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

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...

FS: Reflex Hagus mirrors
http://www.unitronic.ca
http://www.pagparts.com

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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

Adrian

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

Lovin' it!!

I can get this setup for $250 shipped. Nobody else offers it in the states...

Adrian

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If you guys want to start a group buy we can do that too

Adrian

1.8t Swap FAQ

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

1.8t Swap FAQ

Thanks!

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Photobucket: JDriver18t

1.8t Swap FAQ

FS: Reflex Hagus mirrors
http://www.unitronic.ca
http://www.pagparts.com

As for speed/gearing, I believe my estimates (with 3.94 final) were suggesting:
85mph - was:3800, will be:3200
80mph - was:3600, will be:3000

Here's the previous pricing info I had found:

For the .717 gearing you'll need:
http://forums.vwvortex.com/zerothread?id=713538 (2/18/03)
02a311361M is $80.50
and 02a311158R is $122.10

I just (8/18/05) checked these sites and found:

1stvwparts.com:
02a311361M: $110
02a311158R: $174

worldimpex.com:
02a311361M: $142
02a311158R: $226

Your my hero.

Only when I have the money, time and energy.

Big envy.

1.8t Swap FAQ

I will check tomorrow morning... on my way to work I usually see 130mph, and if I am running a bit late, well... you know

Schoolbus, Yeah those are old links and they don't work. I have no idea why the prices would go up ( maybe cause gas prices ). I talked to the manager of our local VW dealer and he said he would give me discount for sure if I were to buy 5 or more sets.

Adrian

Modified by El Romano Loco at 9:56 PM 10-19-2005

That's totally what I want to know as well.