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

JettaTDI

Well-known member
Joined
Feb 21, 2008
Location
North East
TDI
02
My mistake - I meant clutch master cylinder (which came with the 6-speed kit). I'm going to replace both the slave & master. I edited my original post (#510) to keep this thread correct. Thx

 
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JettaTDI

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Feb 21, 2008
Location
North East
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02
It's not leaking, but I'm not sure if that's the culprit for the no pedal function (possibly leaking past the piston seals)? I only thought of it after I ordered the new slave cyl/release bearing. The current clutch master in my car came with the 6 speed kit (used take-out).
 

Smokin' Dually

Veteran Member
Joined
Dec 3, 2006
Location
N.E. Wisconsin
TDI
Jetta
Interested in 6 speed conversion, my local salvage yard has (2) 6 cylinders and (1) 4 cylinder with 6 speeds and the prices are good. I realize that the ratios would be wrong and I'm planning on getting a gearbox from Darkside. What other parts can I get locally that I wouldn't need to get from Darkside to save $?

I have a 5 speed so I think I would need to source locally:

Starter (6 cylinder)
Axles
Transmission to body Bracket
Transmission (dogbone) mount
Tins
Flywheel/clutch
Clutch hydraulics
Fasteners

Is there anything else I should grab?

Please contact me via message regarding price for the gearbox (please quote both ratio price options) and anything else that I wouldn't be able to get locally.
 

Smooth_Puddin

Well-known member
Joined
Mar 25, 2012
Location
Marietta, OH
TDI
03 Jetta TDi Wagon 6 Speed
Put over 10 years on my 02M and just had a throw out bearing go out. Put another in and it lasted all of 10 miles. I have a new oem metal one to put in but I think my clutch might have been contaminated. Being in the states, will any MK4 VW with a gas 02M 6 speed clutch work? All the companies I’ve called (ECS, Tdi Parts, FCP Euro) said they don’t have a clue.
 

arne487

Veteran Member
Joined
Jan 16, 2008
Location
Fort Collins, CO
TDI
'03 Golf TDI, '10 TDI Cup Jetta
My throwout bearing/slave cylinder failed and spewed all the brake fluid inside the bell housing at about 10 years/70-80k miles as well. OEM replacement has been great since.

I had a fancy aftermarket clutch and pressure plate that broke at some point a few years before that. At that point I went with this kit that has been utterly fantastic since: https://www.darksidedevelopments.co...ywheel-smf-clutch-kit-for-vw-02m-6-speed.html
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
Being in the states, will any MK4 VW with a gas 02M 6 speed clutch work?
It will not. (Ask me how I know.)
Now granted this was like 10yrs ago, but I figured I could get away with it because they looked the same, but after it felt fine getting out of the driveway, as soon as I put any oomph into it, the clutch slipped.

Took it apart again and saw what you see below - gasser on the left, bespoke TDI on the right....which has slightly longer fingers.


With that said, if the clutch did get doused with with hydraulic fluid, I'd think you should be able to clean it (brake cleaner, degreaser) back to "good", but the friction disk would be cooked.
I'd check with Darkside to see if they'd sell you just a 02M TDI friction disk.
 

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 ........
Put over 10 years on my 02M and just had a throw out bearing go out. Put another in and it lasted all of 10 miles. I have a new oem metal one to put in but I think my clutch might have been contaminated. Being in the states, will any MK4 VW with a gas 02M 6 speed clutch work? All the companies I’ve called (ECS, Tdi Parts, FCP Euro) said they don’t have a clue.
The DMF and clutch set up on the 02M's are the same on diesel and petrol's, DSD1144.1 on our site.
Full throttle on a new clutch that hasn't been bedded in over 500 miles, it slipping right away would be expected as this disc has likely glazed.
 

Smooth_Puddin

Well-known member
Joined
Mar 25, 2012
Location
Marietta, OH
TDI
03 Jetta TDi Wagon 6 Speed
The DMF and clutch set up on the 02M's are the same on diesel and petrol's, DSD1144.1 on our site.
Full throttle on a new clutch that hasn't been bedded in over 500 miles, it slipping right away would be expected as this disc has likely glazed.
I did the Valeo SMF with the South Bend clutch upgrade.
The DMF and clutch set up on the 02M's are the same on diesel and petrol's, DSD1144.1 on our site.
Full throttle on a new clutch that hasn't been bedded in over 500 miles, it slipping right away would be expected as this disc has likely glazed.
It’s a Valeo SMF setup with the South Bend Clutch upgrade From TDI Parts. They don’t have this setup anymore and won’t sell me just the friction disk. South Bend Clutch wont separate either. Would you happen to have a friction disk that would work until I have enough money saved to buy a whole new setup? TIA.
 

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 did the Valeo SMF with the South Bend clutch upgrade.

It’s a Valeo SMF setup with the South Bend Clutch upgrade From TDI Parts. They don’t have this setup anymore and won’t sell me just the friction disk. South Bend Clutch wont separate either. Would you happen to have a friction disk that would work until I have enough money saved to buy a whole new setup? TIA.
We wouldn't be aware of the clutch disc that can be used with a South Bend pressure plate.

However the complete clutch kit is available to suit the 02M Valeo single mass - https://www.darksidedevelopments.co...eplacement-clutch-kit-for-valeo-smf-only.html
 

Smooth_Puddin

Well-known member
Joined
Mar 25, 2012
Location
Marietta, OH
TDI
03 Jetta TDi Wagon 6 Speed
We wouldn't be aware of the clutch disc that can be used with a South Bend pressure plate.

However the complete clutch kit is available to suit the 02M Valeo single mass - https://www.darksidedevelopments.co...eplacement-clutch-kit-for-valeo-smf-only.html
The pressure plate is still a Valeo 701814. The friction disk is a 701813. The receipt from purchase said was 1 x Valeo Single Mass Flywheel and Clutch Conversation Kit (6 Speed)
- SBC Upgrade Modification + $425 usd. Man Number 52405615. I’m hoping all I would need is a friction disk if you just sell them individually. Thanks.
 
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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 ........
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