MK4 TDI 5 Speed - 6 Speed Swap

[Moses Buckwalter]

Hello! I have purchased a 6 Speed transmission from Europe and I'm looking to do a swap on my 02 ALH TDI Golf. I've done a lot of scouring the internet, and the guides all seem to be a bit inconsistent and inconclusive so I'm hoping to get some responses from people who have done this swap. My current parts list is as follows

6 speed O2M EFF
6 Speed Starter
6 Speed Shifter Bracket and Transmission Bracket
6 Speed Engine Mount
6 Speed O2M Sachs DMF and Clutch Kit

Clutch Line - heard the 5 speed one could be bent, but I'm going to just purchase a new one
T Bleeder
Shifter ends x 2 - this is what I'm confused about, I was told the linkage is fine to use from the 5 to 6 speed, but not the ends, however all the parts websites show the ends as compatible between all MK4 models.
Full Bolt Kit
Dust Tin - Multiple people have said this is different, but the guy I purchased the transmission from assured me it's the same between the O2J and the O2M
Axles - Will be purchasing a used set, although I hear that only the driver's side one is different between the 2.

I've also heard that some of the hubs are different for different axles, but it seems that the only axles that wouldn't work are R32/AWD TT ones?

I've also heard that the power steering line need's some bending to work, but that it can work. Does anyone have a link for the correct one, should I want to do that, or have any insight on if doing that is worth it?

Is there anything I'm missing here? Hoping to have everything ordered so I don't run into any snags along the way! Thanks!

 

[P2B]

If I were doing an ALH 6 speed swap today would use an O2S from a 2019+ Golf or Jetta w/1.4T gas engine since it's more or less bolt in with no euro specific parts required.

02S 6 speed conversion into 02J case

Hi, I am looking into swapping the factory-installed SMF in my mk7 Golf 1.6 TDI DDYA engine, RTD MQ250 (0A4) 5-speed transmission with a DMF from the mk7 Golf with the same engine, but 6-speed manual gearbox (02S) (there is none for my model). Reading all over the internet about this...

forums.tdiclub.com

This thread lists the parts required for an O2M swap (but not the part numbers). I bought a couple of conversion kits from @ryanp 10 years ago, they were complete

Ryan P's 02M 6 Speed Tranny Conversions - £1100 inc SHIPPING!!

Ryan P's 02M 6 Speed Tranny Conversions Hi, I have sold over 100 of these 6 Speed conversions now, so there are a lot of very happy people cruising on the freeway in 6th! These come with all the items you see in the picture. It is everything you need to upgrade from a 5 Speed Manual to...

forums.tdiclub.com

Part numbers are listed here, but the list also includes stuff you only need for an O1M auto to O2M swap.

Auto to 6 Speed Swap

I just finished an auto 01M to 6 speed 02M DRW swap with no extra pieces left over. It's not the first but probably one of the few. It can be done by one person if you have the time and patience. A few tips for any manual swap: - Wear eye protection - all sorts of stuff falls on you under the...

forums.tdiclub.com

 

[boertje]

I’ve done a number of 5 to 6 speed swaps. 5 speed 02j axles are not interchangeable with the 02m trans.
There is a howto in my sig with a much more updated parts list.

 

[Moses Buckwalter]

I’ve done a number of 5 to 6 speed swaps. 5 speed 02j axles are not interchangeable with the 02m trans.
There is a howto in my sig with a much more updated parts list.

Hey there! I’ve seen your Auto to 6 speed swap guide, nice work!

Can you answer my question about dust tin and shifter ends?

Shifter ends x 2 - this is what I'm confused about, I was told the linkage is fine to use from the 5 to 6 speed, but not the ends, however all the parts websites show the ends as compatible between all MK4 models.

Dust Tin - Multiple people have said this is different, but the guy I purchased the transmission from assured me it's the same between the O2J and the O2M

Also I’m planning on getting a full set of axles, but is it incorrect that the passenger side axle is the same on both 02J and 02M vehicles?


Edit: and given that you've done some 5 to 6 speed swaps. Can you confirm that the dogbone mounts are the same?

 

[Moses Buckwalter]

If I were doing an ALH 6 speed swap today would use an O2S from a 2019+ Golf or Jetta w/1.4T gas engine since it's more or less bolt in with no euro specific parts required.

Wow! It would have been great to know about this option before I ordered a 6 speed and accompanying starter and mounts from Europe haha!

 

[P2B]

Can you answer my question about dust tin and shifter ends?

Dust tin is different, shifter ends were the same on the 03 conversions I've done.

Also I’m planning on getting a full set of axles, but is it incorrect that the passenger side axle is the same on both 02J and 02M vehicles?

Both axles are different

Can you confirm that the dogbone mounts are the same?

They are not.

 

[ghohouston]

Wow! It would have been great to know about this option before I ordered a 6 speed and accompanying starter and mounts from Europe haha!

That stuff would probably sell easy here, if you decide to change course and run an 02s. I've put about 2k miles on my swap so far and really like it. Doesn't cost anywhere near what you're trying to do, and it's essentially plug and play.

 

[boertje]

Hey there! I’ve seen your Auto to 6 speed swap guide, nice work!

Can you answer my question about dust tin and shifter ends?





Also I’m planning on getting a full set of axles, but is it incorrect that the passenger side axle is the same on both 02J and 02M vehicles?


Edit: and given that you've done some 5 to 6 speed swaps. Can you confirm that the dogbone mounts are the same?

What P2B says is accurate however i’ve always used the same dog bone whether from auto or 5 speed and not had any issues.

 

[Moses Buckwalter]

What P2B says is accurate however i’ve always used the same dog bone whether from auto or 5 speed and not had any issues.

Good to hear, thank you! Do you have any experience with using the 5 speed dust tin? Frans from Dutch Auto Parts assured me that they were the same...

 

[boertje]

Good to hear, thank you! Do you have any experience with using the 5 speed dust tin? Frans from Dutch Auto Parts assured me that they were the same...

I have not. I used the 6 speed tin that was sent with the 6 speed kit.

 

[P2B]

Do you have any experience with using the 5 speed dust tin?

Maybe. The other day I noticed a dust tin labelled 'P2B' in my parts shed, which probably means it came from a 6-speed kit group buy years ago and wasn't used - so I may have reused the 5-speed dust tin

 

[Moses Buckwalter]

Maybe. The other day I noticed a dust tin labelled 'P2B' in my parts shed, which probably means it came from a 6-speed kit group buy years ago and wasn't used - so I may have reused the 5-speed dust tin

I'll cross my fingers then!

 

[Nuje]

The outer "ring" of the dust tin will be the same as the holes for the mounting bolts engine<-->transmission are the same.

Worst case, there's some tin where you don't want it to be from the 5sp, in which case you get out the tin-snips and make your own 02M dust tin.

 

[bn_]

5 speed plate is fine to use, they are not identical but both will work.

If you didnt buy the DMF yet, the PD130/PD150 DMF was discontinued by both VW and Sachs and replaced with the one for the Seat Ibiza CR143, might be worth it to look out for that one as that car has more torque in lower revs. It also comes in sets with clutch or clutch+slave cylinder
DMF VW part# 03L105266CE

 

[Matt-98AHU]

5 speed plate is fine to use, they are not identical but both will work.

If you didnt buy the DMF yet, the PD130/PD150 DMF was discontinued by both VW and Sachs and replaced with the one for the Seat Ibiza CR143, might be worth it to look out for that one as that car has more torque in lower revs. It also comes in sets with clutch or clutch+slave cylinder
DMF VW part# 03L105266CE

I would be careful using a flywheel meant for an 02Q in an 02M-equipped car.

02Qs have a few mm extra spacing further back from the engine. Often, when you use a 02Q flywheel in an 02M, it has a similar additional offset, which will cause the pressure plate to rub on the bellhousing...

 

[bn_]

I would be careful using a flywheel meant for an 02Q in an 02M-equipped car.

02Qs have a few mm extra spacing further back from the engine. Often, when you use a 02Q flywheel in an 02M, it has a similar additional offset, which will cause the pressure plate to rub on the bellhousing...

Not true in this case. Ibiza 4 2.0 TDI has a MQ350 0A8 gearbox, not 02Q (Codes LNK or PNF to be exact). And like I said, VW and Sachs replaced the Mk4 02M flywheel with the Ibiza flywheel, this is the official replacement part

 

[Moses Buckwalter]

The clutch/DMF is a new kit sourced from Frans at Dutch Auto Parts, Sachs Version 2290601005.

Everything should be arriving this week... does anyone have a good source for O2M CV axles?

 

[P2B]

Everything should be arriving this week... does anyone have a good source for O2M CV axles?

Mk4 Golf / Bora / Jetta Platform 02M 6 Speed Driveshafts

Replacement OE / Aftermarket Driveshafts / Axles for 02M 6 Speed Mk4 Golf / Jetta / Bora Platform Vehicles

www.darksidedevelopments.co.uk