RYAN P's 6 speed 02M Conversions and ALL Euro TDI Parts

1tdi

Veteran Member
Joined
Mar 21, 2004
Location
CT
TDI
Jetta 99.5 Black
I installed the 02M kit in my 99.5 and it has been great, I opted for the single mass Valero flywheel and I have to say it’s about the same if not quieter than the G60 VR6 setup I had before. So far I have put 1200 miles on the setup since install.
 

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 ........
Great stuff, the Valeo works OK for mild tuned cars!
 

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 ........
Hi Wayne

I think you have emailed me as well? I will respond on there fully. Fitting an 02M is not straight fit. The Driveshafts are different, as are the Starter, Flywheel and a few other little pieces, as well as the mounts.

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 ........
The brass syncro's seem to be what people want.

I have a lot of Gearbox conversions on the shelf ready to ship out as well as all the other parts we sell on our site, take a look:

https://www.darksidedevelopments.co.uk/

I also still have a box full of BRAND NEW VE injector bodies, they are genuine Bosch and we can fit whatever nozzle you like, once these 5 sets are gone there will be no more. I also have a few random nozzles and injectors lying around, here is the list:

New Bosch 520 Nozzle - Qty 3
New Bosch 748 Nozzle - Qty 1
New Bosch Injector sets inc Square plug Lift sensor injector - Qty5
New Bosch non lift sensor injectors loose - Qty 4

Reconditioned Bosch injector with New HFLOX .341 nozzle - Qty 2
Reconditioned Bosch injector with New HFLOX .240 nozzle - Qty 1
New HFLOX Warp 2 .216 nozzle - Qty 1
New HFLOX Warp 7.275 nozzle - Qty 1
 

Wmt6820jetta

Active member
Joined
Oct 24, 2018
Location
Sw fla
TDI
2005.5 jetta
Ryan and Scott’s customer service is top notch, I had issues with my swap and Ryan and Scott were right there every step of the way! I wish we had this kind of service to the customer in the USA!
 

packarman2000

Member
Joined
Feb 15, 2014
Location
North Carolina
TDI
5
Ryan customer service has been amazing. Got an o2m transmission from him really quick and it seems perfect. Thank you for you help Ryan. I truly appreciate it. i am with wmt8620jetta.
 

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 ........

JettaTDI

Active member
Joined
Feb 21, 2008
Location
CT-CA
TDI
'02 Jetta, '03 Golf
Does anyone have the part # for the right and left axle assemblies that come in this kit?

found it...

boertje said:
Part numbers.
1J0 407 271 GC x1 left drive shaft* Löbro 304351 GKN (EKG 923769, Spidan 23769)
1J0 407 272 GD x1 right drive shaft* Löbro 303927 GKN (EKG 922267, Spidan 22267)
CV joints outer left and right 1JO 498 099 E Löbro 303551 GKN (EKG 921522, Spidan 21522)
CV joint gear box side 1JO 498 103 E Löbro 302464 GKN (EKG 922902, Spidan 22902)
Boot outer 3B0 498 203 E Löbro 303552 GKN (EKG 921524, Spidan 21524)
Boot inner 1JO 498 201 E Löbro 304113 GKN (EKG 923176, Spidan 23176)
 
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TDIlast

Active member
Joined
May 26, 2006
TDI
2002 Jetta TDI 5-spd; 2006 Beetle TDI DSG; '00 GTI VR6 SC; '07 T-egg V8 FSI
I purchased my 02M Swap for my '02 ALH in February 2018, including a Valeo SMF kit. Danny and Rob at Darskside development were very helpful and responsive in answering my questions and items were delivered promptly. The transmission code is DRW.
Because I didn't use the car as my daily driver and the many projects I had to deal with due to a domestic and international move, I could only spend few hours on the swap on the weekends, often taking two or three month brakes on the project due to the reasons already mentioned. Finally I completed the swap yesterday. After I stated the car and ran it while still on jack-stands I noticed a strange noise and vibration and want to rule out anything wrong before i start driving it.
I placed links to two you tube videos I made below.
There is a a constant pattern background sound (almost sheet metal like/skidding vibration "like" noise) when the car is idling. The noise doesn’t go away if I depress the clutch pedal which in theory should stop the internals of the transmission from rotating and its pattern and it does not seems to be somewhat very correlated to engine RPM. Also it can really be heard from inside the car but not from the top of the engine as the engine noise over takes it.

Update 11/22 - This ended being the front passenger axle rubbing on the heat shield until it worked its way through to a bigger clearance.


What I am trying to figure out though is in the higher gears, especially 5th and 6th. There is a noise under load/part load condition that i cannot determine the root cause of. When I look at the transmission from underneath the engine with engine idling in 5th or 6th, this is accompanied by more pronounced vibrations.

Update 11/22 - After 2000 trouble free miles i came to the conclusion the vibrations come from the SMF. Vibrations in diesels are much much stronger than on a gasser and SMFs carry those straight into the chassy. Hint... Go with a DMF route :) Road noise also helps a lot to attenuate what you'd hear when running on stands like i did in the video.


I did the install following everything to the T, taking my time to clean every component and torque every bolt per specification and using factory OEM products. While this was my first swap, I have done many clutch replacements in my lifetime so I am not new to this and MKiVs in general.
I placed two video links below. Please let me know what you think. I prefer to find out now while it's still on jack stands and not even registered.
I absolutely do not want to sound negative towards Darkside Development, who as I said before are very professional, and offer great products for those of us on this side of the pond and are extremely responsive. I am posting to ask for help to those that already performed swaps and can provide advise. At present I am still diagnosing and it may turn out to be nothing or the fact that it's now a SMF vs DMF. Just trying to pin point cause before i start driving it.

I confirm this as being the SMF. Darkside Development clearly stand by their customers and products and I will look to do business
with them again as the need arises. Also having a 6th gear totally changes the highway experience and the ALH handles it just fine even without a tune.


Thank you!
https://youtu.be/nU4k-HxX2Hs
https://youtu.be/j9308gfMTEU
 
Last edited:

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 ........
Hello,

Sorry to hear you are having issues, its always a good idea to email us first rather than post publicly about the problems.

First thing to ask, What oil did you fill it with?

If its engine speed related with the clutch depressed its usually the dust guard touching the flywheel.

After that, if all the above is OK it wont hurt to drain a little oil and see if there is anything in there.

There are very few common issues with these boxes and its very rare we get a bad one, let alone send one out but rest assured we will make this right for you!

Thanks

Ryan
 

Louie710

Veteran Member
Joined
May 15, 2019
Location
Northern California
TDI
2003 Jetta sedan 2002 Jetta wagon
I purchased my 02M Swap for my '02 ALH in February 2018, including a Valeo SMF kit. Danny and Rob at Darskside development were very helpful and responsive in answering my questions and items were delivered promptly. The transmission code is DRW.
Because I didn't use the car as my daily driver and the many projects I had to deal with due to a domestic and international move, I could only spend few hours on the swap on the weekends, often taking two or three month brakes on the project due to the reasons already mentioned. Finally I completed the swap yesterday. After I stated the car and ran it while still on jack-stands I noticed a strange noise and vibration and want to rule out anything wrong before i start driving it.
I placed links to two you tube videos I made below.
There is a a constant pattern background sound (almost sheet metal like/skidding vibration "like" noise) when the car is idling. The noise doesn’t go away if I depress the clutch pedal which in theory should stop the internals of the transmission from rotating and its pattern and it does not seems to be somewhat very correlated to engine RPM. Also it can really be heard from inside the car but not from the top of the engine as the engine noise over takes it.
What I am trying to figure out though is in the higher gears, especially 5th and 6th. There is a noise under load/part load condition that i cannot determine the root cause of. When I look at the transmission from underneath the engine with engine idling in 5th or 6th, this is accompanied by more pronounced vibrations.
I did the install following everything to the T, taking my time to clean every component and torque every bolt per specification and using factory OEM products. While this was my first swap, I have done many clutch replacements in my lifetime so I am not new to this and MKiVs in general.
I placed two video links below. Please let me know what you think. I prefer to find out now while it's still on jack stands and not even registered.
I absolutely do not want to sound negative towards Darkside Development, who as I said before are very professional, and offer great products for those of us on this side of the pond and are extremely responsive. I am posting to ask for help to those that already performed swaps and can provide advise. At present I am still diagnosing and it may turn out to be nothing or the fact that it's now a SMF vs DMF. Just trying to pin point cause before i start driving it.

Thank you!
https://youtu.be/nU4k-HxX2Hs
https://youtu.be/j9308gfMTEU
This is totally the wrong place to post your questions, but glad to see darkside respond and be willing to help. Makes me feel more comfortable about ordering from them in the future :)
 

CrazyQuantumMan

Veteran Member
Joined
Aug 22, 2009
Location
Oregon
TDI
96 Bagged B4V TDI Syncro Haldex Peloquin, 05 Beetle BEW Beastmobile
Can you find me a TDI-geared 4motion 02M? Currently running an 02C with 17/27 angled drive. If you cannot find the whole gearbox I can use the guts and build an Audi TT 02M. Shipping to 'merica.
 

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 ........
I have everything in stock to build you an FMH AWD tranny, always easier if you want some upgrades, especially the diff as its half out!
 

Scottyb01

New member
Joined
Dec 12, 2019
Location
Australia
TDI
Golf 1.9 MK5 Manual
02s gearbox or 02q

Really weird question about your gearbox swaps.
What TDI engine are they going on?
Are any of the gearboxes out of 2013 vws?
I have a golf mk5 2004 but it has a 02s gearbox. Trying to work out what other TDI engines it fits even if I have to modify the mounts. I have access to a 2.0 TDI but told I need a 02q box. If that’s true would the 2.0 tdi with your 02q kit work?
Scott
 

Ryan_GNV

Member
Joined
Oct 14, 2019
Location
Gainesville, FL
TDI
04 Jetta Wagon BEW TDI x2
Dust covers

I see in your 6 speed swap layout you have the 2 dust shields. I'm getting ready to swap in a DRW and don't have them.

Do you sell them separately from your kits, or would you be able to provide parts numbers for them?

It's the only thing holding me up at the moment.

Thanks!
 

52172

Veteran Member
Joined
Oct 5, 2007
Location
Buellton, Ca
TDI
2001 Golf TDI GLS
I hit a deer and my airbox is cracked top and bottom I believe. I was running your pd150 tip pipe with r32 maf sensor does I’ll need an r32 airbox lid. I’ll just source factory lower airbox and cold air pipe. Could you please pm me the price of an r32 lid shipped to 93427? Thanks Ryan!
 
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