Group buy / order: 0.65 / 0.643 5th for TDI

Likewise, i too would prefer the 'taller' ratio so if we can establish a german supplier contact info my g/f can order over the phone for me and i am sure anyone else who is looking at this. My only (slight) reservation is that it does not create too big a gap between 4th/5th. Bret, those owners who have already done this, what are thier general views?
 
I can't see how you can change the cogs without removing the gearbox from the car?

I have said else where that it takes about 5 hours just to remove and refit the gearbox so I don't understand how it can be done in 2 hours.
 
If you read through this thread and the others linked it is clear it can be done without removing the box! By good fortune the internals are arranged so the relevant cogs can be accessed without major dismantling.
 
I spoke to an independent VAG specialist today who I used to use regularly to do servicing/mod work on my S2 coupe and my 80Sport before that. I said that what I was interested in doing was changing the gearing on the 5th gear of the A2 and what sort of job was it.
He said that whilst he's not done that job on an A2, he's worked on the polo gearbox on which it's based and changing the 5th gear cogs should be a straightforward and relatively quick job. Without prompting he said it should just be a case of taking off the end plate of the 'box and popping the 5th gear cogs off. Gearbox removal is not required, and would probably be a 1-2 hour job.

I think that verifies what we know from our German colleagues without prompting.

This gives me confidence to go for it. I'll definitely use this garage for the work. So now it's the question of buying the gearset, hopefully as a group buy!
 
It seems to be a DIY job

Hi

For all of those who still doubt in a DIY job, I have found a small guide on the german audi owners club.
enjoy here!

It seems to be a simple job.
Only one special tool is needed (picture 3) and a bottle of box oil.

I am interrested in the group buy (I live in france) depending on the final price.
 
I'm interested and would prefer the 'taller' ratio [though I couldn't see where it's mentioned there is a choice or a comparison of the difference]. I would need to be reassured about quality - after a cambelt and bigend failure a gearbox failure must be the next worst thing to happen.
 
you're welcome. :)
I bookmarked the page last year when I first heard about this interresting mod as i've allways thought that the A2 is too noisy a 130KM/h(from 2200+ rpm), this gear could decrease the noise level and consumption.
 
bretti_kivi said:
yep, the old cogs need to go back, probably. We can do that via a collection point in the UK and then pharos.

Bret
Click to expand...

Bret

What's the reason for the gears being supplied on an exchange basis. Are they not standard VAG parts. Is a deposit required (how much) which presumably will be refunded on receipt of the old gears.

Cheers Spike
 
Yes, I'm intrigued by this too - the normal way in which exchange parts are dealt with is that you pay the full price for the part and then when the old parts are accepted back, you get a cheque for them.

The fitting of a new 5th gear seems pretty straight forward really, although the setting of the gear wheel and the other components is pretty critical.

I'd be interested in this mod, but only if the gears were VAG originals, as the longevity of aftermarket parts can be questionable (and I'm already over-stressing my 'box!).

Cheers

Mike
 
I don't know.

For my part, I'm pretty sure these are Rosenkranz gears, depending on the source. VAG ones will go to 0.65 I think, but I need to check this.

Bret.
 
This is looking increasingly 'doable', I understand your concerns Mike about 'aftermarket' non OE parts mike, however we are talking German quality here........ not Italian, Chinese etc..... I am pretty much decided to order the gears once we are sorted with supplier details, cost etc. If i find a '90' in the meantime they can be fitted to that otherwise i will probably hang onto the current car and do a few bits to that.

The German/English fitting instructions are quite funny as well as extremely useful!
 
Tools now!

Good news

%21BQ25MWQBmk%7E$%28KGrHgoH-CUEjlLl1UPiBJ7GTsl8d%21%7E%7E_12.JPG


The gear pullers are very cheap (less than £10 on ebay.uk, uk delivery included)
For a 4" - 100mm, look here
For a 6"-150mm, look here

I Don't think we need better quality tools as it's not for an intensive use (only once for me ).

[ "A SUPERB ADDITION TO A PROFESSIONAL OR DIY ENTHUSIAST COLLECTION" ] (says the bid ;) )
 
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required Parts

Still according to the german A2 site, there are 3 (three) parts required by this mod


@bretti , Wee have to make sure that the package includes all of these parts (not only the cogs). Are we ?


picture here :
attachment.php
 
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5th gear mod?

Hi i have just spotted this thread, wondering if this is available for the 1.4 petrol?? or is it just for the TDI's, brett has a petrol i think, so information please, would be 'in' if it is possible, many thanks ALAN.
 
on a flat road with light load, I think the 1.4 can run a slightly taller 5th, but it really doesn't have the torque of a remapped diesel engine to take full advantage. The sweet sport is 3000 - 4500rpm and the current setup will happily run to 90mph. But a similar fuel saving gear will mean 70mph at, perhaps 2.5k, and i think the engine won't like it that much; I'll have to drive nearer to 3000rpm which would be above the speed limit, increasing wind resistance and probably cancelling out mpg gain. The annoying thing is, the engine noise is just starting to become irritating at 3k (not as bad as the diesel though), [email protected] would be such a ride...
 
ariles said:
Hi

For all of those who still doubt in a DIY job, I have found a small guide on the german audi owners club.
enjoy here!

It seems to be a simple job.
Only one special tool is needed (picture 3) and a bottle of box oil.

I am interrested in the group buy (I live in france) depending on the final price.
Click to expand...

Hi Ariles,

Thank you for finding the page and posting the link. These are the photographs that I referred to in my previous post.

John.
 
if you don't mind losing cruise, I think it's doable. I might have to talk to one of the guys in Germany to see if we can get a hack to make it work.

@ariles: mais oui, it will be a full kit.

Bret
 
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