punkassjim

<center><img src="http://jetta_gli.tripod.com/other/02m.txt"></center><p>I'm going to be doing this soon, and I want to collect as much information and expertise as possible before I even pick up the tranny I'll be working on. That's the good news: my car doesn't have to be down and out while the work is happening.

Ok, so the 5-speed 02M tranny has these fundamental differences from the 6-speed counterpart:
1. there's a spacer in place of 6th gear
2. the ratio is different for all gears except 2nd

Aside from these basic differences, it seems I'll also need to change the shift rod.

I want to keep the gearing the same, but add a really, REALLY low ratio 6th gear from a TDI 6-speed. I think it's a 0.805 gearset, so that'd give me nice low RPMs for top gear.

What I need to know, from any tranny experts out there, is this...are there any red flags going up in your head? Anything that says "you're missing a few things there, buddy."<ul><li><a href="http://forums.vwvortex.com/zerothread?&amp;id=1199856">further info on vwvortex</a></li></ul>

fredfromny

If high miles might as well rebuild the whole thing.

sTTanford

any difference in the shift linkage? can u shift into where 6th gear would be?

meem

cool project man

joe@vwvortex

This really shouldn't be that difficult. Even though all the ratios are different, they aren't that different. Should be able to fit any gears you want in there. It's just a matter of finding the right ratios. You will really only need to change 5th and 6th.

RafaTT

Isn't there any computer setup for the 6-speed that differs from the 5 sp? I mean that would throw a CEL because speed/rpm doesn't match or whatever. I'm asking because I'm thinking doing the same thing on my 2K TTQC.

punkassjim

As far as I know, the engine speed and road speed are measured independently, and there won't be a problem. People put lower gear 5th's and higher ratio R&amp;P into their trannies all the time, and I've heard nothing about DTC's. The speedo gear is a concern, but my speedo is off already, since I'm running an 02J in a mk3 GTI.

punkassjim

if I can find a crazy-low 6th gear from a euro TDI/02M, I'd love it, and I might not even need to change 5th (hoping). I'm just a little concerned that the gearing for 4th and 5th would be too close, or from 5th to 6th. That'd be a real problem, and it'd make the whole project for naught. Need to do the match 100 times before I commit.

As for procedure...no, it doesn't seem that hard at all. As long as it doesn't cost too much.

punkassjim

I'm not sure about the shifter box in the cabin, but I know the shift lever in the tranny needs to be changed. There's a different part number from DQB to DXW.

punkassjim

The tranny has 15k miles on it. I'm not worried.

Also, there's a possibility I'll put a quaife in it, but that's not certain yet. Might be cost-prohibitive at this point.