6 speed conversion kit

rwthomas1 said:

So I have to ask, can the 6 speed conversion be done with the transmission still in the car? Thanks, RT

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YES! See post 96 in this thread for the installation in my car with the transmission in place.

skyking1 said:

I was looking at the charts and now realize that my stock tire size is not 185 cm circumference, it is about 195 CM.
I wish they had a .62 gear

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The tire size you select can have more difference than a .62 or .59 Sixth gear ratio.

My stock tire size is 195/60 x 14 with a 23.2 inch diameter. I went with 185/70 x 14 tires which had a 24 inch diameter. From there I have gone to 195/60 x 15, also a 24 inch diameter. Now looking at 195/65 x 15 with a near 25 inch diameter. That is a change of 7.75% from the 195/60 x 14 factory tires.

the stock tire size in the beetle is 205/55r16, and 24.9" diameter. I can't really do much bigger.
I keep putting all the numbers in and I am sure the .65 final gear, or a 3.16 R&P gear set is what I need.

I need to remove my transmission for a clutch. Trying to get it done this weekend. Is there anyway if I ordered the kit tomorrow i'd have it by friday?

Are there any shops in the bay area familiar with this install?

Delivery time

kuleinc said:

I need to remove my transmission for a clutch. Trying to get it done this weekend. Is there anyway if I ordered the kit tomorrow i'd have it by friday?
Are there any shops in the bay area familiar with this install?

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We have kits in stock, consignments are sent in 2 weeks after ordering, shipping time to USA, Canada takes about 5-8 days...

Really, Really, Really want one of these kits for my GTDI...

GTiTDi said:

Really, Really, Really want one of these kits for my GTDI...

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Just do it!! It is worth it.

If I was in possession of an 02J or another 02A in a car I planned to keep, I would get another of these kits over an 02M or 02Q - cheaper, easier to install. Mine has 100k km with no issues.

my GTI already does 140+ with the stock CTN..wondering how much trouble this kit will get me in I really really really don't need it my insurance is through the roof..GTI might have to become a track car and get myself into a vanagon with an N/A IDI

Love my 6th gear.

Anyone know if a shop in the California east bay area that does these installs?

kuleinc said:

Anyone know if a shop in the California east bay area that does these installs?

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Good news

Matt-98AHU did the first install in the U.S. for me. And Matt has moved to the Bay Area. He did mine without removing the transmission!

The BAD news is Matt is still snowed under from his move and the new job. So not doing any side work right now.

See this post: http://forums.tdiclub.com/showthread.php?t=297973

Anywhere else?

I think there are maybe a dozen or so of these installed in North America - I'm happy with my kit.

The install is not all that difficult- any tranny shop could do it.

kuleinc said:

Anywhere else?

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I might be persuaded to do it... depends on timeframe. I still need to contact the 20 or so people who need work done at the GTG next month...

I still need to buy a kit, install my injectors, and get my car malone tuned. THEN if it has tons of power in 5th, I'll prolly do the conversion. I ll try to keep you in mind franken car.

My 96 Passat TDI wagon is stock except a stage 2 chip. Love my 6th gear.

I was looking at the pay back time for this and this is what I came up with.

$1000 cost of 6th gear /$4 / gallon of gas = 250 gallons @ 50mpg – 12,500 miles you could drive on $1000 of diesel at highway speed

12,500 miles / 5 miles per gallon increase with mod assuming a generous 10% increase in fuel mileage = 2,5000 gallons to recoup cost * 55mpg = 137,500 miles of 6th gear driving.

Is my math wrong? If this is the case, and you're just looking at the MPG, then adding a 6th gear is probably a bad economic addition for most.

I find the math is much easier if you use the metric measurements: Litres per 100km

Assume diesel is $1.00/L ($3.79/USgal - which yes, is low, but makes the illustration easier).

And just to use round numbers, we'll assume 5sp. gets me 5.5L/100km, while 6sp. gets me 5.0L/100km (again - close to my numbers).

So, every 100km saves me 0.5L = $.50.

To save $1000, then, it's pretty simple math: $1000/$0.50per100km = 2000 *(100km) = 200,000km = 124,000mi

And as the price goes up, your "payback" time comes down; around Vancouver right now, diesel is around $1.50/L - at that price, the km to save $1000 goes from the 200K in the example above, down to 133K km.

So, yes, your math is correct (you used different base numbers), and yes - it takes a while.

Thing is, though, it's a much nicer driving experience going 75-80mph at 2100 rpm vs 2700rpm; it's not $$$, but it is worth something to me.

It also depends on how much driving you do annually. If you only drive 15,000km it will obviously take a longer time to recoup the cos compared to someone who drives 50-60,000km annually

6th Gear Kit

Hey, I have a 2009 Jetta TDI. I was wondering if there are any steeper 6th gear kits? I know this was possible with the MK4 But would this be possible with my transmission. (6-Speed)

Fahrspaß TDI said:

Hey, I have a 2009 Jetta TDI. I was wondering if there are any steeper 6th gear kits? I know this was possible with the MK4 But would this be possible with my transmission. (6-Speed)

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The '09 and '10 model had slightly taller gearing if I'm not mistaken... You're only upgrade would be from a '11+ car.

Thanks, you wouldn't happen to know where I can get one?

Fahrspaß TDI said:

Thanks, you wouldn't happen to know where I can get one?

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Nope sorry.

You can do all the math you want. It saves mileage and the biggest gain is when you drop it in to 6th and everything goes mmmmmmmm quieter. I love my 6th gear.

greenie said:

You can do all the math you want. It saves mileage and the biggest gain is when you drop it in to 6th and everything goes mmmmmmmm quieter. I love my 6th gear.

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Yes, the noise reduction is great and you get it right away! The math tells me the long 5th gear conversion (.622) gets me about the same highway fuel savings and the noise reduction for less money. I ran that combination for about 15 months, so I know from experience.

BUT with the 6 speed conversion, all your gear ratios just work great together. There is no "gap" or unnatural jump from one gear to the next. No running in 4th gear at 45/50 because the .622 5th is too long. I can climb from floor of California's Central Valley over the Tejon Pass at 70/75 mph with the a/c running in 6th. That is from 400 ft to 4160 ft. In heavy traffic you drop to 5th gear at 55/60 mph.

If are looking for a cheap car to operate, you can do better than a VW diesel. Look at a Mazda3 or a Honda Fit for lifetime costs. No terrible dealer service reputations there. No expensive DSG transmission service - just lower costs and much better resale value.

The 6 speed conversion is just the best modification I have done to this old B4V. Don't spend your money on the long 5th gear mod. Go directly to the 6 speed conversion and enjoy.

john.jackson9213 said:

Don't spend your money on the long 5th gear mod. Go directly to the 6 speed conversion and enjoy.

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I agree. I'm running a .622 5th and shifting into it is quite unnatural. It's also terrible not having the gear the belongs in the middle. I will be installing a 6-speed as soon as I get the fresh long-block together.

greenie said:

You can do all the math you want. It saves mileage and the biggest gain is when you drop it in to 6th and everything goes mmmmmmmm quieter. I love my 6th gear.

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This is half the reason I am going to try and do this kit by the end of this year.

The other half being a combo of the efficiency gain possible with a daily commute, and having friends from Ohio to Maine to North Carolina, so impromptu long distance highway trips at even lower costs for the B4V would be tempting indeed....

So for $1470 I'll get a complete 6 speed conversion shipped to my door in the US? Any other parts needed?

GTSLOW said:

So for $1470 I'll get a complete 6 speed conversion shipped to my door in the US? Any other parts needed?

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Fluid.

And a clutch if you decide to install with the transmission out of the car (plus a rear main seal?)

If you are installing the kit in the car, all you need is 2L of fluid to replace the fluid lost when the end cover is removed.