used these tools.
http://shopping.boraparts.com/product_info.php?products_id=543
And...
http://shopping.boraparts.com/product_info.php?products_id=581
Great info!

I got my 9mm 12 point at SEARS, it was the only place other than off the Snap On or Matco truck to get one. Most places only carry 6 point and you need a 12 for the clutch/flywheel.
I wonder if they also carry the triple square bits... Might have to check them out!
 

EMD_Driver

Veteran Member
Joined
Oct 6, 2011
Location
Ravenel, SC
TDI
2006 Jetta
You should have gotten a link in an email from Ryan.
I didn't get an email from Ryan.....


Edit: Ryan did tell me he was missing some of the parts I need and had to order them from VW.. Maybe he did not get the parts yet.
 
Last edited:

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
FYI the clutches and flywheels are different between the 5 & 6 speeds.
 

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 didn't get an email from Ryan.....


Edit: Ryan did tell me he was missing some of the parts I need and had to order them from VW.. Maybe he did not get the parts yet.
The bolt kits arrived incomplete, AGAIN!, tracking will be sent ASAP!!! really sorry for the delays but i was caught off guard when 5 conversions sold in 2 days whilst in the middle of our move!!!!

Normal rapid servce will resume soon i promise!!

Speak soon

Ry
 
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