Gearbox change

[seat_lion]

I'm having gearbox related issues and this will be my second replacement so just looking for some advice on what other boxes might fit?

My car is a 1.9 Tdi been thinking about trying to change to the 6 speed box from the 150 bhp Tdi

Does anyone know the gearbox code? Also what is different between the 5 speed and 6 speed boxes? Any difference between the clutches? Starter motor? Gear linkage cables?

Any advice would be great

 

[Brettyboy]

Be interested to hear if this can be done

 

[seat_lion]

Looks like its a popular choice to change from a 02J to 02M gearbox

Looking at ratios etc I would probably look to change to a 02M DRW gearbox the ratios from 1st-5th pretty much match the 5 speed box but just has the 6th gear which would be perfect for motorway cruising

Found this for a conversion kit, I recon I could source it cheaper thou

http://forums.tdiclub.com/showthread.php?t=331943

 

[Brettyboy]

Is alot of cash but as you said you could probably source the parts for less & also £300 is for shipping so could be done alot cheaper

 

[Brettyboy]

Just read ur awesome spec in ur sig,i think a 6 speed would benefit you alot

 

[seat_lion]

Thanks buddy, done a few other things to it recently aswell S3 quick Steering rack, TT rear subframe bushes, Miltek decat pipe

My gearbox is on its way out and would rather upgrade than replace with something that could end up the same way and 6 speed would just be cool aswell lol

 

[Brettyboy]

Thanks buddy, done a few other things to it recently aswell S3 quick Steering rack, TT rear subframe bushes, Miltek decat pipe

My gearbox is on its way out and would rather upgrade than replace with something that could end up the same way and 6 speed would just be cool aswell lol

Make sense,i would if mine went

 

[cupra_r_ick]

i know the clutch and fly wheels are different sizes from the 5/6 speeds

 

[seat_lion]

Yeah I saw that yesterday my current clutch is 228 and the 6 speed is 240 I'm not sure if it would be a matter of just changing to the larger flywheel clutch arrangement or if this cant be done

 

[Muttley]

I think the clutch must be changed as the smaller clutch will not mate with the splines on the 02M input shaft. And there is the problem of engaging with the starter motor.

The Darkside Development kit looks to be the bees knees, with everything you need. One thing that is mentioned in Elsa is that the 02M casing is magnesium, and the bolts must be appropriately treated to avoid corrosion, so you can't re-use bolts from the 02J even if you wanted to.

 

[Dan1720v]

you need:
shafts
box
shifter(interior)
starter
clutch
flywheel
New slave cylinder.

 

[seat_lion]

Apparently you can get away with just hanging the ends of he shifter cables to the squared ones rather than changing the shifter in the interior