Six speed conversion

[Paazuzu]

Happy to say the six speed conversion was completed roughly 2 weeks ago - apologies I haven't had time to post an update!

I think we're looking at the first conversion in Oz which is pretty cool! It also means I can provide a write-up on how to do it for all members of the forum.

A big thank you to Gav for his support (and tools!) as I wouldn't have completed the job without his advice, guidance and patience! Also a shout-out to Junior from the UK Polos forum for providing some advice on his conversion.

The car ran perfectly for a few days, albeit without the correct shift bracket and it felt like there was a big increase in in-gear acceleration between 2nd-4th. Sixth gear sits at about 2,900rpm @ 100km/h, so not too far off the standard 02R box.

Unfortunately, the clutch is now slipping so will have to pull the sucker out again and upgrade the clutch. Oh well - good excuse for a solid flywheel and stage 2 or 3 clutch.

In coming weeks I'll develop this into a write up with all the tools and modifications you to make.

For now, here's a teaser (please excuse my shifting - we'd barely connected the clutch!).

Polo GTI six speed conversion gear check - YouTube

And check out the tight fit against the stabiliser (a few mm!):

[kaanage]

Great to see this completed. Do you notice the extra weight of the 6 speed 'box at all?

[h100vw]

Great to see this completed. Do you notice the extra weight of the 6 speed 'box at all?

I noticed the weight wrestling it into the clutch

[Paazuzu]

Haha Gav - it was definitely a two person job!

Kaanage - didn't really notice much difference to be honest. The gearboxes felt very similar. I can probably weigh them both when the clutch comes out.

[Umai Naa!!]

The swaybar link fouling on the inner guard liner is normal. They all do it.

You can use a heatgun to reshape it for clearance.

[Blue9N3]

2900rpm@100kph?? That's one close ratio box then unless 1st is very short


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[seangti]

Great effort Dan. Must be satisfying having got it done it DIY. What car/s are the 6 speed boxes from that fit?

it was definitely a two person job!

don't tell me that, I'm planning to drop my box this weekend. Doing LSD, not 6 speed, but should still be good.

[Paazuzu]

2900rpm@100kph?? That's one close ratio box then unless 1st is very short


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1st is super short.

[Paazuzu]

Six speed conversion

Definitely better than paying a grease monkey Sean! Although I had Gav on hand too

Any 02S coded box will fit. Its the ratios that are different. Mine's from a Mk5 golf tfsi.

I found manoeuvring the box was easier with two. But with patience you could do it yourself.

[sambb]

Sean what diff have you chosen to run? My box is the HWY (I think that's right) in an 06' - is that the same as yours? I'm trying to work out what the difference is between my box and the 02R that everyone else seems to talk about.

[h100vw]

Sean what diff have you chosen to run? My box is the HWY (I think that's right) in an 06' - is that the same as yours? I'm trying to work out what the difference is between my box and the 02R that everyone else seems to talk about.

O2R is the series of gearbox Sam. HWY refers to the particular box for the Polo GTI. You'll find many 02R boxes on ebay for example. Some for TDIs etc.

GAvin

[Bora Sport]

Because the Polo wheel and tyre total diameter (which reflects in the revolutions per kilometre) is less than the wheel and tyre total diameter ie rolling radius of the Golf, the total overall gearing will be lower than that when that gearbox is in the Golf.

[seangti]

Sean what diff have you chosen to run? My box is the HWY (I think that's right) in an 06' - is that the same as yours? I'm trying to work out what the difference is between my box and the 02R that everyone else seems to talk about.

Yeah, so what Gav said, it's an 02R box. The issue is the size of the "ring diameter of crown wheel" (that's a quote, I actually don't know what that means) as there are 2 sizes and no way to tell till the box is open.

I got the box out over the long weekend. In the most part it was straight forward. I did need a hand only for the box removal once it was free from gearbox mount but separating from the engine. Unless your missus does weights, best not to seek her help. I'm planning to run a wavetrac diff and use a local race car building workshop to do that install. The workshop suggested going a plate clutch style differential instead, they are going to make some calls for me and price up an option. At this point I don't see any need for stronger gears.