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

[boertje]

No, thats a totally different animal. What you bought is correct for the 02M trans.

 

[JettaTDI]

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

Clutch Master Cylinder (A4)

New replacement cylinder for A4 manuals....

www.idparts.com

 

[boertje]

Ok, yeah that part is the same. Why replace that one? Is it leaking?

 

[JettaTDI]

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]

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]

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]

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]

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]

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]

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]

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]

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.

 

[ryanp]

We sell the clutch kit but not the individual components,

Valeo 02M / 02Q 2 Piece Replacement Clutch Kit for Valeo SMF ONLY

This is a Two Piece Valeo Replacement Clutch Kit for Valeo SMF (Single Mass Flywheel) Conversion on the 02M and 02Q 6 Speed Manual Transmission

www.darksidedevelopments.co.uk

 

[Smooth_Puddin]

We sell the clutch kit but not the individual components,

Valeo 02M / 02Q 2 Piece Replacement Clutch Kit for Valeo SMF ONLY

This is a Two Piece Valeo Replacement Clutch Kit for Valeo SMF (Single Mass Flywheel) Conversion on the 02M and 02Q 6 Speed Manual Transmission

www.darksidedevelopments.co.uk

Just pulled the clutch out. It’s beyond spent and the pressure plate is worn to. I will be buying the kit shortly. I do have a few new throwout bearings. My mechanic buddy tried to bench bleed them, even though it states not to touch them per instructions. None of them will take in fluid, or push air out. He’s very adamant if they don’t bench bleed, they won’t work. I just told him to install and a pressure bleed will work out the air but he’s set in his ways. I will post this to the regular forum but figured I might as well give it a shot here first. Thank you!

 

[ryanp]

We never bench bleed them.
Pressure bleed when installed and they are usually perfect.

 

[nivekqwerty]

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 kits can be purchased directly here - https://www.darksidedevelopments.co...di-02q-5-speed-to-6-speed-conversion-kit.html

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....-single-mass-flywheel-and-clutch-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....ywheel-smf-clutch-kit-for-vw-02q-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'

Going to be doing this conversion soon, have all the parts except the non reusable bolts. I know typically any non reusable bolt has torque spec torque to yield or nm + X degrees, but could you confirm which bolts exactly need to be bought new for the conversion?