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Old January 7th, 2013, 03:54   #1
ryanp
 
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Default RYAN P's 6 speed 02M Conversions and ALL Euro TDI Parts

UPDATE FOR Christmas 2017 - CONVERSIONS ARE IN STOCK AS ALWAYS + LOTS of EURO 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 have sold over 400 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).

The kits can be purchased directly here - https://www.darksidedevelopments.co....rsion-kit.html



5 Speed Manual to 6 Speed Parts list:

02M 6 Speed Gearbox
2 x Drive Shafts
NO Flywheel and Clutch Kit - Options below
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.



Or a Budget Single Mass Flywheel (SMF) Setup for 325 Extra:



The Solid Flywheel can give a little chatter at Idle and Low RPMs but these are more than acceptable.

We also offer our own HD Single mass flywheel kit (SMF) at a 50 discount:

http://www.darksidedevelopments.co.u...m-6-speed.html

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 325 GBP extra. All new genuine parts.



FOR THE AUTO TO 6 SPEED SWAP, PLEASE TAKE A LOOK AT THIS FANTASTIC GUIDE BY BOERTJE - Auto to 6 Speed 02M Swap with Wiring Instructions - 5 speed AUTOMATIC customers need to notify me prior to purchase, i need to include a few extra parts.

So to summarise:

5 to 6 Speed Swap - 1250 GBP
New Sachs PD150 Dual Mass Flywheel, Clutch Kit and Releaser - 300 extra
Budget Single Mass Flywheel, Clutch Kit and Releaser - 325 extra
Darkside HD SMF, Clutch Kit and Releaser - 700 extra
6 speed Clutch fluid line - 100 Extra - This is not required but will save bending your stock hose to work on the 6 speed.
Complete Auto - Manual Setup - 350 GBP Extra (comes with the above hose already)
LSD Installation including ARP Bolts, New Diff Bearings and Upgraded forks - 900 GBP extra

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 Wire Transfer, PayPal or Credit Card through my website, WITHOUT ANY FEES!!

The kits can be purchased directly here - https://www.darksidedevelopments.co....rsion-kit.html


Cont'
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02M 6 Speed Conversions + Euro Parts - 6 Speed Setups for A4 + A5 platform,PD150 Intakes, TIP kits, Turbo's, Injectors as well as anything else!! PM Me! - Click HERE

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Old January 7th, 2013, 03:54   #2
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EURO TDI PARTS

I am based in the UK and have contacts throughout Europe so I can get hold of the best Euro parts at the best prices!

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/.


Intakes

All of these intakes will bolt up to all 1.9 PD and VE heads with the same gasket as the stock intake.

PD150 Intakes



PD150 Intake manifold (Bare) - 140 Much better than the stock ALH intake and wont kill your engine like the US PD intakes do when they ingest the butterflies.



Complete PD150 Intake with EGR and Elbow Pipe - 175
Can also be supplied with EGR Cooler for 10 Extra

Passat RHS / Driver side PD Intake



Passat RHS PD intakes (Bare) - 140 These are required if you want a clean install for a FMIC to cut down on excessive pipework.

SDI ‘Snail’ Intake

These are the best inlet I’ve come across so far, the runners are over a foot long and it has a large plenum and fits in a very compact space.



With Genuine VW 'RacePipe' (2.5"), Genuine VW EGR Blank and Plugged Breather Hole. READY TO FIT - 175


PD150 TIP Kit’s



They come complete with everything you need to fit them - 120

For an extra 70 when purchased with a TIP Kit I can supply a R32 DSG Snorkel Kit (a small mod to the Air box bottom is needed for the MUCH larger snorkel)


If you want a complete OEM setup the R32 air box kit (including new filter element, the Air box Bottom is NOT available on itself) can be purchased for an extra 100 on top of the snorkle price - The R32 Airbox and Snorkle are 170 combined



This will need to be used with a R32 MAF housing, the PD150 accordion hose will slip over the MAF with a little persuasion to make the largest OEM Intake setup. I can supply a new R32 DSG MAF sensor for 125



If you already purchased a TIP kit shipping will be 50 for the above 2 items together due to the size of the box!


PD150 GT1749VB Turbo Also known as the VNT-17




New - 580 Shipped
Used - 475 Shipped

VNT-17s are shipped with either the Red Outlet Pipe or Modified to fit the ALH / BEW Directly (welded outlet)

cont...
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Last edited by ryanp; October 24th, 2015 at 02:48.
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Old January 7th, 2013, 03:59   #3
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ALH Non A/C alternator, PAS and injection Pump bracket



This is required to remoce the AC entirely on your ALH engine - 130 shipped
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Last edited by ryanp; August 22nd, 2017 at 09:17.
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Old January 7th, 2013, 03:59   #4
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A5 Golf / Jetta Mk5 02Q 6 Speed Tranny Conversions




I keep getting asked for a long ratio 6 Speed Setup for the A5 Golf. I've sold a few of these without advertisement so far, now it's time to actually make a topic about them!

These come with all the items you see in the picture. This is everything you need to upgrade from a 5 Speed Manual to the 6 Speed.

5 to 6 Speed Parts list:

02Q 6 Speed Gearbox
2 x Drive Shafts
Used Dual Mass Flywheel and Complete Clutch Kit
Gearbox Mount (bolted to box)
Dog Bone Mount
Starter Motor
Dust Tins between Engine/box
Linkage Cables
Cable Mount and End Links
6 speed Gearknob and boot
All bolts required including New where needed

The price for the complete conversion is 1300 GBP. I include ALL the bolts required for the conversion, including new bolts where the original are single use only.

I can include BRAND NEW VW/SACHS DUAL MASS FLYWHEEL, CLUTCH KIT and RELEASE BEARING for 325 GBP Extra

Or a Budget Single Mass Flywheel (SMF) Setup with 50 discount:

http://www.darksidedevelopments.co.u...h-kit-smf.html

The Solid Flywheel can give a little chatter at Idle and Low RPMs but these are more than acceptable.

We also offer our own HD Single mass flywheel kit (SMF) with a 75 discount:

http://www.darksidedevelopments.co.u...q-6-speed.html

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 or PayPal.


There are 2 main groups of subcode with the same ratios (there are 4 groups in total, but the other 2 have almost the same ratios as the 5 speed so I have left them out).

They are all based on the 02Q 6 Speed Box, which is an uprated version of the 02M found in the A4 Golfs. The difference being the lack of a speed sensor and strengthening to the casing on the 02Q.


02Q 6 Speed Group 1

1st 3.769 - 2nd 2.087 - 3rd 1.324 - 4th 0.919 - 5th 0.902 - 6th 0.757 - Rev 1.643 - FD1 3.684 - FD2 2.917

02Q 6 Speed Group 2

1st 3.769 - 2nd 2.087 - 3rd 1.324 - 4th 0.977 - 5th 0.975 - 6th 0.814 - Rev 1.643 - FD1 3.45 - FD2 2.76

The 02Q Uses 2 final drives. FD1 for 1st - 4th, FD2 for 5th & 6th.

02J 5 Speed - GQQ, JCR - For comparison

1st 3.778 - 2nd 2.063 - 3rd 1.348 - 4th 0.967 - 5th 0.744 FD 3.389


With the Group 1 ratios, you are looking at about 100mph in 6th @ 3000RPM with 205/55/R16 Tyres. The Group 2 would be @ 98MPH.
This compares to 88MPH in 5th on the 5 Speed, a very nice increase!

To put it another way, at 75MPH the BRM 5 Speed is @ 2555RPM, whereas the 6 speed is @ 2237RPM (318RPM Decrease), with 205/55/R16 Tyres.

Here is a topic from a while ago discussing the A5 conversion:
http://forums.tdiclub.com/showthread.php?t=302432

cont'
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02M 6 Speed Conversions + Euro Parts - 6 Speed Setups for A4 + A5 platform,PD150 Intakes, TIP kits, Turbo's, Injectors as well as anything else!! PM Me! - Click HERE

Last edited by ryanp; August 22nd, 2017 at 09:18.
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Old January 7th, 2013, 04:09   #5
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BRM 1.9 TDI 8v 200bhp Top mount Turbo Upgrade

The Turbo is a direct replacement for the stock BRM Unit and is capable of 200bhp when fitted along with a set of PD150 Injectors and a custom Tune.



http://www.darksidedevelopments.co.uk/products/vw-caddy-1-9-tdi-8v-pd105-bls-brm-200bhp-turbo-upgrade.html

This will be a bolt on upgrade for you guys with the BRM engines, I've fitted a few of these to Caddy Vans with the BLS engine (our BRM basically) and they work a treat, one customer claimed 190WHP but i've not seen the dyno printout

We can do a good deal along with some PD150 injectors
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Last edited by ryanp; January 25th, 2013 at 01:54.
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Old January 7th, 2013, 04:10   #6
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TDI Braided Oil Feed

These are a direct fit on just about any Turbocharger on the 1.9 TDI Engines (VE and PD). These are reusable and easy to remove still fitted to the turbocharger.


50 inc Shipping with Royal Mail

3 BAR MAPs

Brand NEW, GENUINE VW 3 BAR Map Sensors. Ideal upgrade from the standard 2.5 BAR MAP sensor, as the standard 2.5 BAR will not read any more than 1.5 BAR (Relative). Obviously your car would be mapped to take into account the new sensor.
VW Part Number - - - 038 906 051 C (038906051 C) (038906051C)
Bosch Part Number - - - 0 281 002 401 (0281 002 401) (0281002401)

25 if shipped with another purchase, 32 Shipped by itself, to the USA and Canada (Will Post Worldwide)
These are the small probe MAP sensors, so would require a rubber spacer if fitting in the place of the early, large probe sensor. These are 2 extra.


4 BAR MAPs

Brand NEW, GENUINE VW 4 BAR MAP Sensors. Ideal upgrade from the standard 2.5 or 3 BAR MAP sensor, as the standard 2.5 BAR will not read any more than 1.5 BAR (Relative). Obviously your car would be mapped to take into account the new sensor.
VW Part Number - - - 03K 906 051 (03K906051)
Bosch Part Number - - - 0 281 006 060 (0281 006 060) (0281006060)


These are 50 Posted on their own, or 40 with another order.

GTB Turbochargers

These are probably the Ultimate Street Turbo for the 1.9 TDIs.

The GTB2260VK, GTB2056VK and GTB1756VK are more or less identical visually, and will all interchange. So, for example, you could upgrade from a GTB1756VK to a GTB2260VK just by changing the Turbo.


I have New, Reconditioned and Used GTB2260VK and GTB1756VKs IN STOCK and Ready to go. All can be converted to Vacuum with OEM Parts, looks like a factory installation. GTB2056VK turbos are almost impossible to source BUT I have one in stock, once it's gone I don’t know when I'll get another.

A new GTB2260VK inc Vacuum Conversion is 935 GBP Shipped


GTB Turbo Kits

We also produce several turbo kits for the TDI Engines, the most popular being our 1.9 8v Kit -



We also have a kit for the 2.0 16v Common Rail Engines:



GTB Turbo Flange Adapter

Fits ALL VW Passat / Audi A4 / A6 and Skoda Superb Vehicles with the 1.9 and 2.0 TDI Engines

This kit consists of:

Darkside Developments Waterjet Cut GTB Turbo Flange
4 x Allen Cap Head Bolts
2 x Countersunk Allen Head Bolts

This flange adapter bolts directly on to your existing Exhaust Manifold to allow the fitment of the Garrett GTB Series Turbochargers (GTB2265VK Hybrid, GTB2260VK, GTB2056VK and GTB1756VK) to your VW Passat, Audi A4, Audi A6 and Skoda Superb. These turbos are tried and tested on the VW Group TDI Engines and have been proven for reliability and power far above any Hybrid turbo.

Please see below for more photos of this flange fitted to a manifold and vehicle.

This flange will require your existing Exhaust Manifold to be post matched to get the best gas flow. This can be done very easily with a Dremmel or Die Grinder.

These are 48 inc Shipping Worldwide.

We can also supply GTB Turbochargers, Downpipe Flanges, Port Matched Manifolds, Oil Feed Lines, Vacuum Actuator Conversions and other parts required for this conversion. Please PM me for details



These are IN STOCK and Ready to Dispatch.


MADE IN THE UK

Please note - this adapter will NOT fit in transverse mounted engine bays, such as the VW Golf and Audi A3.


Fitted to a Passat/A4 1.9 8v AWX Manifold (Manifold available seperately for 100)




Fitted to an Audi A4 1.9 8v AWX Exhaust Manifold with a GTB2260VK Turbocharger and Darkside Developments Oil Feed Line (Turbo, Downpipe Flange, Manifold and Oil Feed Line available seperately)



http://www.darksidedevelopments.co.u...d-2-0-tdi.html

Most of our range of TDI Parts are listed on our website - http://www.darksidedevelopments.co.uk/

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).

Delivery times with DHL Express are normally 24-48hrs across the US, Canada are 48hrs but can be a little longer due to Customs.
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02M 6 Speed Conversions + Euro Parts - 6 Speed Setups for A4 + A5 platform,PD150 Intakes, TIP kits, Turbo's, Injectors as well as anything else!! PM Me! - Click HERE

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Old January 7th, 2013, 04:10   #7
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Place marker
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Old January 7th, 2013, 04:12   #8
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Clutch Upgrades

02A / 02J 5 Speed Upgrade
Fits ALL VW / Audi / Seat and Skoda 4 Cyl 5 Speed 02J & 02A Vehicles

This kit consists of:
Darkside G60 Single Mass Flywheel (10Kg)
Darkside / Sachs 228mm Clutch Disc
Darkside / Sachs Pressure Plate
Release Bearing
Flywheel and Pressure Plate Bolts
Alignment Tool

The Solid Flywheel Kits are a popular conversion on the 1.9 TDI Engines to remove the OEM Dual Mass Flywheel when running increased power.
The Clutch Kit is rated to 300Ft/Lbs with a stock pedal feel and bite
This Clutch kit is vibration, judder and chatter free, unlike other kits on the market

http://www.darksidedevelopments.co.u...d-02j-02a.html
341 Shipped for the complete kit

Mk5 Platform 02J-B 5 Speed / 02S 6 Speed Upgrade
Fits ALL VW / Audi / Seat and Skoda 1.9 TDI 5 Speed 02J-B & 6 Speed 02S Vehicles

This kit consists of:
Darkside 02J-B Single Mass Flywheel (10Kg)
Darkside / Sachs 228mm Clutch Disc
Darkside / Sachs Pressure Plate
Release Bearing
Flywheel and Pressure Plate Bolts
Alignment Tool

The Solid Flywheel Kits are a popular conversion on the 1.9 TDI Engines to remove the OEM Dual Mass Flywheel when running increased power.
The Clutch Kit is rated to 300Ft/Lbs with a stock pedal feel and bite
This Clutch kit is vibration, judder and chatter free, unlike other kits on the market

http://www.darksidedevelopments.co.u...-platform.html
371 inc Shipping for the complete kit

Darkside Single Mass Flywheel (SMF) & Clutch Kit for VW 02M 6 Speed
its ALL VW / Audi / Seat and Skoda 4 Cyl 6 Speed 02M Vehicles

This kit consists of:
Darkside 240mm Single Mass Flywheel
SACHS SRE 240mm Organic Clutch Disc
SACHS SRE Upgraded Pressure Plate
Release Bearing
Flywheel and Pressure Plate Bolts
Alignment Tool

The Organic Disc will give a stock like bite, with a heavier pedal feel due to the upgraded Pressure Plate. This makes it a good Daily use setup as well as occasional Track use
The Sintered disc is only recommended for use on a Fast Road, Race or Track car due to the increased grab caused by the sintered facings, as this makes driving in traffic more difficult and increases wear rate
Both kits are easily rebuilt when the Clutch Facings are worn out, meaning you will not require a new Flywheel or Pressure Plate. The expected life is 50 - 60K Miles for the Organic Kit, and 20 - 30k for the Sintered Kit


http://www.darksidedevelopments.co.u...m-6-speed.html
800 inc Shipping for the complete kit

Darkside Single Mass Flywheel (SMF) & Clutch Kit for VW 02Q 6 Speed
its ALL VW / Audi / Seat and Skoda 4 Cyl 6 Speed 02Q Vehicles

This kit consists of:
Darkside 240mm Single Mass Flywheel
SACHS SRE 240mm Organic Clutch Disc
SACHS SRE Upgraded Pressure Plate
Release Bearing
Flywheel and Pressure Plate Bolts
Alignment Tool

The Organic Disc will give a stock like bite, with a heavier pedal feel due to the upgraded Pressure Plate. This makes it a good Daily use setup as well as occasional Track use
The Sintered disc is only recommended for use on a Fast Road, Race or Track car due to the increased grab caused by the sintered facings, as this makes driving in traffic more difficult and increases wear rate
Both kits are easily rebuilt when the Clutch Facings are worn out, meaning you will not require a new Flywheel or Pressure Plate. The expected life is 50 - 60K Miles for the Organic Kit, and 20 - 30k for the Sintered Kit


http://www.darksidedevelopments.co.u...q-6-speed.html
800 inc Shipping for the complete kit

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 or PayPal

Last edited by ryanp; November 11th, 2014 at 03:35.
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Old January 7th, 2013, 04:23   #9
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We are always parting out complete Euro cars and have lots of VE and PD engines + Parts in stock, Just ask!!
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Last edited by ryanp; January 25th, 2013 at 04:19.
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Old January 7th, 2013, 04:32   #10
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We also offer a Nozzle Fitting Service, as well as a core exchange sysytem, so you will not be left without Injectors for any time
http://www.darksidedevelopments.co.u...l-service.html



PD150 Injectors


Latest Prices here - http://www.darksidedevelopments.co.u...30-073-al.html
These are a perfect upgrade to take the PD100 BEW and BRM to the next stage!

Race PD Injector Upgrades



For those who the 230bhp from PD150 Injectors is just not enough, we stock Firad +80% and +120% Nozzles.
These are Recondition Bodies fitted with NEW Genuine Firad Nozzles and are sold in sets of 4
With the Firad +80%s there is enough fuel for 320bhp and +120%s will do 350bhp+

The Race PD injectors are fully reconditioned and fitted with larger Uprated Nozzles. All wear items are replaced and new seals fitted (these can cost 25 per injector on their own). Digital calibration is then carried out to the most extreme accuracy meaning these injectors will drive like stock with regards to smoke and economy

The various options are listed here:
http://www.darksidedevelopments.co.u...80-or-120.html

1.9 TDI PD Injector Harness




Genuine VW Injector Loom to fit all 1.9 TDI PD Engines.

It is recommended these are replaced at the same time as the Injectors. The wires can also perish and cause erratic running issues.
http://www.darksidedevelopments.co.u...d-engines.html

65 Shipped

1.9 TDI PD Tandem Fuel / Vacuum Pump




Brand New Pierburg (VW Supplier) Units with a 2 Year Warranty

http://www.darksidedevelopments.co.u...h-k-m-n-q.html

260 Shipped

1.9 & 2.0 8v TDI PD Injector Seal Kits

Genuine Bosch Complete Injector Seal kit for the 1.9 and 2.0 8v TDI PD Engines




Listed here - http://www.darksidedevelopments.co.u...d-engines.html
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Old January 7th, 2013, 05:44   #11
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2013 Turbo Clearout - Random turbo's going Cheap!!!!

Questions about fitment wont be answered, these are being sold as we dont have time to make any 'kits' to fit them!! We can weld in shorter Actuator levers if required.

We only have what is listed here!!!!!!!!!

http://www.darksidedevelopments.co.uk/clearance/
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Old January 7th, 2013, 05:45   #12
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US Spec Parts

Upgraded Side Mount Intercooler Kit for 1.9 TDI PD130 ASZ and US Spec BEW PD100 Engine
Fits ALL Mk4 Platform VW / Audi / Seat and Skoda Vehicles with the 1.9 TDi PD130 ASZ / PD100 BEW Engine
The Intercooler replaces the stock plastic intercooler and eliminates the clip connectors that can cause boost leaks. The end tanks of the Intercooler are also Alloy so will also hold a higher level of boost

http://www.darksidedevelopments.co.u...00-engine.html
300 Shipped for the complete kit

Hard Pipework Kit for 1.6 / 2.0 TDi Common Rail Engines
This Intercooler Kit replaces the standard rubber and plastic hoses with the clip connectors that can cause boost leaks. The Alloy Pipe Kit eliminates most of these problematic connectors
There are a number of different options available with this kit, dependent on your Turbo and Intercooler setup. Please select the options in the listing to get the final price for your kit.

Price (dependant on options) - http://www.darksidedevelopments.co.u...l-engines.html

2.0 16v Common Rail 140bhp CJAA CBEA 200hp Turbo Upgrade
This is a plug and play, bolt on turbo upgrade for the US Spec 2.0 16v TDi CR140 CJAA and CBEA Engines. This turbo is capable of 195 - 205hp Smoke free
A Custom Remap will be required immediately after fitting. We also strongly recommend deleting the DPF at the same time as tuning.
2009 Jetta TDI and 2009 Sportwagen
Vehicles made before July 2009 require a Turbo Outlet Dampener
The outlet on this replacement turbo is not compatible with the outlet dampener fitted to vehicles made before July 2009


Price (dependant on options) - http://www.darksidedevelopments.co.u...o-upgrade.html

Hard Pipework Kit for 1.9 8v TDi BLS / BRM PD105 and BMM PD140 Engine
This Intercooler Kit replaces the standard rubber and plastic hoses with the clip connectors that can cause boost leaks. The Alloy Pipe Kit eliminates most of these problematic connectors
There are a number of different options available with this kit, dependent on your Turbo and Intercooler setup. Please select the options in the listing to get the final price for your kit.

Price (dependant on options) - http://www.darksidedevelopments.co.u...40-engine.html
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Old January 7th, 2013, 05:45   #13
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