5th gear swap out

TDI4all · August 11th, 2012, 10:55

Has anyone in the northeast Ga. area done a 5th gear swap out? I have the .681 gearset,gasket and trans. fluid but lacking the tools. I had gear pullers at one time, but can not find them. I do have a propane torch. I just hate to invest in tools that will only be used once.

sccaddy · August 12th, 2012, 15:57

You should bring them to the next GTG. There are some guys that could give you a hand and have some advice and tools to lend.

TDI4all · October 7th, 2012, 08:54

5th gear (.681) is installed thanks to the help of a local fellow member. Shifts are really smooth and my cruse control still works great. At 70mph I am at roughly 2100rpm's. I will be taking a 1100 mile trip this coming week and see what it does for the mpg.
For those of you who saw the thread of a "free clutch" with install awhile back in the southeast forum, I am the one that got it. They replaced it with a SMF,pressure plate,clutch. It is rather chattery, so when I replaced the 5th gear and passenger side CV axle I put sound deadener on my dieselgeek skid plate. That seems to help a little. She is back on the road again !!!!!

TDI_G · October 8th, 2012, 06:49

glad you got it all together and sorry I wasn't able to join you during the installation. I tried to get that free clutch too but you beat me to it.

TDI4all · October 12th, 2012, 09:28

So after the trip here is what the mpg looks like.

First top off : all highway mostly using CC = 46.5 mpg @ 70 to 75 mph ( flat land no real inclines )

Next top off: Very spirited driving thru winding roads, mountains running thru gears no CC = 39.5mpg

Last top off: mountains tried using CC ( would disengage on incline and sometimes on decline also noticed that engine did not want to pull in 5th gear around 2000 to 2500 rpms) = 43 mpg @ 70 to 75 mph

I am wondering if the torque band is low at 2000 to 2500 rpm's and that is what was causing the issue with CC ?

I have made this trip in that past ( never using CC) and it would pull thru the mountains with no issue in 5th gear.

rkovacs · October 21st, 2012, 03:27

TDI4all, hopefully your issue with power has been solved after finding that partially disconnected intake hose this weekend. After all the work I have done it seems like I am getting some crazy MPG now. I hit almost 300 miles before the fuel needle moved off full.
Hope you got all your other upgrades done this weekend at the GTG. I will see you soon!

TDI4all · October 21st, 2012, 09:01

rkovacs, that is some really crazy mpg's. I got the ERG Cooler delete done, which was foremost on my mind and the lower intake hose boost leak resolved ,thanks to Bruce. The dieselgeek oil bypass will wait until Jan. GTG in SC.

moterhead · November 1st, 2012, 19:50

Was it worth the gear swap i have a 05 im getting that kind mpg running 80mpg

TDI4all · November 1st, 2012, 21:08

I had some other things wrong, so I have not had a chance to really gauge the MPG's yet. So far it looks good. It has definitely made it quieter in the car driving 70 or more and lower RPM's means less wear on the engine. I did not pay retail for it, so all in all I would say yes.

moterhead · November 2nd, 2012, 05:58

Ok se d me a pm im having a issue with my car wonding if u have the same issue seem pretty common in pds