Cool thread I stumbled on over at tdi club.
http://forums.tdiclub.com/showthread.php?t=346876
Having just installed one of these, I can say it's a nice piece of kit.
In the stock 02A/02J, 5th is closest to the transmission, the synchros and selector hub on the very end of the shafts. There's a pivot on the shifter so when the shifter pushes out for 5th it moves the selector hub in to engage 5th. For the Eurotuning kit, 6th is inside, 5th is outside. ET removed the pivot so the shift pattern is maintained. Figuring that you'll spend most of your highway time in 6th, having 6th on the original shafts should keep things stronger. Smart, that. The kit replaces the stock 5th, giving you something to sell to the gasser crowd.
The kit installs easily enough, I had the trans on the bench so I pulled it apart instead of the pseudo-laparoscopic method keeping the trans in the car.
The gears used in the kit are nice and heavy, seem to be either modified OEM parts, or parts modeled off OEM bits.
The kit is infinitely superior to the VLEnt Option6 020 6-speed kit I had years ago.
The 02S is the factory 02A based 6 speed, but there aren't any diesel friendly gearsets, as far as I know. Additionally the 02S seems to have the ratio for 6th about the same as a 5spd would be, with 1-5th being geared closer together. The Eurotuning kit gives you an additional overdrive gear.
The tranny I built is a CTN transmission from a mk3 TDI. It's a 3.16 final drive with a 0.76 5th as delivered by VW.
I opted for the tall kit from ET, 0.71 5th and 0.59 6th.
The trans went into my Rabbit pickup behind a mk4 ALH TDI. 0.205 injectors, rocketchip stage 3, dyno'd at 149WHP. I'm replacing an oddball 020 transmission with a 0.71 5th and VW Motorsport 3.42 R&P. After ~250,000kms on the swap the clutch was giving way. It had been slipping under full power for a very very long time, but given I was driving 275+ torques on an 020, I'd rather the clutch slip than the trans explode.
I built my own mounts for the 02A, installed a cable shifter, and used a cable clutch adapter with a Civic clutch cable. G60 flywheel, VR6 clutch.
The 02A+6th gear housing is shorter in length than the stock 5spd 020, so no body modifications to make it fit. On my mk1 GLI I had to modify the inner fender to clear the Option6 kit.
I installed the shifter box under the tunnel. The shifter is very low, and I mixed up and mounted it too far back, so 2nd gear hits the driver's seat. Once spring comes I hope to install an 02J shift tower and shifter. It should raise things up a bit, and improve the shifter over the 02A.
The kit shifts well, runs well, but I can't really say how well it performs. The day after I finished the install the sky opened and dumped a pile of snow and the highways have been horrible ever since so I haven't been able to do any nice mileage runs. The 3.16/0.59 is quite low, rpm-wise. I probably should have opted for the 0.65. The 0.59 would probably go well with the mk4 02J with it's 3.4 final for running in a mk1.
The gearset runs about 1890 rpm at 110kph in 6th, 1720 rpm at 100kph. Very long legs...
Theoretical top speed, at redline (4500rpm), 260kph, 160mph.
The day after the install was finished
I suppose there are 3 options for low gearing,
1. swap 5th for a lower OEM gearset (0.71, 0.68, 0.65, 0.59)
pro: cheapest option, con: rpm drop between 4th and 5th
2. EuroTuning 6th gear add-on kit
pro: maintain a 5th gear, well built. cons: not exactly cheap
3. OEM 02M 6spd
pro: OEM, con: expensive, lots of parts to swap, dual mass flywheel or expensive single mass flywheel kit, 108mm flanges
I look at the price involved as being a no-brainer. I'll be driving the pickup for a very long time, and 6th gear will make the highway drives even nicer. The 02M would be nice, but to install it in a mk1 would require custom flanges or hybrid axles to suit the 108mm flanges on the transmission. The 02A uses 100mm flanges, so I can run 100mm axles from a Scirocco 16V. I had already swapped the outer hubs to fit the larger CVs.
The 02M swap makes sense on a mk4, where all the parts fit, and the old 5spd can be sold to somebody whose slushbox died. For a mk3 or earlier swapped mk1/mk2, the Eurotuning kit makes sense, at least to me.
Would I do it again? Of course. I'm having a good year, I bought 2 kits, one to go into the next project TDI...
-Dave
Topic: O2a 6 speed conversion (Read 9039 times)
