Gearbox Recondition and 6-Speed Conversion

[6cyl Chris]

Top post Tom!!

I find that the sweet spots are:
* 1250rpm for very low load (downhill, steady low speed driving, etc),
* 1400rpm for steady medium loads
* 1750rpm peak efficiency (gentle hills, 60mph, 197BSFC on the chart)
* up to 2000/2200rpm when you want to accelerate (torque peak)

I know exactly what Jarmoke and Maso mean, and as such, whilst I know it's subjective, I would be inclined to add maybe 50-100rpm to Mike's figures, but otherwise, an excellent observation.

Argh. It's just such a costly upgrade...
If I need to get my 2nd/3rd gear synchro looked at and the clutch replaced at some point, I suppose it could be argued that the box will be broken out then anyway so why not, but....

This is my line of thought aswell!
With the labour cost then justified, I calculate approximately 30-35k miles at >60mph would constitute a breakeven point. (That's probably 6-7 years for me in my current circumstances, so I shan't be taking the decision lightly)

Spending e70 on a gearknob was a bit of a luxury.

Think how much fuel you could fo bought for that!!

 

[MikeMarsUK]

[discussing RPM ranges]... whilst I know it's subjective, I would be inclined to add maybe 50-100rpm to Mike's figures, ...

I used to actually use slightly lower RPMs in low speed situations, e.g., 1000 @ 30mph. But after I looked at the BSFC chart I increased my target RPM a bit, hence the figures you can see above. When using these low RPMs, if it looks like you might need to apply more power in the near future, drop down a gear as preparation (for example, coming up to a junction or hill, a potential overtake, or if the traffic conditions are changing).

Think how much fuel you could fo bought for that!!

Yeah, to paraphrase Vicky Pollard, 'Cost/benefit analysis says no'

 

[nuttinnew]

This was the gearknob I picked, I liked it because it was very similar to the original (the illumination providing the OEM+ feel), recommended from the German forum.
http://www.innovativcar-tech.de/product_info.php?language=en&info=p504_1CA20.html

You do get the option of picking a 5 or a 6 gear emblem, so don't worry, you don't have to shell out for the kit as well!

Spending e70 on a gearknob was a bit of a luxury.

Thanks for the link
In the big scheme of 6 speed costs €70 isn't so bad, and it's a nice reminder of where the money's gone rather than it remaining unseen in the dark depths of the engine bay.
Have you noticed any difference in the ride now it's got a little extra weight on the front?
I view the conversion the same as V-Power (etc) fuels; not worth it for fuel economy alone, but the added quietness as well as the bit more mpg makes it worthwhile.

 

[nuttinnew]

Yeah, to paraphrase Vicky Pollard, 'Cost/benefit analysis says no'

Though the general forum opinion is;

 

[MikeMarsUK]

... Have you noticed any difference in the ride now it's got a little extra weight on the front? ...

Nope, but it didn't really add that much ... if I had to wildly guess I'd say it added 2 to 3kg (2 extra cogs & a slightly larger casing), but I could be out either way.

 

[timmus]

Thread Updated

I've updated the first posts in this thread to include gear charts, a few extra photos, the relevant info for the TDI90 and a comparison to the 'longer 5th' setup.

Cheers,

Tom

 

[MikeMarsUK]

I think Radim was equally as impressed by your walkthrough because he's linked to it from the new version of his website

http://www.eurotuning.cz/images/image/en/optimizing/index.html
http://www.eurotuning.cz/images/image/en/optimizing/links.html

 

[dan_b]

According to their website there are over 350 cars running around with these kits in them now - guess most are not A2s?!

 

[MikeMarsUK]

According to their website there are over 350 cars running around with these kits in them now - guess most are not A2s?!

Most would probably be T4 / T5 transporters in the Czech republic (probably the vehicles with the best economic argument for the mod), the others would be various models from VW / Audi / Skoda / Seat lineup, again mostly Czech cars. I know that it has been installed in some Passats & Jettas in the US. I *think* but am not sure, that mine was the first A2 (certainly the first in the UK).

 

[timmus]

I think Radim was equally as impressed by your walkthrough because he's linked to it from the new version of his website

Radim emailed me and asked if I'd be willing to let him do this. He's also used some of my photos in the gallery section of the website...
http://www.eurotuning.cz/images/image/en/optimizing/gallery_conversion_kit.html

I must confess, this is a massive honour. I'm hugely complimented.

 

[Danilo Croci]

I hope this has made for interesting reading. If you're tempted to add a 6th gear to your A2 TDI, I cannot recommend Vince enough. He was thorough in the extreme, communicated with me regularly about progress, and was, quite obviously, happy to indulge my desire for photos!

Cheers,

Tom

Very interesting read Tom. Its got me thinking, as I drive mostly on motorways and dual carriageways. How much did it all cost?

Cheers

Danilo

 

[timmus]

Very interesting read Tom. Its got me thinking, as I drive mostly on motorways and dual carriageways. How much did it all cost?

An eye-watering amount. The honest truth is that you do this conversion because you want to, not because the increased fuel economy is going to save you money. The kit of parts cost ~£1200 and you've then got installation on top. Quite clearly, this is a job for a gearbox specialist, not your average garage.

Carrying over your current musings about the longer 5th from another thread...

The longer 5th is, by comparison, a compromise solution, but it's cheap enough for it to pay for itself within a moderate period of time. Adding a 6th gear would require you to drive over 100,000 miles in 6th gear before you're close to the break-even point.

Cheers,

Tom

 

[hotstuff]

6th gear mod.

I want it - I'm getting it!
I sense a road trip coming up .

blue skies
tony

 

[Birchall]

6th gear mod.

I want it - I'm getting it!
I sense a road trip coming up .

blue skies
tony

There is absolutely no financial sense in the 6 speed conversion
(I have my 6 speed conversion kit reserved and will be asking Vince to fit it and I am looking forward to it)
I even have the 6 speed gearstick "badge" ready to swap into the car !!!

I have more money than sense ( not that I have any money, just very short on sense!!!)

Steve B

 

[dan_b]

I hope you're getting the LED illuminated 6 speed gear knob as per MikeMars? SSpeaking of which he's not been on the forum for a long time?

 

[Birchall]

That sounds a little bit "tacky", so I MIGHT consider it after a while with the non-illuminated version.

Is the wiring completely hidden and does the illumination only come on with the lights??

Steve B

 

[timmus]

That sounds a little bit "tacky", so I MIGHT consider it after a while with the non-illuminated version.

Is the wiring completely hidden and does the illumination only come on with the lights??

The whole gear knob and gaiter is an aftermarket part, not just the emblem. The wiring is indeed hidden and it illuminates with the rest of the controls when you turn on the side lights. Whilst there's no doubt that it's quality, it does not, to my mind at least, have an OEM look and feel.

Tom

 

[Birchall]

The whole gear knob and gaiter is an aftermarket part, not just the emblem. The wiring is indeed hidden and it illuminates with the rest of the controls when you turn on the side lights. Whilst there's no doubt that it's quality, it does not, to my mind at least, have an OEM look and feel.

Tom

Hi Tom,

Thanks for that.

It looks like that is not for me then. I don't mind straying from the OEM look a little but I would prefer my mods to be as close to OEM as possible.

So I will stick with the Audi 6 speed one.

Cheers
Steve B

 

[timmus]

Speaking of which he's not been on the forum for a long time?

He last logged on some time back: 20-12-2013 - I've got his mobile number, so will send him a text.

 

[MikeMarsUK]

... It looks like that is not for me then. I don't mind straying from the OEM look a little but I would prefer my mods to be as close to OEM as possible.

So I will stick with the Audi 6 speed one.
...

Tom discovered that it was possible to swap the emblems after I'd already ordered my 6-speed gearknob. If I'd have known, I'd have (probably) done that instead since it would have been a simpler & more OEM solution.

On the other hand, it was nice to have a new gear-stick rather than an old tatty one, and the illumination is reasonably subtle (it is linked to the normal illumination circuit so the brightness is adjusted by the instrument lighting thumb-wheel, and only comes on if the headlights are on).

He last logged on some time back: 20-12-2013 - I've got his mobile number, so will send him a text.

I didn't get that? If it was when I was changing my phone I may have missed it however. If you want to check the number you've got, send me a PM & I'll see if it's right.