![]() For safety reasons I cannot recommend you drive your car after doing this and should thus be considered an Off road only modification. Be advised, there is also the possibility that this might result in your death if things were to fail at speeds other than being not moving. If you do screw this up there is potential that your car might stop function as per the specifications of Volkswagen. I take no responsibility for the whatever outcome you might have. In doing this there is a large potential that you might screw something very important causing damage to your very expensive perfectly good transmission. In doing so you might or might not gain any benefits. WARNING!!!! This procedure discusses the way you would open up the end of your very expensive transmission in order to replace a gear that is perfectly fine. Ok, If that didn't leave you horribly terrified here is the more detailed overview.Ĥ BIG IMPORTANT WARNING AGAIN in case you skipped the first one. Mine let out a loud crack which fortunately was the gear coming off the shaft. Once the puller is on the gear selector assembly and you are cranking down on it, it can take A LOT of force to get the gear office. At about this point you would reach the scary part of the project. Once you get the puller on you will want to heat the gears so they expand as this should make the removal a little easier. For the selector assembly any gear puller about the right size should work without issue but for the smaller gear some modification might be needed as the case is pretty close to the gear which makes getting the puller arms around the gear a little challenging. So to remove both of these you will need a gear pullers. The smaller gear along with the selector are both pressed onto a splined shaft. You have 2 gears to remove, The larger drive gear with the associated selector assembly and the smaller driven gear. Sounds simple enough right? It basically is except for the removing of the original gears, thats where things get tricky. In short all you have to do is remove the end cover of the tranny, remove 2 retaining bolts, remove both the gears, put on the new gears, replace bolts and end cap, refill with gear oil and you are done. The procedure for swapping out the 5th gear is rather simply. This document is for educational purposes only.ģ Prelude: Welcome to dave's 5th gear swap. I HIGHLY recommend you obtain a legal copy of the Bentley CD manual as it includes additional detailed instructions pertaining to swapping out the 5th gear in your transmission. I did have success with this modification in my own vehicle but your results might vary greatly. Same thing goes for reinstalling, heat it to 100C and it slide right onto the shaft.1 th 5 Gear Swap How-to 02A/02J By david_594 5/9/06 v 1.32Ģ BIG IMPORTANT WARNING WARNING!!!! This procedure discusses the way you would open up the end of your very expensive transmission in order to replace a gear that is perfectly fine. If you try to pull the gear without heating it you will crack it nearly every time. Pulling the gears is VERY easy! Don't sweat the puller instead you are supposed to heat the gear using an electric heat gun to 100C, the gear(s) slide right off! You may lose cruise control, but that can be restored with an ECU tune. 658 will drop RPMs by approximately 600 over the stock 5th gear, depending on wheel and tire sizes. Recommended for those who drive consistently over 75 MPH, the. 658 5th gear is an awesome upgrade to any TDI. The proper small spring plate is included so no modification of current spring plates is needed. This gearset will work in a MKV Jetta TDI with no issues. 658 gearset will work with the NA BEW motored MK4 PD vehicles but cruise control functionality may be lost. 658 gearset drops RPMs in 5th gear by 13%. Set includes large gear, small gear, and spring plate (concave washer) for the small gear.Īll North American TDI's from 1996 through 2003 came with a. 658 5th gear set for Volkswagen 02A and 02J transmissions.
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