New Transmission?

[catlin_cava]

Is there a 6speed transmission that would fit an AAZ in a 97 MK3 without alot of modification?

[lord_verminaard]

Depends on what you define as a lot of modification.

Short answer, no.

First of all, the only readily-available 6-speeds that would bolt up to an AAZ engine are the ones that came in 1.8t cars, the gearing would not be adequate for a diesel car, and the 6-speed VW trannys have a dual-final drive setup so you cannot (easily) change final drive ratios like you can with the 5-speed boxes.

You can get a TDI-specific 6-speed transmission, it was only available in Europe.  Making an 02M transmission fit in a mk3 will require 2 custom mounts, either a hydro clutch swap or a cable-clutch 02A actuator fitted, and the rod-shift tossed and a cable-shifter swapped in.  There will probably be issues with axles, you will more than likely need to mix and match 020 and 02m axle parts.  Or you could use 02M axles, and swap the front suspension with VR6 stuff.  Then you would have to figure out how to get a speedometer output to your cluster, and re-wire your reverse lights.  Then you'd need all new clutch parts, and probably an 02M starter.  The list goes on.....

It's all stuff that's been done before, so it's not really THAT hard, but the end result is not really worth it.

Brendan

[catlin_cava]

I guess I'll stay with a 5speed lol

[jtanguay]

if you are handy with a welder, then go for it.  the problem is finding a cheap 6 speed TDI box though...

[tSoG-84bit]

well, you might want to check on it, but I believe there is a member of the TDIclub selling 6speed swaps, expensive, but you're getting a new tranny, and all the mounts, bracketry, and what not for a complete 5/6 swap. I believe he sold conversion kits so earlier cars could enjoy the 6th gear as well... I swore I had bookmarks, but I'm not seeing it on here...

[jtanguay]

people worry too much about mounts... they can be relatively easy to fab up.  just move the tranny into place with an engine crane or equivalent, check level, and tack a piece of metal to hold it in place.  take the mount and bring it to a professional welder and tell him you need it not to crack.  you might want to grind/paint it though, but it will do the trick. just look at arb's caravan! 

the '97 should be cable shift with a hydraulic clutch, so thats all good.  the only thing is having to swap your drive flanges on the transmission so you don't need new driveshafts as well.

but, the cost of the actual 6 speed box makes this type of conversion very prohibitive. 

[catlin_cava]

A 97 is cable clutch and shift rod from inside, hydro clutch and cable was only TDI's

[burn_your_money]

A 97 is cable clutch and shift rod from inside, hydro clutch and cable was only TDI's

Correct with the exception of AAZ Passats. They used to 02A tranny like the TDI

There are/were 6 speed conversion kits available for the 020 and the 02A transmissions. It's generally considered a bad idea on the 020 transmission since it's really just a 4 speed with a 5th gear tacked on.

Again, pricey.