So last Sunday, I finally swapped out the 5th gear I purchased about a month ago that was being used as a paper weight at work
I'll try to make a step by step (i am not good at this crap):
1. Took the wheel off
2. Removed the fender liner.
3. Drained the tranny.
4. Removed the six 11mm( ) bolts that hold the end cap.
5. Removed the bolt holding the shift fork bracket.
6. Removed the two bolts holding the shift fork and took it off.
7. Wiped of as much oil as i could of the gears.
8. Took off the big Torx bolt and washer holding the "big" gear on the left.
9. I took off the ring and the three clips that hold/push the syncro, slid that out of the way (but i don't think it's necessary).
10. Wiped as much oil as i could off the gear.
11. I used a propane/butane torch to heat up the gear(not the shaft!) for about a good minute.
12. I modified/grinded the hell out of the "fingers" of a gear puller, to fit it behind the gear(big one).
13. It came off real easy with an impact(weakest setting).
14. Took torx bolt off the smaller gear on the right.
15. Heated it up for a minute too.
16. As i went to install the puller, the gear fell off!
That's pretty much it. When i put the new gears on, I also heated them up for a minute and they went on real easy Don't forget to fill up the tranny. I used the OEM stuff, 1.9 liters.
Driving impressions: For those of us with the 3.94 final drive, it should have been like this stock.
Just to give you an idea: My revs use to be 4500 at 100mph. Now, at 4500rpm I am right at 135mph I couldn't believe I was cruising along at about 120mph(normal for the autobahn) and the motor wasn't screaming for help.
Not to mention the powerband is much wider in 5th. It's real nice to shift from 4th to 5th now. Actually pulls harder at higher speeds, because i am in the meat of the torque.
I am not for sure about MPG savings, but i am very curious(especially with gas prices) This is totally worth it in the sense of noise and engine friction while at higher speeds. It sounds like a completely different car in 5th. I will post MPG changes in the next week or so.
BTW I purchased the gears locally for about $230. and I can get any combo you need, just let me know.