Is the 6 speed really worth all the extra hassle of getting into a mk2. Im not really looking for big power maybe 150-175hp with the 1.9 diesel looking more for economy than anything. I cant really seem to find the B4 pedal assemblies so i was looking at the aftermarket kits and they have the hydro and cable clutch thatll work with the factory mk2 assembly. Is there any advantage/disadvantage to either. The cable can snap but the hydraulic seals can go bad and the line can leak so i kinda figured reliabilty is probably about the same.
If it’s economy based consider the cost of the project in money and time and see how that compares to the saving in fuel. how long would it take you to get that outlay back? However, we all love a project and sometimes they are worth doing just for the experience
I would say it's not cost effective, compared to using a standard diesel 02j. With the cable clutch. I've that, albeit a petrol gti box, and while the pedal is firm, it's fine for me.
6 speed would need shafts, mounts, modified subframe and hydraulic clutch, which I got relatively cheaply. But a diesel 5 speed o2j is what I have in the car, due to speed of getting it in, and the speedo drive is still mechanical, not electrical as on o2m. Did keep the bits planning to swap over at some point but let them go the other day due to one thing and another. I do run a hydro kit for clutch, but the slaves are generally mismatched to master on all you can buy so will sort a new hose and fit later slave to it, nit a mk3. There should be no leaks if installed correctly, it's no different to a brake system, same with cable, it's along the lines of a handbrake and I'm sure you don't worry about those things as a problem waiting to happen. 5 speed can use all standard shafts, may have to swap output flange to a 100mm not 108, standard mounts, subframe etc, so is mainly down to cost and your choice of clutch mechanism.
Yea seems like I'll just go with a 5 speed. I just like a project so the cost of the swap doesn't really matter.
How's the clutch pedal effort between the two. There's a lot of different hydro kits available is there one that's superior over the others
Kits generally have transporter master and a mk3 slave, which is larger than the polo/fabia/mk4/transporter slave so pedal seems a little low, I'm going to change mine when get a new hose made. Can't comment on the cable really as mine was auto beforehand, but feel was same in wife's 1.6 standard cable mk2 to my 1.8t swap except my pedal bite was lower.
I have them both: mk2 pd150 6 speed gearbox and mk2 with ve 110bhp 5 speed gearbox, both are running hydraulic clutch system. The real advantage of going 6 speed is stronger driveline and nicer spacing on the gearbox speeds, the 5 speed is more than tough enough for your power goal ! The 6 speed require shorter driveshafts and gearbox support fabricated, the 5 speed drops in using stock hardware…I would go with hydraulic clutch release, it’s just nicer especially if you’re going to use vr6 clutch and flywheel combo !
On my mk2 pd I keep breaking inner driveshafts with spirited drive, the cage that’s holding the ball bearings just shatters and then no drive ! But it’s runngin over double the power it came from factory…the mk2 with the ve tdi engine and 5 speed gearbox, that’s a lovely car to drive, nice softly set suspension setup (still looks great) and the engine is just more refined and revs higher ! The pd is an animal, hard to tame !
Just today i bought the jetta i was looking at and at first i thought the clutch didnt work as the pedal took no effort at all. Turns out im just used to my old big truck that takes 100lbs of force. If even the aftermarket heavier clutch are similerly light i dont thing pedal effort is going to be a concern
Looking at all the different ratios it looks like the 02a ctn or chu with the 3.15 gear is what i want. Is there much of a strength difference between the 02a and 02j. I believe the newer mk2 actually came with the 02a so mounting wouldnt be a problem.
CTN tops out in 5th at about 260km/h at 5200rpm, tdi stock limiter. Car has 200hp maybe, so far drive train/gearbox still good.
If you are going cable clutch, make sure you use a clutch cover designed for a cable - probably a smf with mk2/toledo/leon clutch. Tried a cable clutch conversion on top of a 02J on a 1.8t, with the standard 1.8t clutch and it was really heavy. Ended up snapping a clutch cable every few months, damaging the seat from bracing against it to push the clutch down, and eventually snapping the clutch release arm on the box. Fitted a hydralic clutch and its been fine since
Alright, looks like I'll be going with a hydraulic clutch. Seems to be better with the heavier clutches and less prone to failure
I can’t say I had any issues, ran them on multiple cars for many years and not an issue, certainly not a heavy clutch
