6 Speed 02M gearbox conversions

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Scott_DeWitt

Vendor
Joined
Apr 7, 2004
Location
Texas USA
TDI
2000 Audi A4 1.9TDI quattro
I'll add that at peak efficiency diesel engines occur at or near max fuel consumption at least with the 1.9 pd.

Also just because your operating in the max torue rpm does not mean your engine is producing max torque.
 
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dremd

Veteran Member
Joined
May 31, 2007
Location
South Louisiana
TDI
06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW
My DRW is here!!!
Everything looks good can't wait to get to work on it.
 

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 ........
Let me know how the install goes!
 
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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 ........
It would bolt up but even with the shortest ratios you would be doing over 200mph in top gear!! if you have some serious power it might help lower down though.

Ry
 

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 dogbone and engine to trans are the only ones that are 1 use as far as i know.
 
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toadz1

banned
Joined
Mar 4, 2009
Location
CA
TDI
A4
DRW's still available? Or a better not so tall gear ratio choice for a very close to stock 110hp 2002 jetta? check your PM's. Thanks!
 
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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 ........
All PM's replied to!
 

dremd

Veteran Member
Joined
May 31, 2007
Location
South Louisiana
TDI
06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW
Bump for a good seller!
If you have any doubts about sending your hard earned money overseas, shoot me a PM.
 

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 ........
Thanks!

To anyone looking to buy, If you sell your stock 5 speed you will get more than half of your your money back!
 
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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 ........

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 ........
If you dont get it from Xavier drop me a PM!

Cheers

Ryan
 
M

mihaj

Guest
Well guys, first I'd like to thank Ryan for outstanding communication and seamless transaction!!!

I've received my DRW on the second day after it was shipped from UK. I did have to pay $36.00 for customs (there is no way around this one). It came in on the pallet with all parts securely strapped and shrink wrapped.

I did the swap three days ago, so it is still fresh in my memory.
I'd like to share some observations about the install.

My car: 2005 Golf TDI MkIV 5spd PD engine.

1. Two long starter bolts that were included were in fact too short. I ended up using ones from my car.

2. Two bolts on top that mount the trany to the engine... original front one had a threaded stud on the hex head of the bolt and was used to connect heavy return (minus or ground) wire to the engine. As it turns out I needed one more bolt of this kind with longer stud to mount shifter cable bracket.

3. Dog bone mount was the same as the one originally installed on my car.

4. Clutch hydraulic line.... after some moderate bending and routing the original one worked just fine. If you do not want to fiddle with it get the correct one from Ryan.

If you are really thorough, get new:
axel bolts PN: N-909-911-02
axel nuts PN: N-905-876-02
transmission mount bolts (sorry do not have the part numbers)
transmission oil PN: G-052-171-A2 (according to the dealer this is the one for DRW and it takes 2.2 liters, so you will need three cans of that at $29.50 each.)
And finally, inspect and replace if needed the rear crank seal (I did not do it because I did not get the seal beforehand and could not be without the car for two days. So I guess pretty soon I will be taking stuff apart again. )


Other than that it was direct replacement without any surprises.

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 ........
Perfect, Glad you are happy!! it's a shame my suppliers cant save the bolts like i ask :(

When i strip them myself i save every one!
 

X@V

Top Post Dawg
Joined
Dec 13, 2004
Location
Sherbrooke, Qc, Canada
TDI
B7 A4 V6 2.5TDI, MK2 frankentdi 2.0 16V TDI PD
For the oil, I'm using AMSoil 80w90 API-GL4. It's wirking very fine and it costs only about 35$/3L. I used 2.3L into my DRW. 3000 miles later, no trouble.

It's used on my MK3 TDI PD150.

Yes I know, the dogbone seems to be same.
 

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 ........
That's good to know, i did call the dealer before i started selling these kits and they said they were different :( if i get them i'll include them but no need to worry anymore!! Wonder if the Auto mount is the same?
 

alkmisc

Veteran Member
Joined
Apr 3, 2008
Location
VT
TDI
2000 Jetta (6 speed)
The auto dogbone mount has the same part number on the main casting but that may not tell us if the rubber part is the same or different. If someone could figure that out, that'd answer the question. The upper transmission mount is different vs the auto with an extra rib on the 02M mount.

That's good to know, i did call the dealer before i started selling these kits and they said they were different :( if i get them i'll include them but no need to worry anymore!! Wonder if the Auto mount is the same?
 

Jerry Freeman

Veteran Member
Joined
Sep 16, 2009
Location
Connecticut
TDI
2000 Jetta TDI

I'm not sure I understand the relationship between these six speed gear ratios and the ratios of the stock five speed transmissions. From another thread, I find the five speed ratios given as:
Per the Bentley for the 02J 5 Speed EGR Transmission
1st 3.788
2nd 2.118
3rd 1.360
4th 0.971
5th 0.756
If I'm reading your chart correctly, the sixth gear on the six speed transmission is a 0.806 or 0.814 ratio, which is not as tall a gear as the 0.756 fifth gear on the five speed.

What am I missing?

Best wishes,
Jerry
 

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 ........
There are 2 final drives on the 6 speed,. i've not got those figures to hand but you will see a significant drop in RPM's. Compare using the overall 6th gear ratio at the bottom of the conversion chart.

thanks

Ryan
 

Jerry Freeman

Veteran Member
Joined
Sep 16, 2009
Location
Connecticut
TDI
2000 Jetta TDI
I've looked at those numbers. The "overall ratios in top gear" are given as 2.1XX, which I don't know how to compare with numbers like 0.756, 0.806 or .60 (from an example given in the "gear ratio primer" post earlier in this thread).

Best wishes,
Jerry
 

dremd

Veteran Member
Joined
May 31, 2007
Location
South Louisiana
TDI
06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW

dremd

Veteran Member
Joined
May 31, 2007
Location
South Louisiana
TDI
06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW
The G60 will not work with the 6 speed. The 6 speed uses a larger diameter setup.
Ryan sells a PD150 clutch which works very smoothly in my car.

Keep in mind that you can sell your 5 speed for $600~700 (maybe more/ less) depending on miles/ condition.
 

dremd

Veteran Member
Joined
May 31, 2007
Location
South Louisiana
TDI
06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW
Jerry, I used the following values

Tire Width in (mm): 195 (from tire size)
Aspect Ratio: 65 (from tire size)
Rim Diameter in (inch): 15 (from tire size)
Transmission Gear Ratio: .806 (from the 6th gear ratio in the chart at beginning of this thread)
Differential Ratio (final drive): 2.615 (From chart also, Use Final Drive 2 for 5th and 6th and Final drive 1 for others)

More info is available in my ecomodder thread.
 
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