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    Thread: Finally did it - .71 5th Gear swap...

    1. 10-18-2005 02:40 AM #1
      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.

      Adrian

    2. 10-18-2005 02:49 AM #2
      that sounds great.. thanks for the input

    3. Member O2VW1.8T's Avatar
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      10-18-2005 02:54 AM #3
      how does the car feel at 170. I know mine at 160 feels real light. Maybe its the stock suspension and H rated tire's. Who knows, its pretty scary
      02 GTi 1.8T haldex'd w/35r-SOLD 7.3@102mph 27psi on 93 octane--04 A4 1.8T converted to AWD also- SOLD--'11 JSW Tdi 6speed Manual- Gone--
      13' BMW 335i M-sport EBII

    4. 10-18-2005 03:01 AM #4
      Honestly, it feels the same after about 150mph. Everything goes by real fast I have race springs with Stiffest Bilsteins available, so its very controllable. However, at those speeds, one little movement and you are three lanes over...
      FYI, I don't normally drive a 170mph. This was just a test to see the difference. I use the same flat strip of autobahn I always do for my tests My hands were sweating big time, but I wasn't nervous or anything, just natural reaction i guess...

    5. 10-18-2005 03:06 AM #5
      Good info.

    6. 10-18-2005 03:09 AM #6
      so at 60-70 mph where are you at rpm wise

    7. 10-18-2005 03:14 AM #7
      The rpms are at 2100@ 60mph, at 70mph not sure, but I can check and post later. Keep in micd that I have the old 3.94 final drive, yours is a 3.6XX I believe...
      Ad

    8. 10-18-2005 03:20 AM #8
      no mine is more like 4:10
      i have a six speed in the ole turbo s beetle
      i was just curious i love my gear ratios the way they are right now............i wish first and secons were a little longer but other than that i think its perfect.......... just not for drag racing

    9. 10-18-2005 03:27 AM #9
      Gotcha... Didn't notice the "S" sorry. Yeah, i actually considered the 02M 6speed, but with my budget, the 5th swap was ~$1500 less
      Adrian

    10. 10-18-2005 08:54 AM #10
      Quote, originally posted by El Romano Loco »
      The rpms are at 2100@ 60mph, at 70mph not sure, but I can check and post later. Keep in micd that I have the old 3.94 final drive, yours is a 3.6XX I believe...
      Ad

      ahhh...that's perfect! I still gotta get around to doing this

    11. 10-18-2005 10:10 AM #11
      Just got back from a beautiful drive on the autobahn. 70mph is right at 2500rpms.
      Lovin' it!!
      I can get this setup for $250 shipped. Nobody else offers it in the states...
      Adrian

    12. 10-18-2005 10:19 AM #12
      good to see someone doing this. I' m *VERY tempted*

    13. 10-18-2005 10:26 AM #13
      IMHO, It's totally worth it [IMG]http://**********************/smile/emthup.gif[/IMG]
      Ad

    14. Senior Member 16vracer's Avatar
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      10-18-2005 02:28 PM #14
      Quote, originally posted by El Romano Loco »
      Just got back from a beautiful drive on the autobahn. 70mph is right at 2500rpms.
      Lovin' it!!
      I can get this setup for $250 shipped. Nobody else offers it in the states...
      Adrian

      Sweet. Sounds like a great winter time swap [IMG]http://**********************/smile/emthup.gif[/IMG]
      '05 Evo GSR 509whp gone 06 Evo RS 409whp gone '10 RX-350 '14 Odyssey Elite I just want to do Race car things with my race car friends teespring.com/race-car-friends

    15. 10-18-2005 02:56 PM #15
      This is more of an afternoon swap. Piece of cake.

    16. Senior Member 16vracer's Avatar
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      10-18-2005 03:25 PM #16
      Quote, originally posted by enginerd »
      This is more of an afternoon swap. Piece of cake.

      True, but it'll be winter before I have the extra cash to do it
      '05 Evo GSR 509whp gone 06 Evo RS 409whp gone '10 RX-350 '14 Odyssey Elite I just want to do Race car things with my race car friends teespring.com/race-car-friends

    17. 10-18-2005 06:13 PM #17
      lol, no poop. I was counting on 3 hours min... I was done in less than two, cleaned up and everything
      If you guys want to start a group buy we can do that too
      Adrian

    18. 10-18-2005 10:44 PM #18
      You have part numbers?
      John

    19. 10-18-2005 10:53 PM #19
      i did this in '01, got the parts from http://www.thescirocco.com/ - cost was ~200ish

    20. 10-18-2005 11:16 PM #20

      oh and how i wish i was back in the motherland again. The autobahn is something everyone should experience at least once in their life.. I need to come visit


      Modified by d0wnShifT at 11:20 PM 10-18-2005

    21. 10-18-2005 11:53 PM #21
      ........I wish it was that easy for the six speed trans that I have.... That O2M with 2 final drive ratios is a different breed of cat........

    22. 10-19-2005 04:59 AM #22
      John, the part number are:
      02a 311 361m & 02a 311 158r
      these are for the .718XXX ratio. Also available for any 02A or 02J tranny are the .75XXX and .68XXX gear sets. For about the same price. Actually the .68 is about $10 cheaper...
      other guy, Yes the 02M is a diff story all together.
      other guy#2, I checked that link and didn't find anything.
      Adrian


    23. 10-19-2005 08:46 AM #23
      as other guy #2....the site doesnt list half the stuff you can get from them....but if you contact them you can get the gear sets needed for the conversion.

    24. 10-19-2005 09:31 AM #24
      lol, other guy #2, couldn't remeber your SN and didn't wan't to go back... So, you did this same swap? .71XX gear set? What was total price shipped?
      Thanks!
      Ad

    25. Member an204421's Avatar
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      10-19-2005 10:26 AM #25
      Is there anything like this for an automatic (the 4 speed), maybe adding a fifth gear

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