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

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Zedbra

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Feb 26, 2006
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Squamish, BC
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2005 Jetta TDI
My Triptragic is starting to slip and miss - the light at the end of the tunnel is getting closer by the day. Looks like you may be shipping to Canada very soon, Ryan. I am uncertain how to pick the right gearing from the front page, however.
 

ryanp

Vendor
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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 ........
Oh dear, at least you have options to upgrade!!

if you get to cruise above 70-75mph the DRW will be a nice transmission! I have lots of all subcodes in stock!!

Thanks!

Ryan
 

boertje

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Ryan, I took my bug out on the highway the other day and had a fellow pass me buy going 90mph. That was a nice rabbit for me to follow and so I did. I followed him for 120 miles in the high desert. Engine is only turning like 2600-2700 rpm at that speed with the ERF trans. it was fun! And I still got 48 mpg.
 

ryanp

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Barnsley, South Yorkshire, UK
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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 ........
Nice, you get banned over here for that!! These are good for high speed economy, where is the fun at 60mph?? haha
 

Automaticmack

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Location
Toledo
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04' Jetta Wagon TDI
04 TDI Wagon, Thanks for the upgrade!

Ryan, You guys rock! This trans swap was a simple much needed upgrade. I should have done this sooner. I have a Mk5 GTI however I would rather drive the old oil burner everyday especially cruising down the highway. Comparing the two trans on the floor was quite an eye opener seeing how much better built the ERF is.:) And as a side benefit I sold the 5 speed no sooner than I got it out of the car.

Thanks!:)
 

boertje

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Ryan, You guys rock! This trans swap was a simple much needed upgrade. I should have done this sooner. I have a Mk5 GTI however I would rather drive the old oil burner everyday especially cruising down the highway. Comparing the two trans on the floor was quite an eye opener seeing how much better built the ERF is.:) And as a side benefit I sold the 5 speed no sooner than I got it out of the car.

Thanks!:)
Absolutely right! Glad you are happy with it. I know I am. Just wish I had more TDIs to swap. Gotta keep Ryan and Scott busy you know.

Now, I have a dumb question. Why would one retrofit their 5 speed transmission into a 6 speed when they can just get the real McCoy 02M with new clutch for the same money after one sells their 5 speed. For me, the 02M over the retro 5 speed is a no brainer. I still have one 5 speed car left that my daughter drives and if the need arises for that extra gear, I would most certainly get the kit from ryan, sell the 5 speed and still be perhaps a few bux ahead.
 
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JettaTDI

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Feb 21, 2008
Location
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02
Ryan - just sent you a pmt for the complete auto kit, with the new Sachs clutch & flywheel.

Just a quick update, I got the 6-speed installed (local VW shop did it)

Drives sooo much better than my ailing automatic. Feels strong in all gears including 6th. Keep in mind, my TDI is all stock & 230,000 miles.
Only issue I had was the little clutch switch on the new clutch pedal. (Cruise control wouldn't engage). Got another for free - all is good.

Great upgrade, highly recommend this mod, especially if your auto is acting up.

:D
 

clyde

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confluence, Snake/Clearwater
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1998 Jetta, 1959 DeSoto with leopard-skin seat covers
Now, I have a dumb question. Why would one retrofit their 5 speed transmission into a 6 speed when they can just get the real McCoy 02M with new clutch for the same money after one sells their 5 speed.
Is the 02M trans compatible with the Mk3?

If not, are any VW six-speed transmissions direct bolt-ins to the Mk3 TDI?

Suuurely would like to have six speeds…
 

boertje

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Is the 02M trans compatible with the Mk3?

If not, are any VW six-speed transmissions direct bolt-ins to the Mk3 TDI?

Suuurely would like to have six speeds…
That is probably a very good reason for a 5 speed retro then. Ryan can much better answer this question.
 

ryanp

Vendor
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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 6 speeds available that fit in the Mk3, the 02S but these have about the same overall top speed as the longest 5 speed from the Mk3 platform (ASD/CTN)

I have both of those 5 speeds in stock and could try to get a conversion together if required!
 

ryanp

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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 ........
Lots of boxes in stock!!
 

Votblindub

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NY
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MK4 Jetta Wagon
Ryan, what sort of MPG increases are people reporting by going to the 6 speed trans? I'm curious to to find out at least a ball park of what it is. I'm not somebody who is hardcore into hypermiling, but i'm just cruious. You can see my jetta mpg in my sig, but I think its low, it's an automatic. I obviously dont expect it to double or anything like that, i'm a realist.
 

boertje

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Ryan, what sort of MPG increases are people reporting by going to the 6 speed trans? I'm curious to to find out at least a ball park of what it is. I'm not somebody who is hardcore into hypermiling, but i'm just cruious. You can see my jetta mpg in my sig, but I think its low, it's an automatic. I obviously dont expect it to double or anything like that, i'm a realist.
I realized a 6-8 mpg increase over automatic on both my golf and jetta.
 

Votblindub

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MK4 Jetta Wagon
I realized a 6-8 mpg increase over automatic on both my golf and jetta.
That's excellent. I'd love to get 55mpg. It's a good savings over the course of even 6 months. Are your cars stock otherwise?
 

ryanp

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Location
Barnsley, South Yorkshire, UK
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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 ........
Answered without touching my keyboard and whilst in bed! :D

Jack has various mods on hin numerous TDIs,but you should see good gains regardless of mods. I would recommend a nice tune though to get that little bit more from the car.

Thanks

Ryan
 

Votblindub

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NY
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Answered without touching my keyboard and whilst in bed! :D

Jack has various mods on hin numerous TDIs,but you should see good gains regardless of mods. I would recommend a nice tune though to get that little bit more from the car.

Thanks

Ryan
I'm thinking Kerma or Malone, so far. I dont want anything aggressive, it's not a race car by any means, it's a daily driven car. I love how APR software changed my A6's feel and I'm looking for similar things from software on the Jetta. Any recommendations?
 

boertje

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My cars are all running stock turbos. All my ALH cars with 6 speeds run Malone stage 2 tunes and nozzles ranging between the T4 to the PP764.
 

ryanp

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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 ........
And again, haha. Thanks Jack.

Any of the reputable tuners in the USA will do a good job for you.

Thanks

Ry
 
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