Audi A2 6 speed upgrade path

A2 Cars

Member
Audi A2 6 speed solution from A2 Cars Milton Keynes.

For many members it has been common knowledge that A2 Cars Milton Keynes has researched and implemented a solution to convert and upgrade the standard 5 speed gearbox fitted to the Audi A2, to a 6 speed gearbox.

Around 18 months ago we made contact with a small engineering firm in Germany that specialises in reconditioning and upgrading VAG group vehicle gearboxes. Following initial discussion, we made several trips to Germany and put in place a commercial partnership agreement whereby A2 Cars Milton Keynes will source, supply & fit reconditioned and upgraded gearboxes.

The first 6 speed gearbox was fitted to “humpy” around 16 months ago with the clutch and pressure plate being replaced at the same time. This fitment was carried out in Germany and humpy has travelled in excess of 22 000 miles since then. Not surprisingly, we can report that there have been no negative issues at all. Several visitors to A2 Cars have also driven humpy to experience the 6 speed conversion and it’s safe to say that all came away so impressed and specified the upgrade for their Audi A2’s.

Two months ago we carried out the first UK 6 speed conversion to an Audi A2 FSi. This car is in daily use and our opinion is that this conversion is even more successful than that on the A2 TDi’s. Utilising the ample and amazingly low rev torque of its engine, the FSi can be driven at 40 MPH in 6th gear and is quite capable of smooth and rapid acceleration without the need to change to a lower gear.

Satisfied and confident of our technical partnership and the lack of issues during a substantial test and evaluation period, we can now formally announce on the forum our 6 speed solution for the Audi A2. This upgrade is suitable for the Audi A2 TDi 75 (EWQ) & 90HP (GRJ) as well as the Audi A2 FSi (GKZ).

So, how does it work?

Our gearboxes are rebuilt by qualified and experienced engineers in Germany. We personally transport the units to and from our technical partners and are fully involved in the rebuild process. The gearboxes are completely stripped down to the last nut and bolt and thoroughly inspected. All parts are chemically washed in an industrial parts cleaner at 60°C and then inspected again. Damaged and defective components are replaced with new genuine parts. The parts then move to a “clean area” where the reassembly is performed. In the final stages, the 6th gear components are fitted. The gearbox is sealed, filled with oil and is then put on a test rig and run at speed for a minimum of 20 minutes with all gears being selected, engaged and validated. After a cool down period, the gearbox is inspected for leaks and then receives a unique serial number for identification.

Our 6 speed gearboxes are sold fitted on an exchange programme and our aim is to have units in stock for a prompt installation. On fitment, we also carry out a thorough inspection of the flywheel and engine rear crankshaft seal, and advice as necessary. Mountings are also inspected and replaced as required following authorisation. Typically, we allow two days for the upgrade. Vehicles are returned to our workshop 1000 miles later for an inspection, gearbox oil change and any adjustment should it be required. Our gearboxes and the upgrade are covered by a 12 month unlimited mileage warranty – clutch, pressure plate, flywheel and wear excluded.

We believe that our upgrade is the best 6 speed solution for the Audi A2…

The gearbox is completely reconditioned with new parts as required.
We retain the original gearbox and upgrade it to 6 speeds.
Our solution makes use of the standard shift mechanism and brackets – no modifications and “vague & funny feel” whatsoever.
All mountings remain original as Audi engineers intended – no missing or omitted bolts.
We offer the best warranty on our gearboxes – 12 months unlimited mileage – no quibbles!
We bring the Audi A2 closer to modern motoring, lower noise, better fuel consumption, less engine wear and a smile.

Cost for this upgrade is £999.00 ex VAT and labour on an exchange basis. We charge an additional £150 refundable surcharge to cover defective components in the original gearbox.

Please call for further information and advice.

blue skies
Tony
 

A2 Cars

Member
Some pictures of the extensive reconditioning of the gearbox and inclusion of the 6 speed gear set.

GB 01.JPG

Gearbox on "dirty" bench ready to be stripped down.

GB 02.JPG

Casing opened and the internals removed - little oblong bits are the magnets in the casing to contain swarf.

GB 03.JPG

Gear sets removed from shafts ready for inspection and cleaning process.

GB 04.JPG

Ready for a hot chemical cleansing.

GB 05.JPG

Syncro cone being inspected.

GB 06.JPG

Another view.
 

A2 Cars

Member
More ...

GB 07.JPG

What it looks like after 100K miles - yuk!

GB 08.JPG

Reverse gear - look closely at the teeth to see evidence of "crunching" when engaging gear. This gear set was replaced.

GB 09.JPG

Getting ready for splish-splash.

GB 10.JPG

Notice the difference?

GB 11.JPG

One box of bits - almost like new!

GB 12.JPG

Another box - where are the instructions you ask?
 

A2 Cars

Member
So, now to put it all back together...

GB 13.JPG

Gears pressed onto the shafts.

GB 13.JPG

Ladies lend a hand and give the gearbox a loving touch.

GB 15.JPG

Differential is strengthened.

GB 16.JPG

All the bits on the "clean Bench".

GB 17.JPG

Starting the re-build.

GB 18.JPG

Work in progress.
 

A2 Cars

Member
More work - lets get to it ...

GB 19.JPG

Getting there ...

GB 20.JPG

All gears in and getting ready to seal the gearbox.

GB 21.JPG

Close up.

GB 22.JPG

Ready for the 5th & 6th gear sets.

GB 23.JPG

It's what we've been waiting for - the 6 speed gear set and extended gearbox casing.

GB 24.JPG

5th & 6th are in, we're almost done now.
 

A2 Cars

Member
Final leg ...

GB 25.JPG

Close up showing the shaft extensions to accommodate the 6th speed gear set.

GB 26.JPG

All done, 6th fitted and shafts bolted down and torqued.

GB 27.JPG

On the test rig - another one passes with flying colours.
 

A2 Cars

Member
On the diesel gearboxes, the shafts are extended to accommodate the 6th speed gear sets.

The FSi however has solid shafts of a smaller diameter. To allow the fitment of the 6 speed gear set, our technical partners had to source a longer shaft to accommodate the upgrade. The shaft is a genuine part sourced from the VAG parts bin.

GB 28.JPG

Original 5 speed shaft is top-most and is replaced by the shaft shown in the middle. Note the extra length to allow the fitment of the 6 speed gear set.

Another A2 Cars first in the UK - Audi A2 FSi with 6 speed gearbox ;).


blue skies
Tony
 

Vonnie

Admin Team
I also had Tony install the 6 speed upgrade to my TDI last year and am very pleased with it.
 

Bruno

New Member
its a GSK gearbox code fitted to a 1.6 FSI, I think that there are several options for 6 speed gearboxes
 

sciroccorrado

A2OC Donor
Mainly the cost to be honest, and the known fragility of the engine. If it's a keeper and you're mechanically adept then probably all good :)
 

Bruno

New Member
I thought that engine was later used in Golf's & Polo's, with a different engine number of course. 6 speeds are available that should fit from £250 up, £350.00 for a low mileage one.
 

sciroccorrado

A2OC Donor
So because it's a diesel it's ok to accept failed dmf, turbo, egr valve,intercooler etc etc etc unless of course your mechanically adept.
Not really what I meant to be honest. My position on the FSI is it's a great engine if it's well looked after, but a very risky/fragile engine especially in you're mechanically inept (like me :) )
 

Bruno

New Member
in a Lupo the 1.6 petrol FSI is a great engine apparently, that also has a well matched 6 speed gearbox according to my ex employee.
 
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